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In-process control

The in-process layer of the Productive Process Pyramid™ features controls that are embedded within the metal cutting process. These active controls automatically respond to material conditions, inherent process variations and unplanned events to minimise process non-conformance.

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Keep control as cutting proceeds

The Productive Process Pyramid™ - In-process control The in-process control layer of the Pyramid tackles sources of variation that are inherent to machining, such as tool wear and temperature variation, providing intelligent feedback to the process and decision-making as machining progresses.

These are active controls that are applied during metal cutting.

In-process gauging allows …

metal cutting to adapt to variations in the machining process such as part distortion, tool deflection and thermal effects
updating of co-ordinate systems, parameters, offsets and logical program flow depending on actual material conditions

Broken tool detection recognises ...

presence of a tool
tool position - to ensure pull-out has not occurred
broken and/or chipped tool edges

Active controls

Active process control enables parts to be made ‘right first time', so capacity needn't be set aside for rework and re-makes.

Automated in-process measurement means your machines will no longer be waiting for operators to re-start them.

In-cycle gauging gives your machine tools the intelligence they need to make decisions for themselves, enabling extended periods of ‘lights out' machining, boosting your productivity.

Renishaw's workpiece inspection probes, TRS2 tool recognition system and Productivity+™ software adapt metal cutting operations to the actual material and environmental conditions with automated feedback.

Workpiece inspection probes		TRS2 tool recognition		Productivity+™
Workpiece inspection probes for automated measurement of component position and alignment.		TRS2 tool recognition system for rapid in-cycle checks for broken tools.		Productivity+™ enables tool and part setting to be seamlessly integrated with metal cutting.

Documents

[4.7MB] Metrology solutions for productive process control brochure
Transform your manufacturing performance with help from the process control experts
[1.8MB] White paper: Survival of the fittest - the process control imperative
In tough times, manufacturers focus on reducing their operating costs, but may not be able to afford to spend their way out by buying more productive machinery. With that pathway closed, what are the opportunities for radically reducing costs without replacing existing machines? This paper explores four areas where substantial savings can be found if firms are prepared to change the way they control their machining processes.

Productive Process Patterns

[485kB] (AP301) Cutter parameter update
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure the actual size of a machined feature and update the relevant tool offset.
[804kB] (AP302 addendum) Three pillar test piece: an example of dynamic re-machining
Explanation of machining processes and strategies used to produce the three pillar test piece, and aid in demonstrating the benefits of in-process control.
[1.6MB] (AP302) Dynamic re-machining
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. The CNC machining process uses semi-finishing cuts or test cuts (slave features) that are representative of the subsequent finishing cut. The probing system on the machine is used to measure the cut feature and adjust the process through tool offsets to improve final part accuracy (using pattern AP301, Cutter parameter update).
[1.0MB] (AP303) Thermal correction - machine drift
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to locate and measure the position of a critical reference feature in order to detect machine drift, or use an on-machine tool setter to track movement in a machine’s Z-axis caused by thermal effects.
[187kB] (AP304) Tool condition monitoring
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. When tool breakage is identified as a significant expected risk, it is useful to monitor the condition of the cutting tools which are being used. Performing a tool breakage check immediately after using a tool can help to infer whether the component has been correctly machined - particularly for components where tool breakage is the primary cause of failure.
[261kB] (AP305) In-process datum setting
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure datum features then store feature or part locations in the CNC in order to reset a current work coordinate system (WCS), or define a new WCS automatically. This procedure can be carried out whenever it is required during a machining process.
[1.0MB] (AP306) Thermal correction - workpiece expansion
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a spindle probe to measure the size of a reference feature in the machine environment and compare it with the known size of that feature at 20 °C. Produce and apply a scaling factor or offsets to subsequent part measurements and proceed with machining operations based on parameters corrected for thermal effects.

Next steps

Contact us online if you require more information or you have a pricing query, or alternatively you may like to speak directly to your local Renishaw office.