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Development of a process model for the simulation of adaptive control concepts for metal-cutting bandsawing

Subject Area Metal-Cutting and Abrasive Manufacturing Engineering
Term from 2016 to 2022
Project identifier Deutsche Forschungsgemeinschaft (DFG) - Project number 289598126
 
Final Report Year 2023

Final Report Abstract

Sawing is often the first step in the machining production chain. Especially for larger workpieces, band sawing is used for this. Nevertheless, sawing processes have long had a niche existence in the research landscape. As a result of attempts to optimise manufacturing processes in terms of economic efficiency, band sawing is increasingly becoming the focus of research. Within the framework of this project, two approaches were pursued to achieve this goal. The optimisation goal of both approaches is to increase the service life or the possible cutting area of the band saw blade. The secondary goal was to reduce the lateral run of the saw band and thus the material waste. For this purpose, a simulation model was first built in Matlab/Simulink, which can predict the cutting course and the process forces. In the course of the project, the model was extended to include the various system models of the new constructions and the associated controllers. Since the simulation works on a database of analogy tests, these were built up in the course of the project and artificial intelligence (AI) approaches were developed with which the test effort can be reduced for the future, should new materials or tools become unmaintained. The first design pursues the approach of actively tilting the saw blade guide system to counteract the cutting process. With the other design, the thesis was verified that chip breaking can be positively influenced by an active vibration excitation in the feed direction. For the saw blade tilting, different concepts were designed and compared. Finally, the choice fell on a concept in which it is possible to change the proportion of translatory and rotatory movement on the saw band and thus to investigate different configurations. Single-acting cylinders were used as actuators. The active vibration superposition in the feed direction was first analyzed with analogy tests, whereby a piezo actuator was used due to the easier control behavior and the higher bandwidth. Here, the process forces and the chip formation were considered. Various parameter pairings were determined which appear to have a positive influence. However, when transferring this to real band sawing, it was found that the vibrations introduced are still clearly visible and measurable in idle operation, but are covered by other vibrations in the process and thus no influence could be determined in the parameter window investigated. On the other hand, it could be shown that a significant increase in the lifetime of the saw blades investigated can be achieved with vibration coupling compared to the conventional machining method.

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