Integrated Modeling for Metal Removal Operations

An integrated CAD/CAM and machine tool control system is implemented to automate tool path generation, cutting condition optimization, and online supervisory control for semi-finishing and rough milling. The part is designed using a solid modeler, and tool paths are generated using a CAM system. A process simulator developed at McMaster University is then used to automatically schedule cutting conditions that maximize the Material Removal Rate (MRR) subject to cutting force, power, and chip load constraints. During actual cutting, the measured spindle power is compared to reference data supplied by the simulator. As the tool wears, the slow increase in spindle power consumption is used to override the scheduled feed rate without operator intervention. All components of the integrated system are designed around industry standard computer hardware, operating systems, solid modelers, and cutter location file representations.