Series Design of Large-Scale NC Machine Tool

Product system design is a mature concept in western developed countries. It has been applied in war industry during the last century. However,up until now,functional combination is still the main method for product system de-sign in China. Therefore,in terms of a concept of product generation and product interaction we are in a weak position compared with the requirements of global markets. Today,the idea of serial product design has attracted much attention in the design field and the definition of product generation as well as its parameters has already become the standard in serial product designs. Although the design of a large-scale NC machine tool is complicated,it can be further optimized by the precise exercise of object design by placing the concept of platform establishment firmly into serial product de-sign. The essence of a serial product design has been demonstrated by the design process of a large-scale NC machine tool.

Algorithm for Detecting Volumetric Geometric Accuracy of NC Machine Tool by Laser Tracker

Quick and accurate detecting the error of NC machine tool and performing the error compensation are important to improve the machining accuracy of NC machine tool. Currently, there are many methods for detecting the geometric accuracy of NC machine tool. However, these methods have deficiencies in detection efficiency and accuracy as well as in versatility. In the paper, a method with laser tracker based on the multi-station and time-sharing measurement principle is proposed, and this method can rapidly and accurately detect the geometric accuracy of NC machine tool. The machine tool is controlled to move in the preset path in a 3D space or 2D plane, and a laser tracker is used to measure the same motion trajectory of the machine tool successively at different base stations. The original algorithm for multi-station and time-sharing measurement is improved. The space coordinates of the measuring point obtained by the laser tracker are taken as parameter values, and the initial position of each base point can be determined. The redundant equation concerning the base point calibration can be established by the distance information of the laser tracker, and the position of each base point is further determined by solving the equation with least squares method, then the space coordinates of each measuring point can be calibrated. The singular matrix does not occur in calculation with the improved algorithm, which overcomes the limitations of the original algorithm, that the motion trajectory of machine tool is in a 3D space and there exits height difference between the base stations. Adopting the improved algorithm can expand the application of multi-station and time-sharing measurement, and can meet the quick and accurate detecting requirements for different types of NC machine tool.

Bayesian Reliability Modeling and Assessment Solution for NC Machine Tools under Small-sample Data

Although Markov chain Monte Carlo（MCMC） algorithms are accurate, many factors may cause instability when they are utilized in reliability analysis; such instability makes these algorithms unsuitable for widespread engineering applications. Thus, a reliability modeling and assessment solution aimed at small-sample data of numerical control（NC） machine tools is proposed on the basis of Bayes theories. An expert-judgment process of fusing multi-source prior information is developed to obtain the Weibull parameters＇ prior distributions and reduce the subjective bias of usual expert-judgment methods. The grid approximation method is applied to two-parameter Weibull distribution to derive the formulas for the parameters＇ posterior distributions and solve the calculation difficulty of high-dimensional integration. The method is then applied to the real data of a type of NC machine tool to implement a reliability assessment and obtain the mean time between failures（MTBF）. The relative error of the proposed method is 5.8020×10-4 compared with the MTBF obtained by the MCMC algorithm. This result indicates that the proposed method is as accurate as MCMC. The newly developed solution for reliability modeling and assessment of NC machine tools under small-sample data is easy, practical, and highly suitable for widespread application in the engineering field; in addition, the solution does not reduce accuracy.

Bayesian zero-failure reliability modeling and assessment method for multiple numerical control(NC) machine tools

A new problem that classical statistical methods are incapable of solving is reliability modeling and assessment when multiple numerical control machine tools(NCMTs) reveal zero failures after a reliability test. Thus, the zero-failure data form and corresponding Bayesian model are developed to solve the zero-failure problem of NCMTs, for which no previous suitable statistical model has been developed. An expert-judgment process that incorporates prior information is presented to solve the difficulty in obtaining reliable prior distributions of Weibull parameters. The equations for the posterior distribution of the parameter vector and the Markov chain Monte Carlo(MCMC) algorithm are derived to solve the difficulty of calculating high-dimensional integration and to obtain parameter estimators. The proposed method is applied to a real case; a corresponding programming code and trick are developed to implement an MCMC simulation in Win BUGS, and a mean time between failures(MTBF) of 1057.9 h is obtained. Given its ability to combine expert judgment, prior information, and data, the proposed reliability modeling and assessment method under the zero failure of NCMTs is validated.

STUDY ON NEW METHOD OF IDENTIFYING GEOMETRIC ERROR PARAMETERS FOR NC MACHINE TOOLS

The methods of identifying geometric error parameters for NC machine tools are introduced. According to analyzing and comparing the different methods, a new method-displacement method with 9 lines is developed based on the theories of the movement errors of multibody system (MBS). A lot of experiments are also made to obtain 21 terms geometric error parameters by using the error identification software based on the new method.

Research on Visual Virtual Design Platform for NC Machine Tools

The fundamental ideas on building the collaborative design platform of virtual visualization for NC machine tools are introduced. The platform is based on the globally shared product model conforming to the STEP Standard,and used PDM system to integrate and encapsulate CAD/CAE and other application software for the product development. The platform also integrated the expert system of NC machine tools design,analysis and estimation. This expert system utilized fuzzy estimation principle to evaluate the design and simulation analysis results and make decisions. The platform provides the collaborative intelligent environment for the design of virtual NC machine tools prototype aiming at integrated product design team. It also supports the customized development of NC machine tools.

The Application of the GM(1,1) Metabolism Model to Error Data Processing of NC Machine Tools

This paper applied the gray system theory to error data processing of NCmachine tools according to the characteristic. It presented the gray metabolism model of error dataprocessing. The test method for the model needs less capacity. Practice proved that the method issimple, calculation is easy, and results are exact.

Research on virtual dynamic optimization design for NC machine tools

Virtual dynamic optimization design can avoid the repeated process from de-sign to trial-manufacture and test.The designer can analyze and optimize the productstructures in virtual visualization environment.The design cycle is shortened and the costis reduced.The paper analyzed the peculiarity of virtual optimization design,and put for-wards the thought and flow to implement virtual optimization design.The example to opti-mize the internal grinder was studied via establishing precise finite element model,modi-fying the layout of Stiffened Plates and designing parameters of the worktable,and usingthe technology of modal frequency revision and the technology of multiple tuned damper.The result of optimization design compared the new grinder with the original grinder showsthat the entire machine's first orders natural frequency is enhanced by 17%,and the re-sponse displacement of the grinding-head has dropped by 28% under the first order natu-ral frequency and by 41% under second order natural frequency.Finally,the dynamic per-formance of the internal grinder was optimized.

METHOD OF ENHANCING THE POSITIONING ACCURACY FOR NC MACHINE TOOLS

Based on the kinematics of the multi-body system , a general model for the positioning errors of NC machine tools by means of the lower numbered body array and the geometric constraint is presented. The parameters identification of geometric errors by an improved 22-line method is discussed. Moreover , an intelligent error compensation controller has been developed. All these are verified by a series of experiments on XH714 machining center. The results show that the prosition- ing errors with compensation have been reduced to ±7 μm from 50 μm.

Bayesian networks modeling for thermal error of numerical control machine tools

The interaction between the heat source location, its intensity, thermal expansion coefficient, the machine system configuration and the running environment creates complex thermal behavior of a machine tool, and also makes thermal error prediction difficult. To address this issue, a novel prediction method for machine tool thermal error based on Bayesian networks (BNs) was presented. The method described causal relationships of factors inducing thermal deformation by graph theory and estimated the thermal error by Bayesian statistical techniques. Due to the effective combination of domain knowledge and sampled data, the BN method could adapt to the change of running state of machine, and obtain satisfactory prediction accuracy. Ex- periments on spindle thermal deformation were conducted to evaluate the modeling performance. Experimental results indicate that the BN method performs far better than the least squares (LS) analysis in terms of modeling estimation accuracy.

Identification of the key thermal points on machine tools by grouping and optimizing variables

The grouping and optimization approach to identify the key thermal points on machine tools is studied.To solve the difficulty in grouping because of the high correlated variables from distinct groups,the variables grouping technique is improved.Temperature variables are sorted according to their relativities with the thermal errors.The representative temperature variables are determined by analyzing the variable correlation in sort order and removing the other variables in the same group.Considering the diverse effect of importing the different variables on thermal error model,the method of variable combination optimization is improved.Regression models made up of different combination of representative temperature variables are evaluated by the index of both the determined coefficient and the average residual squares to select the combination of the temperature variables.For the machine tools with complicated structures which need more initial temperature measuring points the improvement is demanded.The improved approach is applied to a precision horizontal machining center to identify the key thermal points.Experimental results show that the proposed approach is capable of avoiding the high correlation among the different groups' variables,effectively reducing the number of the key thermal points without depressing the prediction accuracy of the thermal error model for machine tools.

Carbon Emission Modeling and Analysis in Manufacturing Process for Numerical Control Machine Tools

Reducing carbon emissions( CEs) is the urgent demand all over the world. In order to realize the low-carbon numerical control( NC) machining, the evaluation model of a part's manufacturing carbon emission with NC machine tools was built by considering the influences of the cutting tool geometrical parameters.The manufacturing CEs were produced by electric power,cutting tools,and cutting fluid consumed in manufacturing process. The parameters of cutting tools affected not only the CEs,but also the machining quality. Then the actual constraint models of the machine performance,machining quality were given in order to optimize the cutting parameters and achieve the low-CEs. Finally,a case was given to analyze the influences of the cutting tool angles on the manufacturing CEs. The results show that the CEs decrease as the rake angle and edge angle increase under the constraints of the machine specifications and machining quality.

MODULE DEFINITION MODEL FOR MODULAR DESIGN AND MANUFACTU－RING OF HEAVY DUTY MACHINE TOOLS

The key techniques of modular design of heavy duty NC mathine tools are described. Amodule definition modelfor modular design and manufacturing of heavy duty NC machine tools isbulit and the essential composition of the module definition model (MDM) is discussed in detail. Itis composed of two models: the part definition model (PDM) and the module assembly model(MAM). The PDM and MAM are built and their structures are given. Using object-oriented know-ledge representation and based on these models, an intelligent support system of modular design forheavy duty NC machine tools is developed and implemented This system has been applied to thepractical use of Wuhan Heavy Duty Machine Tool Works

基于改进阿林斯法的数控机床子系统可靠性分配

根据采集到的某国产数控机床的故障信息进行分析整理并进行子系统划分,结合数控机床相关性模型改进可靠性分配方法进行目标值分配.应用层次分析法建立影响因素隶属度集,采取DEMATEL决策实验室分析法确定故障相关数据的中心度影响因素,结合维修性、维修时间、故障停时、故障次数及复杂度确定隶属度函数集,对于各影响因素的权重的确定采用熵权法,进而计算出数控机床的可靠性分配因子.将影响度因素引入阿林斯分配法进行改进,使改进后的方法适用于各子系统串联且存在故障相关性的系统.数值算例表明,相较于传统阿林斯法,本文方法能够减少子系统对故障时间的要求.同时,为验证本文分配结果的合理性,采用蒙特卡洛仿真法以分配结果为基础对目标机床整机进行可靠性预计,计算结果证明了方法的可行性.

㶲耗散法对数控加工刀具路径能耗评估研究

针对数控加工中不同刀具路径加工的能耗问题进行研究,基于㶲(yòng)分析理论提出了一种㶲(yòng)耗散方法,对不同刀具路径加工进行能耗的评估;㶲耗散方法通过对加工过程中的切削热、切削液、机床待机、刀具切削磨损、压缩空气等能耗源进行分析,并对各个能耗源进行数学建模,计算不同刀具路径加工情况下的能耗,通过比较不同刀具路径加工能耗的大小,在保证加工质量的前提下选择能耗较少的刀具路径,达到节能目的;最后分别使用三种不同的刀具路径对曲面进行加工实验,通过实验结果证明:实际加工的能耗与㶲耗散法评估的能耗一致,等间距环形刀具路径比往复刀具路径的总㶲能耗降低了10.93%,等间距环形刀具路径比斜45°刀具路径的总㶲能耗降低了15.24%,说明㶲耗散法评估刀具路径加工能耗是可行的;创新点在于提出了㶲耗散法,通过㶲耗散把电能和物料能等不同类型的能量转化为同一形式进行计算,使能耗评估更加全面。

不同类型CNC五轴工具磨床的运动参数转换原理

详细分析了CNC五轴立式砂轮平动工具磨床 (P型 )和砂轮摆动工具磨床 (B型 )的运动形式及其加工原理 ,并将之与传统机床进行了比较 ;从所要求的同一个几何参数刀具具有相同的几何本质出发 ,给出了P型和B型 2种类型CNC工具磨床的内在运动参数的转换关系。研究阐明了在刀具磨削成形的过程中 ,控制每个瞬时砂轮几何体和工件几何体在空间的相对位姿和相对运动趋势是精确成形的关键。

自由曲面NC加工无干涉刀具轨迹生成

对自由曲面ＮＣ加工中的干涉情况和现有处理方法进行分析．以曲面模型→刀具接触点数据→无干涉刀位数据为基本求解策略，综合多种优化措施。

数控机床误差补偿技术及应用──NC型误差补偿控制器的开发

如何实现数控机床空间误差值的控制是误差补偿技术关键之一。文章介绍以单片机为核心的ＮＣ型误差补偿控制器，并在ＸＨ７１４立式加工中心和ＸＨＦＡ２４２０仿形定梁龙门加工中心上得以实现。该方法对在其他机床及开放型数控系统上应用补偿技术有其重要的参考意义。

NC机床运动误差的矢量分析法

提出了数控机床圆弧插补运动误差的矢量分析方法。可用双球规测量装置测得数控机床圆弧插补运动的综合误差。在分析运动误差与误差矢量关系的基础上以几种典型误差为例，从理论上提出了单一误差源数学模型的建立方法，给出了与单一误差源所对应的误差特征曲线。用这些数学模型和特征曲线可以诊断出数控机床圆弧插补误差产生的原因。

基于MATLAB的镜片NC加工程序生成研究

为了解决非球面镜片数控加工程序难以编写的问题,探讨了基于慢刀伺服加工技术的镜片数控加工程序的自动生成。建立球面和环曲面镜片的数学模型,对数学模型进行笛卡尔坐标向柱坐标的转换。利用镜片数学模型进行等角度离散和法向半径补偿生成刀位点,通过MATLAB软件对得到的刀位点进行轨迹仿真,同时后置处理刀位点生成数控加工程序。加工实例表明,所探讨的基于MATLAB的镜片数控加工程序自动生成过程可以满足加工需要。