A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine i...A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine is introduced, and the workpiece locating system and the post processing system of the cutter location （CL） data file are analyzed. The new machine has advantages of low costs, simple structure, good rigidity, and high precision. It is easy to be transformed and used to process the workpiece with a complex surface.展开更多
By making use of the advantages of non-uniform rational B-spline （NURBS） curves to represent spatial curves, an instruction format with double NURBS curves suitable for 5-axis coordinated real-time interpolation is ...By making use of the advantages of non-uniform rational B-spline （NURBS） curves to represent spatial curves, an instruction format with double NURBS curves suitable for 5-axis coordinated real-time interpolation is presented to replace the current 5-axis coordinated linear interpolation method defective in low-speed, low-accuracy and enormous numerical control （NC） files in sculptured surface machining. A generation procedure of the NC files with the presented format is introduced and the method to realize the interpolation in an open computer numerical control （CNC） system is developed by ourselves. These illustrated the feasibility of the proposed method and its capability of avoiding all the shortages of 5-axis linear interpolation method.展开更多
Spatial circular arc can be machined conveniently by a 5-axis NC machine tool.Based on the data sampling method,circular interpolation in two-dimensional plane is discussed briefly.The key is to solve the problem of c...Spatial circular arc can be machined conveniently by a 5-axis NC machine tool.Based on the data sampling method,circular interpolation in two-dimensional plane is discussed briefly.The key is to solve the problem of circular center ex- pressed in the workpiece coordinate system by means of the transformation matrix.Circular interpolation in three-dimensional space is analyzed in detail.The method of undetermined coefficient is used to solve the center of the spatial circle and the method of coor- dinate transformation is used to transform the spatial circle into the XY-plane.Circular arc in three-dimensional space can be ma- chined by the positional 5-axis machining and the conical surface can be machined by the continuous 5-axis machining.The velocity control is presented to avoid the feedrate fluctuation.The interpolation algorithms are tested by a simulation example and the inter- polation algorithms are proved feasible.The algorithms are applied to the 5-axis CNC system software.展开更多
This machine tool produced by theQinchuan Machine Tool Worksincorporates all the commonmachining functions, and is equipped withan advanced CNC system. It can continuouslyfinish multiple working procedures such asdril...This machine tool produced by theQinchuan Machine Tool Worksincorporates all the commonmachining functions, and is equipped withan advanced CNC system. It can continuouslyfinish multiple working procedures such asdrilling, milling, boring, reaming and tappingwithin one clamping. Not only is it universaland efficient, but also it can machinecomplicated parts which cannot be machinedon general universal machines, such as variouskinds of precision molds, plates, disks,展开更多
A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind m...A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind milling tool and a 5-axis CNC horizontal milling machine are introduced. This new milling model can efficiently enlarge the material removal volume at the tip of the whirlwind milling tool and improve the producing capacity. The machining strategy of this model is to regulate the orientation of the whirlwind milling tool relatively to the principal directions of the workpiece surface at the point of contact, so as to create a full match with collision avoidance between the workpiece surface and the symmetric rotational surface of the milling tool. The practical results show that this new milling model is an effective method in machining complex three- dimensional surfaces. This model has a good improvement on finishing machining time and scallop height in machining the freeform surfaces over other milling processes. Some actual examples for manufacturing the freeform surfaces with this new model are given.展开更多
Aiming at the approximate error of commonly used methods on calculation of hydrostatic pressures of closed hydrostatic guideways with multiple pockets, a more accurate solution is proposed. Taking design of beam ＆ sl...Aiming at the approximate error of commonly used methods on calculation of hydrostatic pressures of closed hydrostatic guideways with multiple pockets, a more accurate solution is proposed. Taking design of beam ＆ slide-rest guideways for a heavy duty CNC vertical turning mill as an example, under an assumption that stiffnesses of guideways and their jointing structure are sufficiently large, the pressures of the pockets can be attained by adding a co-planarity equation that constrains pocket centers. Then, an optimization model is built to minimize the highest pocket pressure under additional constraints that are posed on the highest seal margin pressure, the highest levitating pressure of the pockets, and the maximum deformation of the guideways. The optimization problem is solved sequentially by using the methods of design of experiments and adaptive simulated annealing on iSIGHT software platform. The results show significant improvements to the original design. Optimized maximum hydrostatic pressure meets the requirement of hydraulic system.展开更多
The cutting forces during end milling process by using Genetic Algorithm are investigated in this paper. However, automated CNC （computer numerical control） programming by milling machine is intended to use for spec...The cutting forces during end milling process by using Genetic Algorithm are investigated in this paper. However, automated CNC （computer numerical control） programming by milling machine is intended to use for special required conditions of programming of tool path length, and analysis of cutting force and optimization of main parameters are presented. Some effective simplification of automated programming is done for cutting force. The cutting force is modelled and analyzed into mathematical simulations in order to optimize the main cutting parameters, also in this case tool path length, it is get as free trajectory. Optimization is carried out by using the Matlab/Genetic Algorithm method that excessively reduce the time and to optimize the main cutting parameters of machining. The number of experiments, measurements and results of cutting force （F~）, are presented in 3D as well as in tables. In order to verify the accuracy of the 3 D simulation with optimization method, the results are compared in experimental and theoretical way. In other word, these results indicate directly that the optimized parameters are capable of machining the workpiece. Achieved results that are presented in this paper may in general help the new researcher as well as manufacturing industries of metal cutting.展开更多
In this work, the cutting forces by end milling operation are analyzed. Therefore, the main parameters of cutting force as cutting speed, feed rate and depth of cut also are investigated in our case. The cutting force...In this work, the cutting forces by end milling operation are analyzed. Therefore, the main parameters of cutting force as cutting speed, feed rate and depth of cut also are investigated in our case. The cutting force is modelled and analyzed into mathematical Wolfram simulations in order to compare the results and in the same time achieve the best solutions. Theoretical results are carried out by using the regression method that required fulfilling the critter by Fisher. The number of experiment, measurements and results of cutting force are presented in 2D as well as 3D. In order to verify the accuracy of the 2D diagram, the results for our case is used both two way such as experimental and theoretical method as well as results are compared. In other hands, these results indicate directly that the optimized parameters are capable of machining the workpiece. The obtained measurement results are compared with theoretical methods in Wolfram software.展开更多
Many small-size precise plastic helical involutes gears are used in electrical appliances to transmit rotary movements con- tinuously and smoothly. Ball-end milling is an effective method for trial manufacture or smal...Many small-size precise plastic helical involutes gears are used in electrical appliances to transmit rotary movements con- tinuously and smoothly. Ball-end milling is an effective method for trial manufacture or small batch production of this type of gear, but the precision of the gear is usually low. In this research, the main sources of the errors of the gear, machining errors of the tooth profile and trace of the gear obtained were analyzed. The correction amounts for these errors are then determined by using a CNC gear tester. They are used to generate a new 3D-CAD model for gear machining with better nrecision.展开更多
Power generators and chemical engineering compressors include heavy and large centrifugal impellers. To produce these impellers in high-speed machining, a 4?-axis milling machine(or a 4-axis machine plus an indexing t...Power generators and chemical engineering compressors include heavy and large centrifugal impellers. To produce these impellers in high-speed machining, a 4?-axis milling machine(or a 4-axis machine plus an indexing table) is often used in the industry, which is more rigid than a5-axis milling machine. Since impeller blades are designed with complex B-spline surfaces and impeller channels spaces vary significantly, it is more efficient to use multiple cutters as large as possible to cut a channel in sections and a blade surface in patches, instead of only using a small cutter to machine a whole blade and a channel. Unfortunately, no approach has been established to automatically calculate the largest diameters of cutters and their paths, which include the indexing table angles. To address this problem, an automated and optimization approach is proposed. Based on the structure of a 4?-axis machine, a geometric model for a cutter gouging/interfering the impeller is formulated, and an optimization model of the cutter diameter in terms of the indexing table angle is established at a cutter contact(CC) point on a blade surface. Then, the diameters of the tools,their orientations, and the indexing table angles are optimized, and each tool's paths are generated for machining its corresponding impeller section. As a test, an impeller is efficiently machined with these tools section by section; thus, this approach is valid. It can be directly used in the industry to improve efficiency of machining centrifugal impellers.展开更多
文摘A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine is introduced, and the workpiece locating system and the post processing system of the cutter location （CL） data file are analyzed. The new machine has advantages of low costs, simple structure, good rigidity, and high precision. It is easy to be transformed and used to process the workpiece with a complex surface.
文摘By making use of the advantages of non-uniform rational B-spline （NURBS） curves to represent spatial curves, an instruction format with double NURBS curves suitable for 5-axis coordinated real-time interpolation is presented to replace the current 5-axis coordinated linear interpolation method defective in low-speed, low-accuracy and enormous numerical control （NC） files in sculptured surface machining. A generation procedure of the NC files with the presented format is introduced and the method to realize the interpolation in an open computer numerical control （CNC） system is developed by ourselves. These illustrated the feasibility of the proposed method and its capability of avoiding all the shortages of 5-axis linear interpolation method.
文摘Spatial circular arc can be machined conveniently by a 5-axis NC machine tool.Based on the data sampling method,circular interpolation in two-dimensional plane is discussed briefly.The key is to solve the problem of circular center ex- pressed in the workpiece coordinate system by means of the transformation matrix.Circular interpolation in three-dimensional space is analyzed in detail.The method of undetermined coefficient is used to solve the center of the spatial circle and the method of coor- dinate transformation is used to transform the spatial circle into the XY-plane.Circular arc in three-dimensional space can be ma- chined by the positional 5-axis machining and the conical surface can be machined by the continuous 5-axis machining.The velocity control is presented to avoid the feedrate fluctuation.The interpolation algorithms are tested by a simulation example and the inter- polation algorithms are proved feasible.The algorithms are applied to the 5-axis CNC system software.
文摘This machine tool produced by theQinchuan Machine Tool Worksincorporates all the commonmachining functions, and is equipped withan advanced CNC system. It can continuouslyfinish multiple working procedures such asdrilling, milling, boring, reaming and tappingwithin one clamping. Not only is it universaland efficient, but also it can machinecomplicated parts which cannot be machinedon general universal machines, such as variouskinds of precision molds, plates, disks,
基金China Postdoctoral Science Foundation(No.2005037348)Science and Technology Research Program of Hubei Province,Ministry of Education,China(No.D200612003)
文摘A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind milling tool and a 5-axis CNC horizontal milling machine are introduced. This new milling model can efficiently enlarge the material removal volume at the tip of the whirlwind milling tool and improve the producing capacity. The machining strategy of this model is to regulate the orientation of the whirlwind milling tool relatively to the principal directions of the workpiece surface at the point of contact, so as to create a full match with collision avoidance between the workpiece surface and the symmetric rotational surface of the milling tool. The practical results show that this new milling model is an effective method in machining complex three- dimensional surfaces. This model has a good improvement on finishing machining time and scallop height in machining the freeform surfaces over other milling processes. Some actual examples for manufacturing the freeform surfaces with this new model are given.
基金This project is supported by National Natural Science Foundation of China(No.60573178)Provincial Natural Science Foundation of Hubei China(No.2006ABA074).
文摘Aiming at the approximate error of commonly used methods on calculation of hydrostatic pressures of closed hydrostatic guideways with multiple pockets, a more accurate solution is proposed. Taking design of beam ＆ slide-rest guideways for a heavy duty CNC vertical turning mill as an example, under an assumption that stiffnesses of guideways and their jointing structure are sufficiently large, the pressures of the pockets can be attained by adding a co-planarity equation that constrains pocket centers. Then, an optimization model is built to minimize the highest pocket pressure under additional constraints that are posed on the highest seal margin pressure, the highest levitating pressure of the pockets, and the maximum deformation of the guideways. The optimization problem is solved sequentially by using the methods of design of experiments and adaptive simulated annealing on iSIGHT software platform. The results show significant improvements to the original design. Optimized maximum hydrostatic pressure meets the requirement of hydraulic system.
文摘The cutting forces during end milling process by using Genetic Algorithm are investigated in this paper. However, automated CNC （computer numerical control） programming by milling machine is intended to use for special required conditions of programming of tool path length, and analysis of cutting force and optimization of main parameters are presented. Some effective simplification of automated programming is done for cutting force. The cutting force is modelled and analyzed into mathematical simulations in order to optimize the main cutting parameters, also in this case tool path length, it is get as free trajectory. Optimization is carried out by using the Matlab/Genetic Algorithm method that excessively reduce the time and to optimize the main cutting parameters of machining. The number of experiments, measurements and results of cutting force （F~）, are presented in 3D as well as in tables. In order to verify the accuracy of the 3 D simulation with optimization method, the results are compared in experimental and theoretical way. In other word, these results indicate directly that the optimized parameters are capable of machining the workpiece. Achieved results that are presented in this paper may in general help the new researcher as well as manufacturing industries of metal cutting.
文摘In this work, the cutting forces by end milling operation are analyzed. Therefore, the main parameters of cutting force as cutting speed, feed rate and depth of cut also are investigated in our case. The cutting force is modelled and analyzed into mathematical Wolfram simulations in order to compare the results and in the same time achieve the best solutions. Theoretical results are carried out by using the regression method that required fulfilling the critter by Fisher. The number of experiment, measurements and results of cutting force are presented in 2D as well as 3D. In order to verify the accuracy of the 2D diagram, the results for our case is used both two way such as experimental and theoretical method as well as results are compared. In other hands, these results indicate directly that the optimized parameters are capable of machining the workpiece. The obtained measurement results are compared with theoretical methods in Wolfram software.
文摘Many small-size precise plastic helical involutes gears are used in electrical appliances to transmit rotary movements con- tinuously and smoothly. Ball-end milling is an effective method for trial manufacture or small batch production of this type of gear, but the precision of the gear is usually low. In this research, the main sources of the errors of the gear, machining errors of the tooth profile and trace of the gear obtained were analyzed. The correction amounts for these errors are then determined by using a CNC gear tester. They are used to generate a new 3D-CAD model for gear machining with better nrecision.
基金supported by the National Natural Science Foundation of China(No.51475328)the National Science and Technology Major Project of China(No.2015ZX04001202)
文摘Power generators and chemical engineering compressors include heavy and large centrifugal impellers. To produce these impellers in high-speed machining, a 4?-axis milling machine(or a 4-axis machine plus an indexing table) is often used in the industry, which is more rigid than a5-axis milling machine. Since impeller blades are designed with complex B-spline surfaces and impeller channels spaces vary significantly, it is more efficient to use multiple cutters as large as possible to cut a channel in sections and a blade surface in patches, instead of only using a small cutter to machine a whole blade and a channel. Unfortunately, no approach has been established to automatically calculate the largest diameters of cutters and their paths, which include the indexing table angles. To address this problem, an automated and optimization approach is proposed. Based on the structure of a 4?-axis machine, a geometric model for a cutter gouging/interfering the impeller is formulated, and an optimization model of the cutter diameter in terms of the indexing table angle is established at a cutter contact(CC) point on a blade surface. Then, the diameters of the tools,their orientations, and the indexing table angles are optimized, and each tool's paths are generated for machining its corresponding impeller section. As a test, an impeller is efficiently machined with these tools section by section; thus, this approach is valid. It can be directly used in the industry to improve efficiency of machining centrifugal impellers.
