1. KE22 FINAL YEAR PROJECT Modeling and Simulation of Milling Forces SIMTech Project Ryan Soon, Henry Woo, Yong Boon April 9, 2011 Confidential – Internal Only

2. 2| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only BACKGROUND AND OBJECTIVE Singapore Institute of Manufacturing Technology (SIMTech) Knowledge Engineering Research Industry Students  SIMTech as a company –Develops high value manufacturing technology and human capital –Enhance competitiveness of Singapore manufacturing industry  Milling process –One of the many manufacturing processes research upon

3. 3| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only INTRODUCTION TO MILLING  A common machining process used in material manufacturing  Customized solid material can be designed and created  Consist of a milling machine, workpiece, fixture, and cutter  Can be manually operated, mechanically automated or digitally automated via Computer Numerical Control (CNC)  Scope is limited to CNC type of milling machine and its processes

4. 4| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only CONCEPT MAP

5. 5| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only Problems Encountered During Milling Process

6. 6| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only Current Milling Process

7. 7| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only Target Goal for Milling Company

8. 8| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only An Intelligent Tool Wear and Failure Prognostic System MILLING PROCESS SETUP Reduce Downtime Improved Utilization Pre- Processing and Feature Selection KE Models and Accuracy Evaluation Knowledge Base GUI Feedback Milling Process Sensor Setup Data Acquisition Tool Wear Measurement Sensory Data Store

9. 9| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only PROJECT SCOPE AND OBJECTIVES NoForce FeatureAE Features 1Maximum Force LevelPeak to peak 2Total Amplitude of Cutting ForceSkewness 3Amplitude RatioKurtosis 4Average ForceMean of band power KE Techniques Under Investigation

10. 10| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only THE END Q&A

11. 11| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only BACKUP

12. 12| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only INITIAL KE TECHNIQUES EVALUATION  Neural Network –No model required ( ) –Hard to extract the rules (  )  Fuzzy Logic –Tolerance imprecision ( ) –Membership/Rule defined (  )  Genetic Algorithm –Fitness Functions Unclear (  )  Heuristics Search –Model Required (  )  Fuzzy Neural –No model required ( ) –Rule Extraction ( )  Case-based Reasoning –Cases Available ( ) –Huge Case-Bases System (  )  Data Mining –Data Available ( )  Rule Based –Domain Rule available (  )