Donchenko Y. Improving the efficiency of milling based on the development and research of an automated diagnostic system for cutters

The dissertation is devoted to solving the urgent scientific and technical problem of increasing the efficiency of rough face milling using small-tooth cutters by creating and researching an automated diagnostic system, which made it possible to increase the reliability of end mills, milling productivity and reduce the need for tool material. When performing experimental studies, a prototype of an integrated system for assessing the quality of the face milling process was created, which includes three channels of piezoelectric vibration acceleration sensors and a sensor for the angle of rotation of the spindle of a milling machine. For the first time, a mathematical model of the pattern recognition system has been developed, which makes it possible to predict the state of the cutting tool during rough face milling on the basis of experimental data. In this work, a computational and mathematical model of the milling process has been developed to determine the relationship between the vibration parameters during face milling and the state of the cutting inserts. The obtained mathematical models for predicting the reliability of the assembled tool with sequential destruction of each tooth for an end mill with an arbitrary number of inserts. The results of the work have found practical use in creating technical solutions and methods for determining the period of regulated tool replacement to ensure a given level of its reliability. Thanks to the introduction of a diagnostic system for end mills during rough milling at PJSC Druzhkovsky Machine-Building Plant, an economic effect of UAH 38,670 was obtained (for the period). The managers of the hardware-software complex for diagnostics of smalltoothed milling cutters "Mriya-Mini" at the TOV "Industrial-trading company Intris trade" planned economic effect 67943 UAH. The staff of the optical sensor with advanced metrological characteristics at the scientific- manufacturing collective enterprise "Intris" is scheduled to have an economic effect of 15000 UAH.