CPS: Synergy: CNC Process Plan Simulation, Automation and Optimization

Machining is a fundamental processing capability critical to production of end-user goods and systems, as well as components used in virtually every industrial process. Machine tool programming to support these processes is critical for production and cost estimation. Unfortunately, currently available automated process planning methods constrain the process along geometrically simple trajectories due to computational constraints, this at the sacrifice of final processing efficiency. This project is establishing the requisite knowledge for a novel computer-aided process planning and control architecture for integrated complex tool path generation and optimization. This includes generic optimization architectures for automated toolpath optimization, which require global solutions to highly non-linear, constrained optimization problems in high-dimensional search spaces of tool motions with time-varying positions and orientations. The research is developing a bi-directional optimization scheme that consists of: (1) a top-down, multi-level decomposition of the problem into fundamental model motions (e.g., curved blocks, peel layers, tool swipes) and (2) a bottom-up optimization of these fundamental geometric model motions. These models and associated fast, parallel computing algorithms will provide for rapid analysis of swept regions, collision avoidance and computing material removal rates that are critical for facilitating rapid toolpath optimization. These new mathematical algorithms will drive effective real-time process control and optimization so to enable substantial increases in machine productivity.