Physics-based process control method and system

Patent metadata

Field	Value
Publication number	US-2025332690-A1
Application number	US-202418644934-A
Country	US
Kind code	A1
Filing date	Apr 24, 2024
Priority date	Apr 24, 2024
Publication date	Oct 30, 2025
Grant date	—

Abstract

A method of machining a workpiece includes receiving at least one input parameter from an ultrasonic impact grinding system having an ultrasonic vibration tool. The input parameter includes a material property of a workpiece and a tool parameter. A physics-based model is applied to the input parameter and an estimation is made of a vibration amplitude for a power level to be provided to the vibration tool and a particle size for abrasive particles to be used with the vibration tool. The power level is provided to an adaptive profile control for the tool.

First claim

We claim:

1 . An ultrasonic impact grinding system comprising:
an ultrasonic vibration tool having a tool tip; a slurry component having a slurry nozzle to deliver a slurry having abrasive particles in an area of the tool tip, wherein the tool tip of the ultrasonic vibration tool engages the abrasive particles to machine a workpiece; a physics-based model configured to optimize a material removal rate for a given particle size for the abrasive particles and a vibration amplitude according to a power level for the ultrasonic vibration tool, wherein the physics-based model receives at least one input parameter including a material property and a tool parameter; and an adaptive profile control having an ultrasonic power generator to receive the vibration amplitude and control the ultrasonic vibration tool according to the vibration level and a vibration frequency.

2 . The ultrasonic impact grinding system of claim 1 , further comprising an adaptive feed rate control system to monitor a feed rate to the ultrasonic vibration tool based on the vibration amplitude.

3 . The ultrasonic impact grinding system of claim 2 , wherein the feed rate is provided to the physics-based model to update an attribute related to the power level.

4 . The ultrasonic impact grinding system of claim 2 , wherein the adaptive feed rate control system includes a controller to control the feed rate to the ultrasonic vibration tool.

5 . The ultrasonic impact grinding system of claim 1 , wherein the physics-based model is configured to determine an ultrasonic impact grinding power based on the vibration amplitude.

6 . The ultrasonic impact grinding system of claim 5 , further comprising a controller to control the power level to the ultrasonic vibration tool using the ultrasonic impact grinding power as a starting point.

7 . The ultrasonic impact grinding system of claim 1 , further comprising an on-machine tool measurement system to measure a tool length of the tool tip of the ultrasonic vibration tool.

8 . The ultrasonic impact grinding system of claim 7 , wherein the tool length is provided to the physics-based model.

9 . The ultrasonic impact grinding system of claim 1 , further comprising load sensors to provide a load profile of operations by the ultrasonic vibration tool according to the vibration amplitude.

10 . The ultrasonic impact grinding system of claim 9 , wherein the load profile is provided to the physics-based model.

11 . A method comprising:
receiving at least one input parameter for an ultrasonic impact grinding system, wherein the input parameter includes a material property of a workpiece and a tool parameter; applying a physics-based model to the at least one input parameter; estimating a vibration amplitude to optimize a power level to an ultrasonic vibration tool of the ultrasonic impact grinding system to be used with the ultrasonic vibration tool; and providing the power level to an adaptive profile control for the ultrasonic vibration tool.

12 . The method of claim 11 , further comprising monitoring an actual power output of the ultrasonic vibration tool.

13 . The method of claim 12 , further comprising adjusting a feed rate provided by the adaptive profile control to the ultrasonic vibration tool according to the actual power output.

14 . The method of claim 12 , further comprising providing the actual power to the physics-based model.

15 . The method of claim 14 , further comprising updating the physics-based model with the actual power output.

16 . The method of claim 11 , further comprising estimating the power level using a vibration frequency along with the vibration frequency.

17 . The method of claim 11 , further comprising optimizing a material removal rate for a given particle size for abrasive particles to be used with the ultrasonic vibration tool.

18 . A method comprising:
providing an ultrasonic vibration tool for impact grinding a workpiece using a slurry having abrasive particles in an area of a tool tip of the ultrasonic vibration tool; providing electrical power having an electrical power level to the ultrasonic vibration tool to induce vibration in the tool tip in a direction of the workpiece; receiving an input signal corresponding the electrical power level; applying a physics-based model to the input signal; determining a desired vibration amplitude of a power level of the ultrasonic vibration tool based on the input signal; and using the desired vibration amplitude to control the electrical power level to the ultrasonic vibration tool.

19 . The method of claim 18 , further comprising:
using the control desired vibration amplitude to control the rate of speed that the workpiece is moved pass the vibration tool.

20 . The method of claim 18 , further comprising:
adaptively controlling the feed rate of the vibrating tool.

Assignees

• Rtx Corp

Inventors

• Wang Zhigang
• Guo Changsheng
• Kuczek Andrzej E
• Fernandez Robin H
• Barron Alan C
• Abdi Ahmed Abdillahi

Classifications

• B24C1/10

  for compacting surfaces, e.g. shot-peening (for deforming sheet metal, tubes or profiles B21D31/06; as a metallurgical treatment C21D7/00, C22F1/00) · CPC title

• G05B19/4163

  Adaptive control of feed or cutting velocity (without NC B23Q15/12) · CPC title

• B24C5/005 Primary

  Vibratory devices, e.g. for generating abrasive blasts by ultrasonic vibrations (sonic cleaning in general B08B3/12) · CPC title

• B24B1/04 Primary

  subjecting the grinding or polishing tools, the abrading or polishing medium or work to vibration, e.g. grinding with ultrasonic frequency (involving oscillating or vibrating containers B24B31/06; superfinishing surfaces on work, e.g. by means of abrading blocks reciprocating with high frequency, B24B35/00) · CPC title