CNC machine control for high tolerance aerospace production

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Authors
Towner, Ridge Daniel
Advisors
Moscoso-Kingsley, Wilfredo
Issue Date
2024-05
Type
Thesis
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Abstract

This research is motivated by the needs for advanced processes and control methods for CNC machines in the aerospace industry. Generally, more metal is removed from a workpiece than what is remaining in the machine after processing. This requires use of all types of tooling, cutters, drills, spindles, drive systems, actuators, controls, processes, etc. Countless decisions by analysts, engineers, planners, machinists, and managers, and the complex physics that govern machine tool movement, accuracy and repeatability demand post-machining quality control measurements be implemented. The ex-situ nature of the typical quality control systems increase cycle time and costs. In-situ quality control is proposed here as an alternative to reduce cycle time and cost, while increasing quality. For this purpose, a (CNC) machine tool was equipped with direct computer control coordinate measuring software and high accuracy contact probing. This special CNC is validated for its capability for self-health monitoring and in-situ part quality control. The validation conforms to international standards for performance evaluation of commercially available coordinate measuring machines (CMMs). The capability of the CNC system to perform CMM-type measurements is demonstrated via a case study. The equivalency between part dimensional measurements obtained directly from the use of the CNC machine tool as a CMM and from part dimensional measurements performed using commercially available CMMs is established via a correlation study. The self-health checks were run for a period of one-year and the measurements are analyzed statistically using standard SPC methods.

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Thesis (M.S.)-- Wichita State University, College of Engineering, Dept. of Industrial, Systems, and Manufacturing Engineering
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Wichita State University
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