Simulation Based Process Monitoring for Single Item Production Without Machine External Sensors

Process monitoring makes an essential contribution to process safety and workpiece quality in cutting machining processes. Conventional monitoring techniques have been successfully used to detect deviations from fault free production. In series production these techniques rely on a teach-in of confidence limits from identical previous machining. However, they fail in the context of small series or single item production since previous process data are hardly available. Therefore, an innovative “teach-free” monitoring strategy is required. In this work, a machine-integrated monitoring technique based on simulation is proposed, allowing monitoring of complete processes in single item production consisting of turning, milling and drilling.