Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills

Yuan Jing , Guanchen Gong , Albrecht Hänel , Steffen Ihlenfeldt
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Abstract

Industry 4.0 has significantly improved data efficiency by leveraging key technologies such as the Internet of Things and Machine Learning. Among these key technologies, digital twins stand out by offering a promising approach to intelligently utilize this data. In the virtual representation of a physical asset, data reflects the conditions of the physical entity, while models simulate and predict its behavior. In this paper, a hybrid cutting force model is proposed for digital twins of helical end mills, focusing on cutting force analysis during the utilization phase of the machining process. This model combines a fairly mature physical process modelling approach with a data-driven method, specifically a neural network trained on real process data, to address the limitations inherent in their respective applications. The physics-based model provides meaningful constraints on the neural network’s training, ensuring reliable cutting force prediction, particularly in scenarios with limited process data availability. The cutter’s profile, generated by the geometric model, and the cutter-workpiece engagement maps, derived from the virtual machining model, together serve as inputs for the hybrid cutting force model.
螺旋立铣刀数字孪生中增强切削力建模的混合物理-数据方法集成
通过利用物联网和机器学习等关键技术,工业4.0显著提高了数据效率。在这些关键技术中,数字孪生通过提供一种有前途的方法来智能地利用这些数据而脱颖而出。在物理资产的虚拟表示中,数据反映了物理实体的状况,而模型则模拟和预测其行为。提出了一种螺旋立铣刀数字孪生体的混合切削力模型,重点分析了加工过程中利用阶段的切削力。该模型结合了相当成熟的物理过程建模方法和数据驱动方法,特别是在实际过程数据上训练的神经网络,以解决各自应用中固有的局限性。基于物理的模型为神经网络的训练提供了有意义的约束,确保了可靠的切削力预测,特别是在工艺数据可用性有限的情况下。由几何模型生成的刀具轮廓和由虚拟加工模型导出的刀具-工件啮合图共同作为混合切削力模型的输入。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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