A Process Monitoring System for Process-Based Product Validation

A process monitoring and visualization system was developed for three-axis milling. The hardware consisted of several sensors that monitored spindle power, cutting force, machine vibration, and acoustic emission output. The visualization routine then color-coded the sensor data and overlaid them onto a 3-D CAD model of the machined part. Hyperpoints were used to relate the sensor data to part geometry. The hyperpoints were Cartesian points in space that augmented the 3-D CAD model with additional information such as force or vibration sensor readings. The key strategy was to detect, diagnose, and correct machining errors at the earliest possible opportunity. In the experimental work, the sensors were integrated into an open architecture machine tool platform. Therefore, the paper also describes the advances in machine tool functionality and process capability that were made possible by using the open architecture controller. Results for two standard test parts are presented.