Spindle Thermal Error Optimization Modeling of a Five-axis Machine Tool

Aiming at the problem of low machining accu- racy and uncontrollable thermal errors of NC machine tools, spindle thermal error measurement, modeling and compensation of a two turntable five-axis machine tool are researched. Measurement experiment of heat sources and thermal errors are carried out, and GRA（grey relational analysis） method is introduced into the selection of tem- perature variables used for thermal error modeling. In order to analyze the influence of different heat sources on spindle thermal errors, an ANN （artificial neural network） model is presented, and ABC（artificial bee colony） algorithm is introduced to train the link weights of ANN, a new ABC- NN（Artificial bee colony-based neural network） modeling method is proposed and used in the prediction of spindle thermal errors. In order to test the prediction performance of ABC-NN model, an experiment system is developed, the prediction results of LSR （least squares regression）, ANN and ABC-NN are compared with the measurement results of spindle thermal errors. Experiment results show that the prediction accuracy of ABC-NN model is higher than LSR and ANN, and the residual error is smaller than 3 pm, the new modeling method is feasible. The proposed research provides instruction to compensate thermal errors and improve machining accuracy of NC machine tools.

Identification of Kinematic Errors of Five-axis Machine Tool Trunnion Axis from Finished Test Piece

Compared with the traditional non-cutting measurement,machining tests can more accurately reflect the kinematic errors of five-axis machine tools in the actual machining process for the users.However,measurement and calculation of the machining tests in the literature are quite difficult and time-consuming.A new method of the machining tests for the trunnion axis of five-axis machine tool is proposed.Firstly,a simple mathematical model of the cradle-type five-axis machine tool was established by optimizing the coordinate system settings based on robot kinematics.Then,the machining tests based on error-sensitive directions were proposed to identify the kinematic errors of the trunnion axis of cradle-type five-axis machine tool.By adopting the error-sensitive vectors in the matrix calculation,the functional relationship equations between the machining errors of the test piece in the error-sensitive directions and the kinematic errors of C-axis and A-axis of five-axis machine tool rotary table was established based on the model of the kinematic errors.According to our previous work,the kinematic errors of C-axis can be treated as the known quantities,and the kinematic errors of A-axis can be obtained from the equations.This method was tested in Mikron UCP600 vertical machining center.The machining errors in the error-sensitive directions can be obtained by CMM inspection from the finished test piece to identify the kinematic errors of five-axis machine tool trunnion axis.Experimental results demonstrated that the proposed method can reduce the complexity,cost,and the time consumed substantially,and has a wider applicability.This paper proposes a new method of the machining tests for the trunnion axis of five-axis machine tool.

Design of Five-Axis Ultrasonic Assistant Compound Machine Tool

A compound machine tool was designed, which combined rotary ultrasonic assisted grinding, electrical discharge machining(EDM) and multi-axis milling. Experimental results indicated that its positioning accuracy was less than 5.6 μm and its repetitive positioning accuracy was less than 1.8 μm; the vibration amplitude of ultrasonic grinding system was uniform and stable, and the EDM system worked well and stably.A smooth surface of K9 optical glass component was achieved by the grinding method.

A Generic Kinematic Model for Three Main Types of Five-axis Machine Tools

Material removal is one of the most used processes in manufacturing. Five-axis CNC machines are believed to be the best tools in sculptured surface machining. In this study, a generic and unified kinematic model was developed as a viable alternative to the particular solutions that are only applicable to individual machine configurations. This versatile model is then used to verify the feasibility of the two rotational joints within the kinematic chain of three main types of a five-axis machine-tool. This versatile model is very useful applied to the design of five-axis machine tools.

PLANNING METHOD OF TOOL ORIENTATION IN FIVE-AXIS NC MACHINING

The planning method of tool orientation in the five-axis NC machining is studied. The problem of the existing method is analyzed and a new method for generating the global smoothing tool orientation is proposed by introducing the key frame idea in the animation-making. According to the feature of the part, several key tool orientations are set without interference between the tool and the part. Then, these key tool orientations are inter- polated by the spline function. By mapping the surface parameter to the spline parameter, the spline function value is obtained and taken as the tool orientation when generating the CL file. The machining result shows that the proposed method realizes the global smoothing of the tool orientation and the continuity of the rotational speed and the rotational acceleration. It also avoids the shake of the machine tool and improves the machining quality.

Tool wear condition monitoring method of five-axis machining center based on PSO-CNN

The effective monitoring of tool wear status in the milling process of a five-axis machining center is important for improving product quality and efficiency,so this paper proposes a CNN convolutional neural network model based on the optimization of PSO algorithm to monitor the tool wear status.Firstly,the cutting vibration signals and spindle current signals during the milling process of the five-axis machining center are collected using sensor technology,and the features related to the tool wear status are extracted in the time domain,frequency domain and time-frequency domain to form a feature sample matrix;secondly,the tool wear values corresponding to the above features are measured using an electron microscope and classified into three types:slight wear,normal wear and sharp wear to construct a target Finally,the tool wear sample data set is constructed by using multi-source information fusion technology and input to PSO-CNN model to complete the prediction of tool wear status.The results show that the proposed method can effectively predict the tool wear state with an accuracy of 98.27%;and compared with BP model,CNN model and SVM model,the accuracy indexes are improved by 9.48%,3.44%and 1.72%respectively,which indicates that the PSO-CNN model proposed in this paper has obvious advantages in the field of tool wear state identification.

An Open CAM System for Dentistry on the Basis of China-made 5-axis Simultaneous Contouring CNC Machine Tool and Industrial CAM Software

China-made 5-axis simultaneous contouring CNC machine tool and domestically developed industrial computer-aided manufacture （CAM） technology were used for full crown fabrication and measurement of crown accuracy, with an attempt to establish an open CAM system for dental processing and to promote the introduction of domestic dental computer-aided design （CAD）/CAM system. Commercially available scanning equipment was used to make a basic digital tooth model after preparation of crown, and CAD software that comes with the scanning device was employed to design the crown by using domestic industrial CAM software to process the crown data in order to generate a solid model for machining purpose, and then China-made 5-axis simultaneous contouring CNC machine tool was used to complete machining of the whole crown and the internal accuracy of the crown internal was measured by using 3D-MicroCT. The results showed that China-made 5-axis simultaneous contouring CNC machine tool in combination with domestic industrial CAM technology can be used for crown making and the crown was well positioned in die. The internal accuracy was successfully measured by using 3D-MicroCT. It is concluded that an open CAM system for den-tistry on the basis of China-made 5-axis simultaneous contouring CNC machine tool and domestic industrial CAM software has been established, and development of the system will promote the introduction of domestically-produced dental CAD/CAM system.

Tool Positioning Algorithm Based on Smooth Tool Paths for 5-axis Machining of Sculptured Surfaces

The current research of the 5-axis tool positioning algorithm mainly focuses on searching the local optimal tool position without gouging and interference at a cutter contact（CC） point,while not considering the smoothness and continuity of a whole tool path.When the surface curvature varies significantly,a local abrupt change of tool paths will happen.The abrupt change has a great influence on surface machining quality.In order to keep generated tool paths smooth and continuous,a five-axis tool positioning algorithm based on smooth tool paths is presented.Firstly,the inclination angle,the tilt angle and offset distance of the tool at a CC point are used as design variables,and the machining strip width is used as an objective function,an optimization model of a local tool positioning algorithm is thus established.Then,a vector equation of tool path is derived by using the above optimization model.By analyzing the equation,the main factors affecting the tool path quality are obtained.Finally,a new tool position optimization model is established,and the detailed process of tool position optimization is also given.An experiment is conducted to machine an aircraft turbine blade by using the proposed algorithm on a 5-axis blade grinding machine,and the machined blade surface is measured with a coordinate measuring machine（CMM）.Experimental and measured results show that the proposed algorithm can ensure tool paths are smooth and continuous,improve the tool path quality,avoid the local abrupt change of tool paths,and enhance machining quality and machining efficiency of sculptured surfaces.

液体静压运动副的四轴联动精密加工机床结构设计

大口径平面、球面、非球面光学元件广泛应用于光刻机、高能激光器、高分相机等高端装备的光学系统中,尺寸大于400 mm×400 mm、表面轮廓精度均方根值(root mean square,RMS)优于1μm等技术指标是大口径光学元件在磨削加工阶段的目标精度要求。磨削工艺主要面临如何实现高平滑的表面轮廓加工以及控制亚表面损伤层深度等问题。根据已有的实验研究,磨削机床采用高精度的液体静压运动副,可以有效地提高光学元件抛光后表面轮廓的平滑程度以及降低亚表面损伤层的厚度。具备上述特性的高性能磨削机床国外对中国禁运,而国内尚无成熟的商品。因此,文章研制了一种采用液体静压运动副的四轴联动精密加工机床,分析了机床的主要构型,进行了机床主要运动部件的精度分配,完成了基于液体静压运动副的X/Y/Z/C四轴的设计方案,最后进行了光学元件磨削加工工艺实验,实现了380 mm×541 mm口径微晶玻璃磨削面形精度±0.471μm(RMS值)、表面粗糙度Ra0.3μm的加工目标。

Design and development of a five-axis machine tool with high accuracy,stiffness and efficiency for aero-engine casing manufacturing

In order to satisfy the machining requirements of aero-engine casing in modern aviation industry, this paper investigates three main issues during the design and development process of a five-axis machine tool with high accuracy, stiffness and efficiency, including whole structure design,key components design, and supporting stiffness design. First, an appropriate structure of five-axis machine tool is determined considering the processing characteristics of aero-engine casing. Then, a dual drive swing head and a compact motorized spindle are designed with enough drive capability and stiffness, and related structure, assembly method, cooling technology, and performance simulation are given in detail. Next, a design method of supporting stiffness of guide is proposed through the deformation prediction of the spindle end. Based on above work, a prototype of machine tool is developed, and some experiments are carried out, including performance tests of swing head and motorized spindle, and machining of a simulated workpiece of aero-engine casing. All experimental results show that the machine tool has satisfactory accuracy, stiffness and efficiency, which meets the machining requirements of aero-engine casing. The main work can be used as references for engineers and technicians, which are meaningful in practice.

Improved closed-loop tracking interferometer measurement for a five-axis machine tool with a bi-rotary milling head

Tracking interferometer based on bi-rotary milling head is a novel scheme to conduct volumetric accuracy measurement of a five-axis machine tool.The laser beam direction of the interferometer can be regulated to follow the retroreflector by moving the bi-rotary head.This is a low-cost implementation of multilateration measurement,and its measurement accuracy is mainly affected by the error motion of the rotary axes.This paper proposes an improved multilateration principle to identify the positionindependent geometric errors of rotary axis and laser beam,and minimize their impact on the measurement uncertainty.A closed-loop tracking interferometer system installed on the spindle is developed to perform the measurement with high tracking accuracy.The device can be installed on an ordinary five-axis machine tool without modifying the machine tool structure.The proposed scheme is conducive to improving the accuracy and practical application of the tracking interferometer based on birotary milling head.Experiments with the corresponding closed-loop tracking interferometer and uncertainty analysis are conducted to verify the performance of the proposed measurement scheme.

Development of an oscillating grinding machine tool based on error analysis

Oscillating grinding machine tool is the core equipment when machining crankshaft pin journal,which directly determines the final quality.This paper describes the development of an oscillating grinding machine tool based on error analysis.First,the error analysis of oscillating grinding for crankshaft pin journal is carried out,including the effect on machining accuracy caused by each error and corresponding error sensitivity.The results show that the tracking error of X-axis has the greatest influence on the grinding accuracy of pin journal,thus,the grinding carriage feed system is the critical component of an oscillating grinding machine tool,which should be given priority during the development process.Next,the development of an oscillating grinding machine tool is described.The whole structure is given,and the grinding carriage feed system is emphatically presented involving drive mode and assembly method.Other components of the oscillating grinding machine tool are also introduced.Finally,some grinding experiments are performed on the prototype,and the results show that all workpieces are qualified under different conditions,which verify the performance of the developed oscillating grinding machine tool.

基于稀疏匹配的机床零件瑕疵投影辅助视觉检测方法

机械臂在自动精准打磨机床零件前需要对机床零件进行特征识别,传统激光点阵扫描精度高,但设备成本高昂而难以规模应用。引入固定式投影产生扫描线图、棋盘格图和随机灰度图等特征作为测量辅助,并结合双目立体视觉测量对零件瑕疵进行检测,改善了传统双目视觉针对光滑平面零件难以识别特征进行立体匹配的情况。分析结果与激光点阵扫描结果进行精度校验。同时,通过5种经典局部立体匹配算法与所提方法进行精度比较,并对辅助图的关键参数进行精度关联分析。最后,引入自适应算法对所提方法进行优化以提高识别精度。结果表明:随机灰度图能够显著提高匹配精度,扫描线优化与子像素拟合能够进一步提高匹配精度,扫描线法与棋盘格法优化后精度提高较大,新方法可有效识别平面零件的瑕疵特征,检测精度达标区域占比大于98%。

一种涡轮盘榫槽的组合加工刀具设计研究

汽轮机涡轮盘连接叶片的位置通常采用榫槽结构。针对小型燕尾型榫槽,目前常采用一种成型刀具一次加工成型,导致被加工零件精度低、表面粗糙度差且刀具成本高。为解决目前制造工艺的局限性,提出了一种组合刀具设计思路。首先,根据燕尾槽型榫槽的结构特点,设计出4把刀的刀具型线和尺寸参数,通过UG等建模软件建立模型,利用ANSYS软件进行有限元分析;然后,制定组合刀具的制造工艺方案,通过NUMROTO刀具编程软件进行路径规划和程序编制;最后在SAACKE五轴工具磨床上磨削加工出合格的组合刀具。通过仿真及实际切削试验验证了该方案切实可行,相较于传统加工方法,有着加工精度高、表面粗糙度低、切削热低且成本低等优点。

基于五轴平台的枞树型轮槽铣刀加工工艺分析

轮槽成型铣刀是加工汽轮机轮毂槽的重要工具,其结构复杂且加工困难。为提高加工效率和精度,以某型高速钢轮槽铣刀为例,提出基于五轴平台的加工工艺方法。使用UG软件基于五轴车铣复合机床规划粗加工刀具路径,并采用专用后置处理器生成数控加工程序,通过虚拟机床进行仿真验证;采用NUMROTO软件规划精加工路径,获得磨削NC代码并进行虚拟加工验证;进行实际切削验证,通过DOOSAN PUMA SMX2600ST车铣复合加工中心对刀具进行粗加工后,在SAACKE UWIF五轴工具磨床上完成刀具的精加工。实验结果证明,该工艺方法不仅能保证产品质量符合工艺设计要求,而且制造效率提高了20%。

机加工刀具用W6Mo5Cr4V2钢开裂原因分析

通过宏观检验、化学成分分析、硬度测试、金相检验和SEM形貌分析等方法对机加工刀具用W6Mo5Cr4V2钢开裂原因进行了分析。结果表明,失效机加工刀具组织存在断续网状与堆集的多角状碳化物以及后续热处理工艺不当导致的刀具出现未淬透现象是造成刀具开裂的主要原因。刀具淬硬区与未淬硬区之间的过渡区域及芯部网状与堆集的多角状碳化物集中处会产生较大应力集中点,在刀具进行磨削加工工艺或操作不当时,表层拉应力超过材料强度极限,并在内部淬火应力作用下,在应力点产生裂纹并扩展,最终导致刀具崩裂。

Analytical modeling of geometric errors induced by cutter runout and tool path optimization for five-axis flank machining

The cutter runout effect has significant influence on the shape of cutter swept surface and the machining surface quality. Hence,it is necessary to integrate the cutter runout effect in cutter swept surface modeling,geometric error prediction and tool path optimization for five-axis flank machining. In this paper,an envelope surface model considering cutter runout effect is first established,and geometric errors induced by runout effect are derived based on the relative motion analysis between the cutter and part in machining. In the model,the cutter runout is defined by four parameters,including inclination angle,location angle,offset value and the length of cutter axis. Then the runout parameters are integrated into the rotation surface of each cutting edge that is used to form the final cutter envelope surface for the five-axis machining process. Thus,the final resulting geometric errors of the machined surface induced by cutter runout can be obtained through computing the deviations from the nominal cutter swept surface. To reduce these errors,an iterative least square method is used to optimize the tool paths for five-axis flank machining. Finally,a validation example is given for a specific ruled surface. Results show the effectiveness and feasibility of the analytical model of geometric errors induced by cutter runout,and also show that the geometric errors can be reduced significantly using the proposed tool path planning method.

A TOOL PATH CORRECTION AND COMPRESSION ALGORITHM FOR FIVE-AXIS CNC MACHINING

A novel approach is proposed for correcting command points and compressing discrete axis commands into a C2 continuous curve.The relationship between values of rotation angles and tool posture errors is firstly analyzed.A segmentation method based on values of rotation angles and lengths of adjacent points is then used to subdivide these command points into accuracy regions and smoothness regions.Since tool center points generated by CAD/CAM system are usually lying in the space that is apart from the desired curve within a tolerance distance,and the corresponding tool orientation vector may change a lot while the trajectory length of the tool center point is quite small,directly machining with such points will lead to problems of coarse working shape and long machining time.A correction method for command points is implemented so that good processing effectiveness can be achieved.Also,the quintic spline is used for compressing discrete command points into a C2 continuous smooth curve.The machining experiment is finally conducted to demonstrate the effectiveness of the proposed algorithm.

TOOL ORIENTATION PLANNING FOR FIVE-AXIS CNC MACHINING OF OPEN FREE-FORM SURFACES

For the geometry characteristics of open free-form surfaces,it is hard to consider global interference during the planning of feasible domains.Therefore,the optimal kinematic orientation of tool axis will no longer be confined to the boundary of feasible domains.In this paper,according to the principle demanding that the tool should be fitted to a surface as close as possible and relevant processing parameters,a feasible domain of tool orientation for each cutter contact is planned in the local feed coordinates system.Then,these feasible domains of the tool orientation are transformed into the same coordinates system of the machine tool by the inverse kinematics transformation.The linear equations based feasible domain method and Rosen gradient projection algorithm are used to improve the optimization process in precision and efficiency of the algorithm.It constructs the variation of tool orientation optimization model and ensures the smoothness of tool orientation globally.Simulation and analysis of examples show that the proposed method has good kinematics performance and greatly improves the efficiency.

Efficiently constructing collision-free regions of tool orientations for holder in five-axis machining of blisk

Blisks with the integral structure are key parts used in new jet engines to promote the performance of aircrafts,which also increases the complexity of tool orientation planning in the five-axis machining.It is an essential task to find the collision-free tool orientation when the tool holder is pushed deep into the channel of blisk to increase rigidity and reduce vibration.Since the radius of the holder varies with the height,the line-visibility is no longer applicable when constructing collision-free regions of tool orientation.In this paper,a method of constructing collisionfree regions without interference checking is proposed.The work of finding collision-free regions resorts to solving the local contact curves on the checking surfaces of blisk.And it further transforms into searching the locally tangent points(named critical points)between the holder and surface.Then a tracking-based algorithm is proposed to search the sample critical points on these local contact curves.And the corresponding critical vectors are also calculated synchronously.Besides,the safety allowance,discrete precision and acceptable deviation are introduced in the algorithm to ensure accuracy by controlling the angle between two adjacent critical vectors properly.After that,the searched critical vectors are mapped orderly to two-dimensional space and the collisionfree regions are constructed.This method is finally verified and compared with a referenced method.The results show that the proposed method can efficiently construct collision-free regions for holder under the given accuracy.