A New Dynamics Analysis Model for Five-Axis Machining of Curved Surface Based on Dimension Reduction and Mapping

The equipment used in various fields contains an increasing number of parts with curved surfaces of increasing size.Five-axis computer numerical control(CNC)milling is the main parts machining method,while dynamics analysis has always been a research hotspot.The cutting conditions determined by the cutter axis,tool path,and workpiece geometry are complex and changeable,which has made dynamics research a major challenge.For this reason,this paper introduces the innovative idea of applying dimension reduction and mapping to the five-axis machining of curved surfaces,and proposes an efficient dynamics analysis model.To simplify the research object,the cutter position points along the tool path were discretized into inclined plane five-axis machining.The cutter dip angle and feed deflection angle were used to define the spatial position relationship in five-axis machining.These were then taken as the new base variables to construct an abstract two-dimensional space and establish the mapping relationship between the cutter position point and space point sets to further simplify the dimensions of the research object.Based on the in-cut cutting edge solved by the space limitation method,the dynamics of the inclined plane five-axis machining unit were studied,and the results were uniformly stored in the abstract space to produce a database.Finally,the prediction of the milling force and vibration state along the tool path became a data extraction process that significantly improved efficiency.Two experiments were also conducted which proved the accuracy and efficiency of the proposed dynamics analysis model.This study has great potential for the online synchronization of intelligent machining of large surfaces.

Reliability Analysis of Satellite Turntable System under Multiple Operation Modes Based on Multi-Valued Decision Diagrams

As a payload support system deployed on satellites,the turntable system is often switched among different working modes during the on-orbit operation,which can experience great state changes.In each mode,the missions to be completed are different,consecutive and non-over-lapping,from which the turntable system can be considered to be a phased-mission system(PMS).Reliability analysis for PMS has been widely studied.However,the system mode cycle characteristic has not been taken into account before.In this paper,reliability analysis method of the satellite turntable system is proposed considering its multiple operation modes and mode cycle characteristic.Firstly,the multi-valued decision diagrams(MDD)manipulation rules between two adjacent mission cycles are proposed.On this basis,MDD models for the turntable system in different states are established and the reliability is calculated using the continuous time Markov chains(CTMC)method.Finally,the comparative study is carried out to show the effectiveness of our proposed method.

OBSERVER/FILTER STRUCTURE BASED ADAPTIVE FRICTION COMPENSATION FOR HIGH PRECISION TURNTABLE

Two adaptive friction compensation schemes are developed for a high precision turntable system with nonlinear dynamic friction to handle two types of parametric uncertainties in the friction. Both schemes utilize a nonlinear observer/filter structure to compensate for uncertainties in corresponding friction parameters associated with the turntable system. Moreover, in the second scheme, adjustable gains are introduced into the dual nonlin- ear filters and they can be tuned to improve the position tracking performance. In both cases, a Lyapunov-like argument is provided for the global asymptotic stability of the closed-loop system. Simulation results demonstrate the effectiveness of the proposed schemes.

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.

Load-induced error identification of hydrostatic turntable and its influence on machining accuracy

In heavy duty machine tools, hydrostatic turntable is often used as a means for providing rotational motion and supporting workpiece, so the accuracy of turntable is crucial for part machining. In order to analyze the influence of load-indcued errors on machining accuracy, an identification model of load-induced errors based on the deformation caused by applied load of hydrostatic turntable of computerized numerical control(CNC) gantry milling heavy machine is proposed. Based on multi-body system theory and screw theory, the space machining accuracy model of heavy duty machine tool is established with consideration of identified load-induced errors. And then, the influence of load-induced errors on space machining accuracy and the roundness error of a milled hole is analyzed. The analysis results show that load-induced errors have a big influence on the roundness error of machined hole, especially when the center of the milled hole is far from that of hydrostatic turntable.

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.

Fault detection of switched linear systems with its application to turntable systems

This paper is concerned with the H∞ fault detection for continuous-time linear switched systems with its application to turntable systems.The solvability condition for a desired filter is established based on the proposed sufficient condition.Based on the double channel scheme of the turntable control system,the turntable system can be modeled as a switched system.Finally,by taking the turntable system as a numerical example,the effectiveness of the proposed theory is well validated.

Research on identifying the dynamic error model of strapdown gyro on 3-axis turntable

The dynamic errors of gyros are the important error sources of a strapdown inertial navigation system. In order to identify the dynamic error model coefficients accurately, the static error model coefficients which lay a foundation for compensating while identifying the dynamic error model are identified in the gravity acceleration fields by using angular position function of the three-axis turntable. The angular acceleration and angular velocity are excited on the input, output and spin axis of the gyros when the outer axis and the middle axis of a three-axis turntable are in the uniform angular velocity state simultaneously, while the inner axis of the turntable is in different static angular positions. 8 groups of data are sampled when the inner axis is in 8 different angular positions. These data are the function of the middle axis positions and the inner axis positions. For these data, harmonic analysis method is applied two times versus the middle axis positions and inner axis positions respectively so that the dynamic error model coefficients are finally identified through the least square method. In the meantime the optimal angular velocity of the outer axis and the middle axis are selected by computing the determination value of the information matrix.

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.

Effect of working parameters on performance characteristics of hydrostatic turntable by using FSI-thermal model

Effects of working parameters on performance characteristics of hydrostatic turntable are researched by applying the fluid-structure-thermal coupled model.Fluid-structure interaction(FSI)technique and computational fluid dynamics(CFD)method are both employed by this new model,and thermal effects are also considered.Hydrostatic turntable systems with a series of oil supply pressures,various oil recess depth and several surface roughness parameters are studied.Performance parameters,such as turntable displacement,system flow rate,temperature rise of lubrication,stiffness and damping coefficients,are derived from different working parameters(rotational speed of turntable and exerted external load)of the hydrostatic turntable.Numerical results obtained from this FSI-thermal model are presented and discussed,and theoretical predictions are in good agreement with the experimental data.Therefore,this developed model is a very useful tool for studying hydrostatic turntables.The calculation results show that in order to obtain better performance,a rational selection of the design parameters is essential.

Axis intersection measurement of three-axis turntable with two crosshair targets

In order to measure three-axis intersection error, two crosshair targets were fixed in the inner axis frame of a three-axis turntable. Also a theodolite was used to point its telescope to the targets and to measure the horizontal angles when three axes were on equi-spaced angle positions. The calculation equations of the axis intersection were deduced from the mounting position of the theodolite, positions of two targets, angular positions of three axes, and the measured horizontal angles with the theodolite. Finally, a practical measurement is carried out on a horizontal three-axis turntable and error analysis is conducted.

Coupling Analysis of Moment of Inertia & Dynamic on Optoelectronic Tracking Turntable

With photoelectric tracking system as the research object,based on the theorem of moment of momentum and Euler dynamic equation,Nonlinear biaxial coupling dynamic model of tracking turntable is established.Effects of moment of inertia coupling,speed coupling and the dynamic coupling between tracking turntable shafts were studied,the analytical relation between them was given in theory.Verify the change trend of theoretical model.And it provides the theory reference and model base,for the future design of the high precision tracking controller And control parameter selection and optimization.In the end,specific measures are made for structure optimization.

Continuity control method of cutter posture vector for efficient five-axis machining

During five-axis machining of impeller, the excessive local interference avoidance leads to inconsistency of cutter posture, low quality of machined surface and increase of processing time. Therefore, in order to improve the efficiency of five-axis machining of impellers, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. By using an MC-space algorithm for interference avoidance, an MB-spline algorithm for continuous control was intended to create a five-axis machining tool path with excellent surface quality and economic feasibility. A five-axis cutting experiment was performed to verify the effectiveness of the continuity control. The result shows that the surface shape with continuous method is greatly improved, and the surface roughness is generally favorable. Consequently, the effectiveness of the suggested method is verified by identifying the improvement of efficiency of five-axis machining of an impeller in aspects of surface quality and machining time.

High accuracy NURBS interpolation for five-axis machine of table-rotating/spindle-tilting type

In this paper, the definition of NURBS curve and a speed-controlled interpolation in which the feed rate is automatically adjusted in order to meet the specified chord error limit were discussed. Besides those, a definition of linear interpolation error of post-processed data was proposed, which should be paid more attention to because it will not only reduce quality of the surface but also may cause interference and other unexpected trouble. In order to control the error, a robust algorithm was proposed, which successfully met a desired error limit through interpolating some essential CL data. The excellence of the proposed algorithm, in terms of its reliability and self-adaptiveness, has been proved by simulation results.

Rotary axis calculation for five-axis FDM printer using a point-fitting optimization method

This paper presents an optimization method to compute the rotary axes of a 5-axis FDM printer whose A-and C-axes have large deviations relative to the x-and z-directions.The optimization model is designed according to the kinematic model in which a point rotates around a spatial line in the machine coordinate system of the printer.The model considers the A-and C-axes as two spatial lines.It is a two-object optimization model including two aspects.One is that the sum of deviations between the measured and computed points should be small;the other is that the deviations should be uniformly distributed for every measured point.A comparison of the new optimization method with conventional error-compensation methods reveals that the former has higher location accuracy.Using the optimized AC axes,5-axis 3D printing paths are planned for some complex workpieces.Data analysis and printing samples show that the optimized AC axes satisfy 5-axes FDM printing requirements for nozzles with a diameter of 1.0 mm.

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.

An Investigation into the Influence of the Airflow Path on the Convective Heat Transfer for an Eddy Current Retarder Turntable

In order to improve the convective heat transfer relating to an eddy current retarder,the finite element model has been used to assess the performances of different possible designs.In particular,assuming the steady running state of retarder as the working condition,flow and temperature fields have been obtained for the rotor.The influence of airflow path on heat dissipation has been analysed,and the influence of the temperature field distribution on the performance of retarder has been discussed accordingly.The results show that when the steady running state of the turntable is considered,the maximum temperature is lower,the level of turbulence flow is mitigated,and the temperature distribution becomes more regular.These factors contribute to improve the heat dissipation ability of the retarder.

Dynamic error research and application of an angular measuring system belonging to a high precision excursion test turntable

Angular measuring system is the most important component of a servo turntable in inertial test apparatus. Its function and precision determine the turntable＇ s function and precision. It attaches importance to research on inertial test equipment. This paper introduces the principle of the angular measuring system using amplitude discrimination mode. The dynamic errors axe analyzed from the aspects of inductosyn, amplitude and function error of double-phase voltage and wavefonn distortion. Through detailed calculation, theory is provided for practical application; system errors are allocated and the angular measuring system meets the accuracy requirement. As a result, the schedule of the angular measuring system can be used in practice.

USB Turntable

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Light pen whole space coordinate measuring system based on a tracking turntable

Light pen coordinate measuring system(LPCMS)is a kind of portable coordinate measuring technique based on vision metrology.In classical LPCMS,the measuring range is limited to the camera’s field of view.To overcome this defect,a new LPCMS is designed in this paper to fulfil whole space coordinate measurement.The camera is installed on a turntable instead of a tripod,so that the camera can rotate to track the movement of the light pen.The new system can be applied to large scale onsite measurement,and therefore it notably extends the application of LPCMS.To guarantee the accuracy of the new system,a method to calibrate the parameters of the tracking turntable is also proposed.Fixing the light pen at a stationary position,and changing the azimuth angles of the turntable’s two shafts,so that the camera can capture the images of the light pen from different view angles.According to the invariant spatial relationship between the camera and the pedestal of the tracking turntable,a system of nonlinear equations can be established to solve the parameters of the turntable.Experimental results show that the whole space coordinate measuring accuracy of the new system can reach 0.25 mm within 10 m.It can be concluded that the newly designed system can significantly expand the measuring range of LPCMS without losing too much accuracy.