Instrumentation and control methodology for zero defect manufacturing in boring operations

Abstract

In this research work an innovative system for quality control of large components boring process is presented in order to get zero defect parts. In traditional manufacturing, the quality control is performed at the end of the manufacturing line so that a defect produced in an initial stage spreads throughout the process. The impact of defective parts in production is particularly important in sectors such as wind energy, aerospace, chemical, etc. due to the large size and high production cost thereof. Moreover, the adjustment of production through statistical process control is inefficient due to the complexity of the parts, the high number of parameters to be controlled and the generally short series. The new methodology is based on modeling the cutting process and in-line monitoring using telemetry hardware specifically developed and integrated into the boring head. Through readings of different sensors and preliminary process modeling, the system resets the machining strategy and working parameters to correct possible deviations due to tool wear, bending and vibration of mechanical components.