Improved machining accuracy of hollow cylinder components based on preventive compensation for tool wear errors

Objective – improvement of the precision of finish reaming of hollow cylinder type components by using preventive compensation for cutting tool wear. The study focuses on hollow cylinder type components, exemplified by the liners of drilling pump cylinders, where the finish machining of the central bore is studied. The machining is performed on a numerically controlled lathe. The proposed approach involves dynamic monitoring of the cutting-edge condition during the production of a test batch. The cutting blade is described as a set of points that subsequently approximate the contour of the cutting edge. Since the wear pattern of each individual insert is random, the study uses an artificial intelligence approach to solve the prediction problem. A neuro-fuzzy model was developed to describe the cutting edge during wear. The model includes a knowledge base that is updated based on the monitoring results of the cutting edge shape. The model also includes a logical block containing a set of conditions that enable the simulation results to be produced with the required accuracy. Testing of the developed model shows that the error in describing the cutting edge contours does not exceed 8%. On the basis of the calculated descriptions of the blade contour, corrections to the cutting tool trajectories are calculated, which allow compensation for the wear of the cutting plate. Research into the effectiveness of the solutions obtained has shown that it is possible to increase tool efficiency (in terms of tool life) by 35–45%. In addition, the developed neuro-fuzzy model can be integrated into an expert system that helps to reduce the risk of sudden cutting tool failure. This is particularly important in the manufacture of hydraulic machine components.

hollow cylinder, cutting-tool life, boring, model, monitoring, corrections