Monitoring of technological systems when cutting complex contoured surfaces

Abstract

The article presents results of the theoretical and experimental research that we conducted to determine the main reasons of errors in the geometry of complex parts on “cold” machine tools. The solution of this problem helps to improve the accuracy of cutting complex parts on CNC machines and semiautomatic machines with copiers. The proposed monitoring system improves the quality of technological systems in general. We developed a new analytical method for assessing the quality of products cut on CNC machine tools. The proposed methodology includes the following:

1. Assessing the state of technological systems of machines based on the results of testing
the program accuracy and rigidity.

2. Controlling the state of machines based on the analysis of technological accuracy of cutting. The obtained dependences of the technological accuracy on the machine accuracy give mathematical support to the problem.

3. Controlling the accuracy of cutting by adjusting control programs and changing cutting modes.

We fully assessed causes and consequences of potential errors of CNC machines. This allowed us to propose alternative technological solutions and reduce the dispersion of errors of machined surfaces of complex contoured parts. Implementation of the research results in production will improve the level of technological support for the accuracy of complex contoured surfaces and the functionality of the equipment. We analyzed the results of experimental verification and established that the proposed solutions made it possible to increase the level of technological support for the accuracy of complex parts from 53 to 78 %.