On-machine measurement(OMM)stands out as a pivotal technology in complex curved surface adaptive machining.However,the complex structure inherent in workpieces poses a significant challenge as the stylus orientation f...On-machine measurement(OMM)stands out as a pivotal technology in complex curved surface adaptive machining.However,the complex structure inherent in workpieces poses a significant challenge as the stylus orientation frequently shifts during the measurement process.Consequently,a substantial amount of time is allocated to calibrating pre-travel error and probe movement.Furthermore,the frequent movement of machine tools also increases the influence of machine errors.To enhance both accuracy and efficiency,an optimization strategy for the OMM process is proposed.Based on the kinematic chain of the machine tools,the relationship between the angle combination of rotary axes,the stylus orientation,and the calibration position of pre-travel error is disclosed.Additionally,an OMM efficiency optimization model for complex curved surfaces is developed.This model is solved to produce the optimal efficiency angle combinations for each to-be-measured point.Within each angle combination,the effects of positioning errors on measurement results are addressed by coordinate system offset and measurement result compensation method.Finally,the experiments on an impeller are used to demonstrate the practical utility of the proposed method.展开更多
Selecting the optimal machining parameters for impeller surface is a challenging task in the automatic manufacturing industry, due to its free-form surface and deep-crooked flow channel.Existing experimental methods r...Selecting the optimal machining parameters for impeller surface is a challenging task in the automatic manufacturing industry, due to its free-form surface and deep-crooked flow channel.Existing experimental methods require lots of machining experiments and off-line tests, which may lead to high machining cost and low efficiency. This paper proposes a novel method of machining parameters optimization for an impeller based on the on-machine measuring technique. The absolute average error and standard deviation of the measured points are used to define the grey relational grade for reconstructing the objective function, and the complex problem of multi-objective optimization is simplified into a problem of single-objective optimization. Then, by comparing the values of the defined grey relational grade in a designed orthogonal experiment, the optimal combination of the machining parameters is obtained. The experiment-solving process of the objective function corresponds to the minimization of the used errors, which is advantageous to reducing the machining error. The proposed method is efficient and low-cost, since it does not require re-clamping the workpiece for off-line tests. Its effectiveness is verified by an on-machine inspection experiment of the impeller blade.展开更多
Although there are some multi-sensor methods for measuring the straightness and tilt errors of a linear slideway, they need to be further improved in some aspects, such as suppressing measurement noise and reducing pr...Although there are some multi-sensor methods for measuring the straightness and tilt errors of a linear slideway, they need to be further improved in some aspects, such as suppressing measurement noise and reducing precondition.In this paper, a new four-sensor method with an improved measurement system is proposed to on-machine separate the straightness and tilt errors of a linear slideway from the sensor outputs, considering the influences of the reference surface profile and the zero-adjustment values. The improved system is achieved by adjusting a single sensor to di erent positions. Based on the system, a system of linear equations is built by fusing the sensor outputs to cancel out the e ects of the straightness and tilt errors. Three constraints are then derived and supplemented into the linear system to make the coe cient matrix full rank. To restrain the sensitivity of the solution of the linear system to the measurement noise in the sensor outputs, the Tikhonov regularization method is utilized. After the surface profile is obtained from the solution, the straightness and tilt errors are identified from the sensor outputs. To analyze the e ects of the measurement noise and the positioning errors of the sensor and the linear slideway, a series of computer simulations are carried out. An experiment is conducted for validation, showing good consistency. The new four-sensor method with the improved measurement system provides a new way to measure the straightness and tilt errors of a linear slideway, which can guarantee favorable propagations of the residuals induced by the noise and the positioning errors.展开更多
The purpose of this study is to develop a Web-based on-machine mould identification and measurement system. The Web-based mould identification system matches obtained vision information with CAD database. Developed We...The purpose of this study is to develop a Web-based on-machine mould identification and measurement system. The Web-based mould identification system matches obtained vision information with CAD database. Developed Web-based system is to exchange messages between a server and a client by making of ActiveX control, and the result of mould identification is shown on Web-browser at remote site. For effective feature classification and extraction, the signature method is used to make meaningful information from obtained image data. For on-machine measurement of the matched mould, inspection database is constructed from CAD database using developed inspection planning methods. The results are simulated and analyzed using developed system to verify the effectiveness of the proposed methods.展开更多
This paper presents an integration methodology for ma chining and measuring processes using OMM (On-Machine Measurement) technology b ased on CAD/CAM/CAI integration concept. OMM uses a CNC machining center as a me as...This paper presents an integration methodology for ma chining and measuring processes using OMM (On-Machine Measurement) technology b ased on CAD/CAM/CAI integration concept. OMM uses a CNC machining center as a me asuring station by changing the tools into measuring probes such as touch-type, laser and vision. Although the measurement accuracy is not good compared to tha t of the CMM (Coordinate Measuring Machine), there are distinctive advantages us ing OMM in real situation. In this paper, two topics are handled to show the eff ectiveness of the machining and measuring process integration: (1) inspection pl anning strategy for sculptured surface machining and (2) tool path compensation for profile milling process. For the first topic, as a first step, effective mea suring point locations are determined to obtain optimum results for given sampli ng numbers. Two measuring point selection methods are suggested based on the CAD /CAM/CAI integration concept: (1) by the prediction of cutting errors and (2) by considering cutter contact points to avoid the measurement errors caused by cus ps. As a next step, the TSP (Traveling Salesman Problem) algorithm is applied to minimize the probe moving distance. Appropriate simulations and experiments are performed to verify the proposed inspection planning strategy, and the results are analyzed. For the second topic, a methodology for profile milling error comp ensation is presented by using an ANN (Artificial Neural Network) model trained by the inspection database of OMM system. First, geometric and thermal errors of the machining center are compensated using a closed-loop configuration for the improvement of machining and inspection accuracy. The probing errors are also t aken into account. Then, a specimen workpiece is machined and then the machi ning surface error distribution is measured on the machine using touch-type pro be. In order to efficiently analyze the machining errors, two characteristic err or parameters (W err and D err) are defined. Subsequently, these param eters are modeled by applying the RFB (Radial Basis Function) network approach a s an ANN model. Based on the RBF network model, the tool paths are compensated i n order to effectively reduce the errors by employing an iterative algorithm. In order to validate the approaches proposed in this paper, a concrete case of the machining process is taken into account and about 90% of machining error reduction is successfully accomplished through the proposed approaches.展开更多
As crucial parts of an aeroengine,blades are vulnerable to damage from long-term operation in harsh environments.The ultrasonic surface rolling process(USRP)is a novel surface treatment technique that can highly impro...As crucial parts of an aeroengine,blades are vulnerable to damage from long-term operation in harsh environments.The ultrasonic surface rolling process(USRP)is a novel surface treatment technique that can highly improve the mechanical behavior of blades.During secondary machining,the nominal blade model cannot be used for secondary machining path generation due to the deviation between the actual and nominal blades.The clamping error of the blade also affects the precision of secondary machining.This study presents a two-sided USRP(TS-USRP)machining for aeroengine blades on the basis of on-machine noncontact measurement.First,a TS-USRP machining system for blade is developed.Second,a 3D scanning system is used to obtain the point cloud of the blade,and a series of point cloud processing steps is performed.A local point cloud automatic extraction algorithm is introduced to extract the point cloud of the strengthened region of the blade.Then,the tool path is designed on the basis of the extracted point cloud.Finally,an experiment is conducted on an actual blade,with results showing that the proposed method is effective and efficient.展开更多
The machining accuracy of the curved surfaces of integrated turbine blades directly determines the performance and service life of the turbojet engine system.In this paper,a non-contact on-machine measurement system i...The machining accuracy of the curved surfaces of integrated turbine blades directly determines the performance and service life of the turbojet engine system.In this paper,a non-contact on-machine measurement system is developed for precision milling of integrated turbines to reduce the impact of workpiece deformation,overcutting,tool chatter,and material work hardening.Milling with the on-machine measurement system obtained high-quality integrated turbine surfaces.The geometric accuracy error(PV)is below 3μm,and the surface roughness(Ra)is less than 2μm.The processed integrated turbine blade can achieve the accuracy requirements in the design and manufacturing and can be practically applied to the entire turbojet engine.展开更多
On-machine tool setting is a pivotal approach in achieving intelligent manufacturing,and laser tool setters have become a crucial component of smart machine tools.Laser tool setters play a crucial role in precisely me...On-machine tool setting is a pivotal approach in achieving intelligent manufacturing,and laser tool setters have become a crucial component of smart machine tools.Laser tool setters play a crucial role in precisely measuring the dimensions of cutting tools during the part machining process,focusing on tool length and diameter.As a measuring instrument,the positions of the laser axis of the laser tool setter need to be accurately calibrated before use.However,in actual calibration scenarios,traditional calibration methods face challenges due to installation errors in the tool setter and geometric errors in the measuring rod.To address this issue,this study proposes a novel calibration method.Initially,the calibration mechanism of the laser beam axis is established.Based on the accurate mathematical model of the laser beam and the measuring rod,and using the polygon clipping algorithm,the mathematical mechanism of the laser tool setter’s work is established.Then,a novel method is introduced to calculate the compensation distance between the laser beam reference point and the rod bottom center point at each moment during calibration.Furthermore,by utilizing the kinematic chain of the tool setter calibration system,a new calibration method is developed to accurately calibrate the position of the laser beam axis in the machine tool coordinate system.Finally,the accuracy of the calibration method is verified through simulation experiments and calibration tests.This method improves the calibration accuracy of the tool setter,and the mathematical model of the laser tool setter can be extended to the measurement of tools,thereby improving the precision of tool measurements.This research significantly improves the efficient production performance of smart machine tools.展开更多
Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixtur...Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixture.How to reduce the position and orientation deviation of workpiece has become a technical problem of improving the processing quality of workpiece.In order to increase machining accuracy,an implementation scheme of fixture system comprehensive errors（FSCE） compensation is proposed.A FSCE parameter model is established by analyzing the influence of contact points on the position and orientation of workpiece.Meanwhile,a parameter identification method for FSCE parameter model is presented by using the 3-2-1 deterministic positioning fixture,which determines the model parameters.Moreover,a FSCE compensation model is formulated to study the compensation value of the cutting position.By using RenishawOMP60 Probe and combining vertical machining centre（SKVH850） equipment with SKY2001 Open CNC System,on-machine verification system（OMVS） is built to measure FSCE successfully.The processing error can be reduced by analyzing the cutting position of the tool with the homogeneous transformation of space coordinate system.Finally,the compensation experiment of real time errors is conducted,and the cylindricality and perpendicularity errors of hole surface are reduced by 30.77% and 28.57%,respectively.This paper provides a new way of realizing the compensation of FCSE,which can improve the machining accuracy of workpiece largely.展开更多
Parts with high-quality freeform surfaces have been widely used in industries,which require strict quality control during the manufacturing process.Among all the industrial inspection methods,contact measurement with ...Parts with high-quality freeform surfaces have been widely used in industries,which require strict quality control during the manufacturing process.Among all the industrial inspection methods,contact measurement with coordinate measuring machines or computer numerical control machine tool is a fundamental technique due to its high accuracy,robustness,and universality.In this paper,the existing research in the contact measurement field is systematically reviewed.First,different configurations of the measuring machines are introduced in detail,which may have influence on the corresponding sampling and inspection path generation criteria.Then,the entire inspection pipeline is divided into two stages,namely the pre-inspection and post-inspection stages.The typical methods of each sub-stage are systematically overviewed and classified,including sampling,accessibility analysis,inspection path generation,probe tip radius compensation,surface reconstruction,and uncertainty analysis.Apart from those classical research,the applications of the emerging deep learning technique in some specific tasks of measurement are introduced.Furthermore,some potential and promising trends are provided for future investigation.展开更多
An on-machine measuring(OMM)system with a laser displacement sensor(LDS)is designed for measuring free-form surfaces of hypersonic aircraft’s radomes.To improve the measurement accuracy of the OMM system,a novel Iter...An on-machine measuring(OMM)system with a laser displacement sensor(LDS)is designed for measuring free-form surfaces of hypersonic aircraft’s radomes.To improve the measurement accuracy of the OMM system,a novel Iteratively Automatic machine learning Boosted hand-eye Calibration(IABC)method is proposed.Both the hand-eye relationship and LDS measurement errors can be calibrated in one calibration process without any hardware changes via IABC.Firstly,a new objective function is derived,containing analytical parameters of the handeye relationship and LDS errors.Then,a hybrid calibration model composed of two kernels is proposed to solve the objective function.One kernel is the analytical kernel designed for solving analytical parameters.Another kernel is the automatic machine learning(AutoML)kernel designed to model LDS errors.The two kernels are connected with stepwise iterations to find the best calibration results.Compared with traditional methods,hand-eye experiments show that IABC reduces the calibration RMSE by about 50%.Verification experiments show that IABC reduces the measurement deviations by about 25%-50%and RMSEs within 40%.Even when the training data are obviously less than the test data,IABC performs well.Experiments demonstrate that IABC is more accurate than traditional hand-eye methods.展开更多
The machining accuracy of workpiece is influenced by its orientation deviation, which is caused by the fixture-workpiece error. Based on the spatial coordinate theory, the orientation deviation of workpiece is measure...The machining accuracy of workpiece is influenced by its orientation deviation, which is caused by the fixture-workpiece error. Based on the spatial coordinate theory, the orientation deviation of workpiece is measured by using an on-machine verification system, which can take into account the errors resulting from fixture manufacturing, installation and adjustment, location and clamping of workpiece. According to the least square method, the model of orientation deviation is built to determine the relationship between the theoretical and actual coordinate systems. The influence of orientation deviation on machining accuracy is quantified, and it is shown that the orientation deviation only affects the dimensional precision and position precision, rather than shape precision. In the experiment, the compensation processing of realtime errors was conducted, and the perpendicularity and inclination errors of the tetragonal part were reduced by 38.46% and 47.06%, respectively.展开更多
A new on-machine profiler employing a cantilever beam was proposed and developed to measure the sharp micro-cutting edges of precision cutting tools with low measuring force of 0.1 mN.The proposed profiler consists of...A new on-machine profiler employing a cantilever beam was proposed and developed to measure the sharp micro-cutting edges of precision cutting tools with low measuring force of 0.1 mN.The proposed profiler consists of a probe unit and a positioning unit.The probe unit employs a stylus mounted on the free end of a hollow triangular cantilever beam and a laser displacement sensor to detect the detlection of the cantilever beam.The positioning unit consists of two single-axis DC servo motor stages for precise positioning of the probe unit.The cantilever is designed with the assistance of the finite element method.In order to demonstrate the feasibility of the proposed measurement system,experiments are conducted and the measurement result for a micro-cutting edge is compared with that by a commercial profiler.Furthermore,a method to com-pensate for the measurement error caused by the lateral displacement of the cantilever beam is proposed.The compensated measurement results show good agreement within±2μm with those obtained by the commercial profler.展开更多
To improve the efficiency and consistency of machined microlens array using single-point diamond turning technology,a theoretical model of surface form error is proposed in this paper.Then,a compensation method for th...To improve the efficiency and consistency of machined microlens array using single-point diamond turning technology,a theoretical model of surface form error is proposed in this paper.Then,a compensation method for this model is studied.In the proposed tool equivalent tilt angle model,the microlens array is regarded as a freeform surface.The corresponding curvature radius of the surface at each cutting point along the cutting direction is calculated by establishing a slow slide servo cutting model.In the spatial form error model,the assumption is that surface form error has a linear relationship with z-axis maximum speed vz.An empirical linear equation is obtained and verified,with a maximum deviation of 0.4μm.Then,after machining,the surface form error is measured and processed using on-machine measurement.The theoretical and measured surface form errors are consistent.The surface form error is compensated in the machining program.The peak-to-valley value is reduced from 5.4 to 0.6μm after compensation.Findings show that the single-point diamond turning and compensation method for the microlens array presented in this paper can predict the surface form error and significantly improve machining accuracy and consistency.展开更多
基金Projects(51775445,52175435)supported by the National Natural Science Foundation of ChinaProject(CX2023051)supported by the Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University,China。
文摘On-machine measurement(OMM)stands out as a pivotal technology in complex curved surface adaptive machining.However,the complex structure inherent in workpieces poses a significant challenge as the stylus orientation frequently shifts during the measurement process.Consequently,a substantial amount of time is allocated to calibrating pre-travel error and probe movement.Furthermore,the frequent movement of machine tools also increases the influence of machine errors.To enhance both accuracy and efficiency,an optimization strategy for the OMM process is proposed.Based on the kinematic chain of the machine tools,the relationship between the angle combination of rotary axes,the stylus orientation,and the calibration position of pre-travel error is disclosed.Additionally,an OMM efficiency optimization model for complex curved surfaces is developed.This model is solved to produce the optimal efficiency angle combinations for each to-be-measured point.Within each angle combination,the effects of positioning errors on measurement results are addressed by coordinate system offset and measurement result compensation method.Finally,the experiments on an impeller are used to demonstrate the practical utility of the proposed method.
基金co-supported by the National Basic Research Program of China(No.2015CB057304)the National Natural Science Foundation of China(Nos.51535004 and91648111)
文摘Selecting the optimal machining parameters for impeller surface is a challenging task in the automatic manufacturing industry, due to its free-form surface and deep-crooked flow channel.Existing experimental methods require lots of machining experiments and off-line tests, which may lead to high machining cost and low efficiency. This paper proposes a novel method of machining parameters optimization for an impeller based on the on-machine measuring technique. The absolute average error and standard deviation of the measured points are used to define the grey relational grade for reconstructing the objective function, and the complex problem of multi-objective optimization is simplified into a problem of single-objective optimization. Then, by comparing the values of the defined grey relational grade in a designed orthogonal experiment, the optimal combination of the machining parameters is obtained. The experiment-solving process of the objective function corresponds to the minimization of the used errors, which is advantageous to reducing the machining error. The proposed method is efficient and low-cost, since it does not require re-clamping the workpiece for off-line tests. Its effectiveness is verified by an on-machine inspection experiment of the impeller blade.
基金Supported by National Natural Science Foundation of China(Grant No.51435006)
文摘Although there are some multi-sensor methods for measuring the straightness and tilt errors of a linear slideway, they need to be further improved in some aspects, such as suppressing measurement noise and reducing precondition.In this paper, a new four-sensor method with an improved measurement system is proposed to on-machine separate the straightness and tilt errors of a linear slideway from the sensor outputs, considering the influences of the reference surface profile and the zero-adjustment values. The improved system is achieved by adjusting a single sensor to di erent positions. Based on the system, a system of linear equations is built by fusing the sensor outputs to cancel out the e ects of the straightness and tilt errors. Three constraints are then derived and supplemented into the linear system to make the coe cient matrix full rank. To restrain the sensitivity of the solution of the linear system to the measurement noise in the sensor outputs, the Tikhonov regularization method is utilized. After the surface profile is obtained from the solution, the straightness and tilt errors are identified from the sensor outputs. To analyze the e ects of the measurement noise and the positioning errors of the sensor and the linear slideway, a series of computer simulations are carried out. An experiment is conducted for validation, showing good consistency. The new four-sensor method with the improved measurement system provides a new way to measure the straightness and tilt errors of a linear slideway, which can guarantee favorable propagations of the residuals induced by the noise and the positioning errors.
基金Project (No. KRF-2005-202-D00046) supported by the Korea Re-search Foundation
文摘The purpose of this study is to develop a Web-based on-machine mould identification and measurement system. The Web-based mould identification system matches obtained vision information with CAD database. Developed Web-based system is to exchange messages between a server and a client by making of ActiveX control, and the result of mould identification is shown on Web-browser at remote site. For effective feature classification and extraction, the signature method is used to make meaningful information from obtained image data. For on-machine measurement of the matched mould, inspection database is constructed from CAD database using developed inspection planning methods. The results are simulated and analyzed using developed system to verify the effectiveness of the proposed methods.
文摘This paper presents an integration methodology for ma chining and measuring processes using OMM (On-Machine Measurement) technology b ased on CAD/CAM/CAI integration concept. OMM uses a CNC machining center as a me asuring station by changing the tools into measuring probes such as touch-type, laser and vision. Although the measurement accuracy is not good compared to tha t of the CMM (Coordinate Measuring Machine), there are distinctive advantages us ing OMM in real situation. In this paper, two topics are handled to show the eff ectiveness of the machining and measuring process integration: (1) inspection pl anning strategy for sculptured surface machining and (2) tool path compensation for profile milling process. For the first topic, as a first step, effective mea suring point locations are determined to obtain optimum results for given sampli ng numbers. Two measuring point selection methods are suggested based on the CAD /CAM/CAI integration concept: (1) by the prediction of cutting errors and (2) by considering cutter contact points to avoid the measurement errors caused by cus ps. As a next step, the TSP (Traveling Salesman Problem) algorithm is applied to minimize the probe moving distance. Appropriate simulations and experiments are performed to verify the proposed inspection planning strategy, and the results are analyzed. For the second topic, a methodology for profile milling error comp ensation is presented by using an ANN (Artificial Neural Network) model trained by the inspection database of OMM system. First, geometric and thermal errors of the machining center are compensated using a closed-loop configuration for the improvement of machining and inspection accuracy. The probing errors are also t aken into account. Then, a specimen workpiece is machined and then the machi ning surface error distribution is measured on the machine using touch-type pro be. In order to efficiently analyze the machining errors, two characteristic err or parameters (W err and D err) are defined. Subsequently, these param eters are modeled by applying the RFB (Radial Basis Function) network approach a s an ANN model. Based on the RBF network model, the tool paths are compensated i n order to effectively reduce the errors by employing an iterative algorithm. In order to validate the approaches proposed in this paper, a concrete case of the machining process is taken into account and about 90% of machining error reduction is successfully accomplished through the proposed approaches.
基金The authors gratefully acknowledge the financial support extended by the National Natural Science Foundation of China(Grant Nos.51975214,51725503,and 51575183)the 111 Project.Zhang X C is also grateful for the support by the Major Program of the National Natural Science Foundation of Shanghai(Grant No.2019-01-07-00-02-E00068).
文摘As crucial parts of an aeroengine,blades are vulnerable to damage from long-term operation in harsh environments.The ultrasonic surface rolling process(USRP)is a novel surface treatment technique that can highly improve the mechanical behavior of blades.During secondary machining,the nominal blade model cannot be used for secondary machining path generation due to the deviation between the actual and nominal blades.The clamping error of the blade also affects the precision of secondary machining.This study presents a two-sided USRP(TS-USRP)machining for aeroengine blades on the basis of on-machine noncontact measurement.First,a TS-USRP machining system for blade is developed.Second,a 3D scanning system is used to obtain the point cloud of the blade,and a series of point cloud processing steps is performed.A local point cloud automatic extraction algorithm is introduced to extract the point cloud of the strengthened region of the blade.Then,the tool path is designed on the basis of the extracted point cloud.Finally,an experiment is conducted on an actual blade,with results showing that the proposed method is effective and efficient.
基金the financial support from National Natural Science Foundation of China(Nos.51775046&51875043&52005040)Beijing Municipal Natural Science Foundation(No.JQ20014).
文摘The machining accuracy of the curved surfaces of integrated turbine blades directly determines the performance and service life of the turbojet engine system.In this paper,a non-contact on-machine measurement system is developed for precision milling of integrated turbines to reduce the impact of workpiece deformation,overcutting,tool chatter,and material work hardening.Milling with the on-machine measurement system obtained high-quality integrated turbine surfaces.The geometric accuracy error(PV)is below 3μm,and the surface roughness(Ra)is less than 2μm.The processed integrated turbine blade can achieve the accuracy requirements in the design and manufacturing and can be practically applied to the entire turbojet engine.
文摘On-machine tool setting is a pivotal approach in achieving intelligent manufacturing,and laser tool setters have become a crucial component of smart machine tools.Laser tool setters play a crucial role in precisely measuring the dimensions of cutting tools during the part machining process,focusing on tool length and diameter.As a measuring instrument,the positions of the laser axis of the laser tool setter need to be accurately calibrated before use.However,in actual calibration scenarios,traditional calibration methods face challenges due to installation errors in the tool setter and geometric errors in the measuring rod.To address this issue,this study proposes a novel calibration method.Initially,the calibration mechanism of the laser beam axis is established.Based on the accurate mathematical model of the laser beam and the measuring rod,and using the polygon clipping algorithm,the mathematical mechanism of the laser tool setter’s work is established.Then,a novel method is introduced to calculate the compensation distance between the laser beam reference point and the rod bottom center point at each moment during calibration.Furthermore,by utilizing the kinematic chain of the tool setter calibration system,a new calibration method is developed to accurately calibrate the position of the laser beam axis in the machine tool coordinate system.Finally,the accuracy of the calibration method is verified through simulation experiments and calibration tests.This method improves the calibration accuracy of the tool setter,and the mathematical model of the laser tool setter can be extended to the measurement of tools,thereby improving the precision of tool measurements.This research significantly improves the efficient production performance of smart machine tools.
基金supported by National Natural Science Foundation of China (Grant No. 50975200)National Key Technologies R & D Programmer of China (Grant No. 2009ZX04014-021)
文摘Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixture.How to reduce the position and orientation deviation of workpiece has become a technical problem of improving the processing quality of workpiece.In order to increase machining accuracy,an implementation scheme of fixture system comprehensive errors（FSCE） compensation is proposed.A FSCE parameter model is established by analyzing the influence of contact points on the position and orientation of workpiece.Meanwhile,a parameter identification method for FSCE parameter model is presented by using the 3-2-1 deterministic positioning fixture,which determines the model parameters.Moreover,a FSCE compensation model is formulated to study the compensation value of the cutting position.By using RenishawOMP60 Probe and combining vertical machining centre（SKVH850） equipment with SKY2001 Open CNC System,on-machine verification system（OMVS） is built to measure FSCE successfully.The processing error can be reduced by analyzing the cutting position of the tool with the homogeneous transformation of space coordinate system.Finally,the compensation experiment of real time errors is conducted,and the cylindricality and perpendicularity errors of hole surface are reduced by 30.77% and 28.57%,respectively.This paper provides a new way of realizing the compensation of FCSE,which can improve the machining accuracy of workpiece largely.
基金partially supported by the Natural Science Foundation of Shanghai(Grant No.22ZR1435200)the National Natural Science Foundation of China(Grant No.52075337)the Open Research Fund of State Key Laboratory of Digital Manufacturing and Equipment Technology,HUST(Grant No.DMETKF2022010)。
文摘Parts with high-quality freeform surfaces have been widely used in industries,which require strict quality control during the manufacturing process.Among all the industrial inspection methods,contact measurement with coordinate measuring machines or computer numerical control machine tool is a fundamental technique due to its high accuracy,robustness,and universality.In this paper,the existing research in the contact measurement field is systematically reviewed.First,different configurations of the measuring machines are introduced in detail,which may have influence on the corresponding sampling and inspection path generation criteria.Then,the entire inspection pipeline is divided into two stages,namely the pre-inspection and post-inspection stages.The typical methods of each sub-stage are systematically overviewed and classified,including sampling,accessibility analysis,inspection path generation,probe tip radius compensation,surface reconstruction,and uncertainty analysis.Apart from those classical research,the applications of the emerging deep learning technique in some specific tasks of measurement are introduced.Furthermore,some potential and promising trends are provided for future investigation.
基金supported by the National Natural Science Foundation of China (Nos. 51875406 and 51805365)
文摘An on-machine measuring(OMM)system with a laser displacement sensor(LDS)is designed for measuring free-form surfaces of hypersonic aircraft’s radomes.To improve the measurement accuracy of the OMM system,a novel Iteratively Automatic machine learning Boosted hand-eye Calibration(IABC)method is proposed.Both the hand-eye relationship and LDS measurement errors can be calibrated in one calibration process without any hardware changes via IABC.Firstly,a new objective function is derived,containing analytical parameters of the handeye relationship and LDS errors.Then,a hybrid calibration model composed of two kernels is proposed to solve the objective function.One kernel is the analytical kernel designed for solving analytical parameters.Another kernel is the automatic machine learning(AutoML)kernel designed to model LDS errors.The two kernels are connected with stepwise iterations to find the best calibration results.Compared with traditional methods,hand-eye experiments show that IABC reduces the calibration RMSE by about 50%.Verification experiments show that IABC reduces the measurement deviations by about 25%-50%and RMSEs within 40%.Even when the training data are obviously less than the test data,IABC performs well.Experiments demonstrate that IABC is more accurate than traditional hand-eye methods.
基金Supported by National Natural Science Foundation of China (No.50975200)
文摘The machining accuracy of workpiece is influenced by its orientation deviation, which is caused by the fixture-workpiece error. Based on the spatial coordinate theory, the orientation deviation of workpiece is measured by using an on-machine verification system, which can take into account the errors resulting from fixture manufacturing, installation and adjustment, location and clamping of workpiece. According to the least square method, the model of orientation deviation is built to determine the relationship between the theoretical and actual coordinate systems. The influence of orientation deviation on machining accuracy is quantified, and it is shown that the orientation deviation only affects the dimensional precision and position precision, rather than shape precision. In the experiment, the compensation processing of realtime errors was conducted, and the perpendicularity and inclination errors of the tetragonal part were reduced by 38.46% and 47.06%, respectively.
基金This research was supported by the Japan Society for the Promotion of Sciences(JSPS)KAKENHI(15H05759,20H00211).
文摘A new on-machine profiler employing a cantilever beam was proposed and developed to measure the sharp micro-cutting edges of precision cutting tools with low measuring force of 0.1 mN.The proposed profiler consists of a probe unit and a positioning unit.The probe unit employs a stylus mounted on the free end of a hollow triangular cantilever beam and a laser displacement sensor to detect the detlection of the cantilever beam.The positioning unit consists of two single-axis DC servo motor stages for precise positioning of the probe unit.The cantilever is designed with the assistance of the finite element method.In order to demonstrate the feasibility of the proposed measurement system,experiments are conducted and the measurement result for a micro-cutting edge is compared with that by a commercial profiler.Furthermore,a method to com-pensate for the measurement error caused by the lateral displacement of the cantilever beam is proposed.The compensated measurement results show good agreement within±2μm with those obtained by the commercial profler.
基金the National Natural Science Foundation of China(Grant No.52075332)the Strategic Priority Research Program of the Chinese Academy of Sciences(Grant No.XDA25040000,XDA25040200,and XDA25040202).
文摘To improve the efficiency and consistency of machined microlens array using single-point diamond turning technology,a theoretical model of surface form error is proposed in this paper.Then,a compensation method for this model is studied.In the proposed tool equivalent tilt angle model,the microlens array is regarded as a freeform surface.The corresponding curvature radius of the surface at each cutting point along the cutting direction is calculated by establishing a slow slide servo cutting model.In the spatial form error model,the assumption is that surface form error has a linear relationship with z-axis maximum speed vz.An empirical linear equation is obtained and verified,with a maximum deviation of 0.4μm.Then,after machining,the surface form error is measured and processed using on-machine measurement.The theoretical and measured surface form errors are consistent.The surface form error is compensated in the machining program.The peak-to-valley value is reduced from 5.4 to 0.6μm after compensation.Findings show that the single-point diamond turning and compensation method for the microlens array presented in this paper can predict the surface form error and significantly improve machining accuracy and consistency.
