Towards Zero-Defect Manufacturing Based on Artificial Intelligence through the Correlation of Forces in 5-Axis Milling Process

Itxaso Cascón-Morán*, Meritxell Gómez, David Fernández, Alain Gil Del Val, Nerea Alberdi, Haizea González

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

Abstract

Zero-Defect Manufacturing (ZDM) is a promising strategy for reducing errors in industrial processes, aligned with Industry 4.0 and digitalization, aiming to carry out processes correctly the first time. ZDM relies on digital tools, notably Artificial Intelligence (AI), to predict and prevent issues at both product and process levels. This study’s goal is to significantly reduce errors in machining large parts. It utilizes data from process models and in situ monitoring for AI-driven predictions. AI algorithms anticipate part deformation based on manufacturing data. Mechanistic models simulate milling processes, calculating tool deflection from cutting forces and assessing geometric and dimensional errors. Process monitoring provides real-time data to the models during execution. The research focuses on a high-value component from the oil and gas industry, serving as a test piece to predict geometric errors in machining based on the deviation of cutting forces using AI techniques. Specifically, an AISI 1095 steel forged flange, intentionally misaligned to introduce error, undergoes multiple milling operations, including 3-axis roughing and 5-axis finishing, with 3D scans after each stage to monitor progress and deviations. The work concludes that Support Vector Machine algorithms provide accurate results for the estimation of geometric errors from the machining forces.

Original languageEnglish
Article number226
JournalMachines
Volume12
Issue number4
DOIs
Publication statusPublished - Apr 2024

Keywords

  • 3D scanning
  • Artificial Intelligence
  • mechanistic model
  • monitoring
  • Zero-Defect Manufacturing

Fingerprint

Dive into the research topics of 'Towards Zero-Defect Manufacturing Based on Artificial Intelligence through the Correlation of Forces in 5-Axis Milling Process'. Together they form a unique fingerprint.

Cite this