Autonomous Milling Operation Based on Real Time Cutting Process Simulation

In order to realize an autonomous milling, the tool paths and the cutting conditions have to be decided in real time using the predicted and the measured information of machining process. In this paper, the algorithm of in-process tool path generation for rough cutting is proposed to enable the modification of the cutting conditions according to the machining status and the machining troubles such as chatter vibration. Machining area is divided into some small cells and the tool path is generated as a removal sequence of machining cells based on the pattern of the relation among eight neighboring cells in 3×3 cells termed mask. The modification of the tool path is also realized by a change of an axial depth of cut and a radial depth of cut during a machining operation. As a case study, suitable cutting conditions are maintained according to the cutting force predicted in real time. In other words, the in-process tool path generation is made by deciding the cutting conditions in parallel with predicting the cutting force using a PC based milling process simulator called VMSim, which was developed already, and the feasibility of autonomous milling is demonstrated.