A reliable machining process by means of intensive use of modelling and process monitoring: approach 2025

Abstract

 This paper covers three significant aspects. Firstly, a global 
approach to manufacture high-added value components 
is presented.. This process involves a holistic perspective 
for the entire process: from design conception to market 
implementation. It needs to be emphasized that the 
manufacturing process implies a global challenge in term 
of modeling and systems integration. Moreover, particular 
progresses in programming, modeling, measuring, monitoring 
and customers´ quality requirements involved a global 
improvement in the mentioned cycle. 
Secondly, inside the different defined stages there are several 
developments of industrial interest.. On the one hand, a cutting 
forces predictive model implies parameters optimization in 
terms of swarf section (feed,axial and radial depth of cut). On 
the other hand, modeling the finishing process to determine 
thermal load and induced stresses, leads to the possibility 
of limiting the cutting speed (Vc) adequately to the process 
specifications.
Finally, in-situ monitoring collects information that indicates 
machining program issues or efforts out from desired levels. 
Moreover, monitoring would be able to predict batch production 
threshold value limits.
In order to apply described approach, an aeronautical industry 
high-added value component was selected as demonstrator. 
Defined component consists of a single blade of Inconel 718 
with thin walls, generated by Selective Laser Melting (SLM) 
additive process. Results showed that applying predictive 
models inside a global vision implied an adequate control of 
the process (spindle loads and unexpected cutting forces). This 
ensures in a further future a stable production of this type 
of components, such as Integral bladed rotors, coming from 
additive manufacturing.