Periodic Reporting for period 1 - MC-SUITE (ICT Powered Machining Software Suite)

Summary
The advances in the Information and Communication Technologies are revolutionizing our everyday life. However, the manufacturing industry does not yet take complete advantage of this huge potential. Using the latest ICT developments, MC-SUITE project wants to boost the...\n\nThe advances in the Information and Communication Technologies are revolutionizing our everyday life. However, the manufacturing industry does not yet take complete advantage of this huge potential. Using the latest ICT developments, MC-SUITE project wants to boost the productivity of manufacturing industry. On the one hand, machining process modelling empowered by High Performance Computing technologies allows simulating precisely the cutting process including force and surface quality. On the other hand, monitoring of the machine empowered by Big Data and Cloud technologies allows analysing the real process including vibration and process instability issues. Bridging the gap between virtual and real worlds, correlations of the simulated and monitored cutting process will allow optimizing both simulation and machining performances.
In agreement with the work programme, the combination of manufacturing technologies and ICT is at the core of the construction of this consortium. The project will complement science with innovation to propose new software frameworks which can collect information from multi-monitoring devices as turnkey technologies to improve the machining process. MC-SUITE will produce multiple impacts in the European industry, reflecting the trans-disciplinary nature of the project. The participation of industrial partners, both SMEs and large companies from ICT and industrial sectors, will ensure that the project will directly impact on wide range of industries such as metal part manufacturing, Computer-Aided Manufacturing software, machine tool industry. MC-SUITE project has the opportunity to produce a new breakthrough in the productivity of the European manufacturing industry.\n\nDuring the first half of the project the MC-Suite consortium worked in the development of the MC-Suite modules to improve the productivity and to use the latest ICT developments in the manufacturing industry. The MC-Virtual module allows simulating the physical milling process. This virtual counterpart includes a cutting force evaluation, stability prediction & surface finish visualization, and helps the process planner to guarantee a correct realization of the first workpiece. MC-CyPhy proposes to introduce three Cyber Physical Systems in the machine to increase the productivity. Two of them, Spindle Speed Variation algorithm and the active damping system are developed to improve the chatter stability. The third physical system, Chip Breaking System, has been developed and tested to reduce the chip length and to allow uninterrupted production. The objective of the MC-Monitor module is to continuously observe machining processes, by gathering data, from both the sensorized machines and the operators on the field, and to upload this data to the cloud. All the end-user?s machines are now connected to the monitoring platform. Using the data collected on the machine, the MC-Analytics module provides visual analytics tool to analyse the machine status and machining process. Moreover, advanced data analytics are currently being performed. The consortium achieved most of the objective and technical goals for this period and the realised work has been adequately reported through the realization of the defined deliverables.\n\nAt this point of the project, a significant progress beyond the state of the art has been realized in the MC-Monitor module. A monitoring platform connected to the numerical controller of the machines and to real time acquisition systems allows collecting production data in real time on the end-users?s machines. The acquired data are exploited by the MC-Analytics module to provide production insights to the different stakeholders of the workshops. The new industry 4.0 technologies introduced in the manufacturing system can help the decision taking processes and improve the machine productivity. The first systems have been deployed on customer?s machines. Another important progress beyond the state of the art is related to the Cyber Physical Systems developed in MC-Cyphy. A complete integration with the MC-Monitor module offers the possibility to remotely monitor the behaviour of the CPSs. The chip breaking system is being implemented on the machine of the first customer.
Concerning the physical simulation of the machining process, the main progress beyond the state of the art comes from the ability to simulate the process all the way from cutting forces to surface finish prediction. The MC-Virtual simulation tool is expected to provide the expected values that will be compared with the measured ones on the MC-Bridge module.
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ICT Powered Machining Software Suite
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