New machining strategies with open architecture controllers

Industrial machine tool controllers have become proprietary commodities that limit innovation by restricting access to the individual sub-functional modules. Providing access to the sub-components by following an open architecture framework allows improvements to be made.; This work illustrates the advancements in machine functionality, process, and capability made possible by Open Architecture Controllers. The exposed functionality allows the machine manufacturer and process engineer to improve the process. By adhering to this type of architecture and exposing the machine's functionality, the controller will be open.; Machine functionality improvements were achieved with new high-fidelity geometry interpolation routines for the machine tool controller. A Non-Uniform Rational B-Spline (NURBS) interpolation routine was created that accepts quadratic through quintic trajectories and feeds. It was tested by machining several conic paths and surfaces. Further improvements were made by providing an interpolator for high-speed Splines, which circumvent the problems associated with the typical machine-code language. These interpolation improvements increase design freedom, accuracy in machining, and productivity in the process.; Open architecture can also reduce the cost of manufacturing. The process can be monitored and validated in real-time, ensuring production of good, uniform products. A process monitoring system was created that monitors spindle power, cutting force, machine vibration, and acoustic output. It then color-codes the data and overlays it onto a 3D model of the machined part. This graphic information permits monitoring products and processes for uniformity and quality throughout and across batch production runs without post-process inspection.; Finally, open architecture can be used to optimize machine performance through better utilization of energy and tools. A control module was developed that uses metallurgical models and measured process inputs to optimize tool wear by manipulating feed and speed on the fly. A literature review provided metallurgical models. A process input measurement system was created that measures tool temperature, cutting force, feed, and speed of a milling machine. Experimental validation of the metallurgical models was attempted. The models were not satisfactorily validated; no control rules were developed. However, the mechanism has been put in place to control the machine feed rate and cutting speed with the mentioned process inputs.