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 int...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.展开更多
Cutting forces with respect to different cutter orientations are analyzed for five-axis NC machining of a ball-end cutter.A measure is then defined to quantify the effects of cutter orientation variation.According to ...Cutting forces with respect to different cutter orientations are analyzed for five-axis NC machining of a ball-end cutter.A measure is then defined to quantify the effects of cutter orientation variation.According to the measure,a novel model and algorithm are proposed to wholly optimize cutter orientations based on a cutter contact(CC) point mesh.The method has two advantages.One is that the cutter orientation smoothnesses along the feed direction and pick-feed direction are both wholly optimized.The other is that only the accessibility cones of mesh points are required to compute and the computation efficiency is improved.These advantages are shown by simulating the machining efficiency,the stability of feed velocities and the smoothness of cutting force.A computational example and a cutting experiment are finally given to illustrate the validity of the proposed method.展开更多
To implement five-axis functions in CNC system, based on domestic system Lan Tian series, an improved design method for the system software structure is proposed in this paper. The numerical control kernel of CNC syst...To implement five-axis functions in CNC system, based on domestic system Lan Tian series, an improved design method for the system software structure is proposed in this paper. The numerical control kernel of CNC system is divided into the task layer and the motion layer. A five-axis transformation unit is integrated into the motion layer. After classifying five-axis machines into different types and analyzing their geometry information, the five-axis kinematic library is designed according to the abstract factory pattern. Furthermore, by taking CA spindle- tilting machine as an example, the forward and the inverse kinematic transformations are deduced. Based on the new software architecture and the five-axis kinematic library, algorithms of RTCP （rotation tool center point control） and 3D radius compensation for end-milling are designed and realized. The milling results show that, with five-axis functions based on such software struc- ture, the instructions with respect to the cutter＇s position and orientation can be directly carried out in the CNC system.展开更多
Accuracy allocation is crucial in the accuracy design of machining tools.Current accuracy allocation methods primarily focus on positional deviation,with little consideration for tool direction deviation.To address th...Accuracy allocation is crucial in the accuracy design of machining tools.Current accuracy allocation methods primarily focus on positional deviation,with little consideration for tool direction deviation.To address this issue,we propose a geometric error cost sensitivity-based accuracy allocation method for five-axis machine tools.A geometric error model consisting of 4l error components is constructed based on homogeneous transformation matrices.Volumetric points with positional and tool direction deviations are randomly sampled to evaluate the accuracy of the machine tool.The sensitivity of each error component at these sampling points is analyzed using the Sobol method.To balance the needs of geometric precision and manufacturing cost,a geometric error cost sensitivity function is developed to estimate the required cost.By allocating error components affecting tool direction deviation first and the remaining components second,this allocation scheme ensures that both deviations meet the requirements.We also perform numerical simulation of a BC-type(B-axis and C-axis type)five-axis machine tool to validate the method.The results show that the new allocation scheme reduces the total geometric error cost by 27.8%compared to a uniform allocation scheme,and yields the same positional and tool direction machining accuracies.展开更多
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 hi...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.展开更多
A new spiral tool path generation algorithm for 5-axis high speed machining is proposed in this paper.Firstly,the voltage contours are calculated to satisfy the machining parameters in the mapping parametric domain by...A new spiral tool path generation algorithm for 5-axis high speed machining is proposed in this paper.Firstly,the voltage contours are calculated to satisfy the machining parameters in the mapping parametric domain by means of the electrostatic field model of partial differential equations.Secondly,the mapping rules are constructed and the machining trajectory is planned out in the standard parametric domain in order to map and generate the spiral trajectory in the corresponding parametric domain.Finally,this trajectory is mapped onto the parametric surface for the obtainment of the spiral tool path.This spiral tool path can realize the machining of complicated parametric surface and trimmed surface without tool retractions.The above-mentioned algorithm has been implemented in several simulations and validated successfully through the actual machining of a complicated cavity.The results indicate that this method is superior to the existing machining methods to realize the high speed machining of the complicate-shaped cavity based on parametric surface and trimmed surface.展开更多
A sudden increase in the radial depth(SIRD)is a distinctive phenomenon in plunge milling.It is typically characterized by a sharp increase in cutting force at the end of the axial feed of the tool,accompanied by harsh...A sudden increase in the radial depth(SIRD)is a distinctive phenomenon in plunge milling.It is typically characterized by a sharp increase in cutting force at the end of the axial feed of the tool,accompanied by harsh machine vibration sounds,which can negatively impact the reliability of plunge milling.This paper proposes an optimization method to eliminate SIRD in five-axis plunge milling.Initially,a five-axis plunge milling experiment and an analysis of the spatial position relationship between the plunge tools and the workpiece revealed that the cause of SIRD is unreasonable tool path planning.Subsequently,using the cutter position and cutter axis vector as variables,an SIRD discrimination model was developed for adjacent cutter positions and extended to multiple cutter positions.Optimizing the plunge milling tool path is considered a multivariate optimization problem that involves determining the cutter point and cutter axis vector.The SIRD discrimination model was used as a constraint function to aid in solving for the variables.The simulation and experimental results indicate that with the remaining volume of material as the optimization target,the optimized plunge milling tool path results in a residual material volume that is less than 60%of the gradually decreasing plunge depth.This optimization decreases the subsequent semi-finishing time of the workpiece and enhances machining efficiency.Additionally,it does not rely on operator experience and facilitates efficient automated optimization of the tool path to exclude SIRD.展开更多
In order to ensure machining stability,curvature continuity and smooth cutting force are very important so as to meet the constraints of both cutting force and kinematics of machine tools.For five-axis flank milling,i...In order to ensure machining stability,curvature continuity and smooth cutting force are very important so as to meet the constraints of both cutting force and kinematics of machine tools.For five-axis flank milling,it is difficult to meet both of the constraints because tool path points and tool axis vectors interact with each other.In this paper,multiple relationships between tool path points and tool axis vectors with cutting force and kinematics of machine tools are established,and the strategies of corner-looping milling and clothoidal spirals are combined so as to find feasible solutions under both of the constraints.Tool path parameters are iterated by considering the maximum cutting force and the feasible range of the tool axis vector,and eventually a curvature continuity five-axis flank milling tool path with smooth cutting force is generated.Machining experimental results show that the conditions of cutting force are satisfied,vibration during the process of machining is reduced,and the machining quality of the surface is improved.展开更多
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 resea...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.展开更多
In five-axis flank milling operations,the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements,especially in aeronautic...In five-axis flank milling operations,the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements,especially in aeronautical manufacturing.To focus on motion problems in milling operations,this paper presents a new model that utilizes elliptical paths as cutting edge trajectories on 3D surface topography machined by peripheral milling.First,the cutter parallel axis offset and location angle are considered,which change the location of the ellipse center and intersection point of the cutting edges.Then,through the proposed model,the predicted surface topography is obtained,and the factors that affect the development tendency of roughness are analyzed.Next,the effects of the cutter location position(CLP)geometric parameters,cutter parallel axis offset and curvature on the roughness are evaluated by a numerical simulation.Finally,machining tests are carried out to validate the model predictions,and the results show that the surface topography predictions correspond well with the experimental results.展开更多
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 c...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.展开更多
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 ess...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.展开更多
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 impr...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.展开更多
A novel five-axis real-time interpolation algorithm for 3[PP]S-XY hybrid mechanism is proposed in this paper. In the algorithm, the five-axis tool path for controlling this hybrid mechanism is separated into two sub-p...A novel five-axis real-time interpolation algorithm for 3[PP]S-XY hybrid mechanism is proposed in this paper. In the algorithm, the five-axis tool path for controlling this hybrid mechanism is separated into two sub-paths. One sub-path describes the movement of 3[PP]S parallel kinematic mechanism module, and the other one describes the movement of XY platform. A pair of cubic Bezier curves is employed to smooth the corners in those two sub-paths. Based on the homogenous Jacobian matrix of 3[PP]S mechanism, a relationship between the position errors of every driving joint in hybrid mechanism and the position deviation of the tool tip center point at the moving platform is established. This relationship is used to estimate the approximation error for the corners smoothing according to the accuracy requirement of tool tip center in interpolation. Due to the high computational efficiency of this corner smoothing method, it is integrated into the look-ahead module of computer numerical control(CNC) system to perform online tool path smoothing. By performing the speed planning based on a floating window scheme, a jerk limited S-shape speed profile can be generated efficiently. On this basis, a realtime look-ahead scheme, which is comprised of path-smoothing and feedrate scheduling, is developed to acquire a speed profile with smooth acceleration. A monotonic cubic spline is employed for synchronization between those two smoothed sub-paths in tool path interpolation. This interpolation algorithm has been integrated into our own developed CNC system to control a 3PRS-XY experimental instrument(P, R and S standing for prismatic,revolute and spherical, respectively). A club shaped trajectory is adopted to verify the smoothness and efficiency of the five-axis interpolator for hybrid mechanism control.展开更多
为探究配筋率和复合层厚度对ECC-NC(Engineered Cementitious Composites to Normal Concrete)复合梁抗弯性能的影响,设计了5根ECC-NC复合梁,通过四点弯曲试验,开展了ECC-NC复合梁抗弯性能研究,分析了复合梁破坏模式和裂缝发展规律,探...为探究配筋率和复合层厚度对ECC-NC(Engineered Cementitious Composites to Normal Concrete)复合梁抗弯性能的影响,设计了5根ECC-NC复合梁,通过四点弯曲试验,开展了ECC-NC复合梁抗弯性能研究,分析了复合梁破坏模式和裂缝发展规律,探讨了配筋率和复合层厚度对结构承载能力、韧性及延性的影响。研究结果表明:与普通混凝土梁相比,ECC-NC复合梁破坏模式不同,能有效发挥ECC材料特性,具有较好的抗弯性能;相同配筋率下,受拉区ECC层厚度增加,ECC-NC复合梁的抗弯承载力增强有限,弯剪区裂缝数量增多,延性增强,刚度退化缓慢,最佳复合层厚度为0.3h~0.5h;ECC层具有替代部分纵筋作用,受压与受拉区同时设置ECC层能极大地提高抗弯承载能力、延性及结构韧性;基于响应面法,配筋率对ECC-NC抗弯性能影响最大,最大配筋率与复合层厚度有关,0~0.5h呈负相关,0.5h~h间呈正相关,受压区设置ECC可提高界限配筋率,高配筋率有利于提高抗弯刚度,减缓裂缝扩展;弯曲荷载下,截面符合平截面假定,变形协调;基于条带法,建立了ECC-NC复合梁抗弯承载能力计算方法,与试验结果及已有文献数据校核,平均误差在6%以内,吻合度较高,可为工程应用提供理论支撑。ECC替代普通混凝土,不仅提高了结构抗弯承载力,还延缓了裂缝扩展,改善了复合梁带裂缝工作性能和抗裂性能,且抗弯性能较为优越。展开更多
A spindle fault diagnosis method based on CNN-SVM optimized by particle swarm algorithm(PSO)is proposed to address the problems of high failure rate of electric spindles of high precision CNC machine tools,while manua...A spindle fault diagnosis method based on CNN-SVM optimized by particle swarm algorithm(PSO)is proposed to address the problems of high failure rate of electric spindles of high precision CNC machine tools,while manual fault diagnosis is a tedious task and low efficiency.The model uses a convolutional neural network(CNN)model as a deep feature miner and a support vector machine(SVM)as a fault state classifier.Taking the electric spindle of a five-axis machining centre as the experimental research object,the model classifies and predicts four labelled states:normal state of the electric spindle,loose state of the rotating shaft and coupling,eccentric state of the motor air gap and damaged state of the bearing and rolling body,while introducing a particle swarm algorithm(PSO)is introduced to optimize the hyperparameters in the model to improve the prediction effect.The results show that the proposed hybrid PSO-CNN-SVM model is able to monitor and diagnose the electric spindle failure of a 5-axis machining centre with an accuracy of 99.33%.In comparison with the BP model,SVM model,CNN model and CNN-SVM model,the accuracy of the model increased by 10%,6%,4%and 2%respectively,which shows that the fault diagnosis model proposed in the paper can monitor the operation status of the electric spindle more effectively and diagnose the type of electric spindle fault,so as to improve the maintenance strategy.展开更多
文摘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.
基金supported by the National Basic Research Program of China ("973" Program)(Grant No.2005CB724103)the National Natural Science Foundation of China (Grant No.50805093) the Science & Technology Commission of Shanghai Municipality (Grant No.07JC14028)
文摘Cutting forces with respect to different cutter orientations are analyzed for five-axis NC machining of a ball-end cutter.A measure is then defined to quantify the effects of cutter orientation variation.According to the measure,a novel model and algorithm are proposed to wholly optimize cutter orientations based on a cutter contact(CC) point mesh.The method has two advantages.One is that the cutter orientation smoothnesses along the feed direction and pick-feed direction are both wholly optimized.The other is that only the accessibility cones of mesh points are required to compute and the computation efficiency is improved.These advantages are shown by simulating the machining efficiency,the stability of feed velocities and the smoothness of cutting force.A computational example and a cutting experiment are finally given to illustrate the validity of the proposed method.
基金supported by the National Basic Research Program of China (No. 2011CB302400)the Important National Science & Technology Specific Projects (No. 2013ZX04007031).
文摘To implement five-axis functions in CNC system, based on domestic system Lan Tian series, an improved design method for the system software structure is proposed in this paper. The numerical control kernel of CNC system is divided into the task layer and the motion layer. A five-axis transformation unit is integrated into the motion layer. After classifying five-axis machines into different types and analyzing their geometry information, the five-axis kinematic library is designed according to the abstract factory pattern. Furthermore, by taking CA spindle- tilting machine as an example, the forward and the inverse kinematic transformations are deduced. Based on the new software architecture and the five-axis kinematic library, algorithms of RTCP （rotation tool center point control） and 3D radius compensation for end-milling are designed and realized. The milling results show that, with five-axis functions based on such software struc- ture, the instructions with respect to the cutter＇s position and orientation can be directly carried out in the CNC system.
基金supported by the Key R&D Program of Zhejiang Province(Nos.2023C01166 and 2024SJCZX0046)the Zhejiang Provincial Natural Science Foundation of China(Nos.LDT23E05013E05 and LD24E050009)the Natural Science Foundation of Ningbo(No.2021J150),China.
文摘Accuracy allocation is crucial in the accuracy design of machining tools.Current accuracy allocation methods primarily focus on positional deviation,with little consideration for tool direction deviation.To address this issue,we propose a geometric error cost sensitivity-based accuracy allocation method for five-axis machine tools.A geometric error model consisting of 4l error components is constructed based on homogeneous transformation matrices.Volumetric points with positional and tool direction deviations are randomly sampled to evaluate the accuracy of the machine tool.The sensitivity of each error component at these sampling points is analyzed using the Sobol method.To balance the needs of geometric precision and manufacturing cost,a geometric error cost sensitivity function is developed to estimate the required cost.By allocating error components affecting tool direction deviation first and the remaining components second,this allocation scheme ensures that both deviations meet the requirements.We also perform numerical simulation of a BC-type(B-axis and C-axis type)five-axis machine tool to validate the method.The results show that the new allocation scheme reduces the total geometric error cost by 27.8%compared to a uniform allocation scheme,and yields the same positional and tool direction machining accuracies.
基金co-supported by the Natural Science Foundation of Beijing(No.3214043)the Project of State Key Lab of Tribology of Tsinghua University(No.SKLT2021D16)the National Natural Science Foundation of China(No.51975319)。
文摘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.
基金supported by the National Program on Key Basic Research Project of China (973 Program) under Grant No.2011CB302400the National Natural Science Foundation of China (NSFC) under Grant Nos.50975274 and 51175479
文摘A new spiral tool path generation algorithm for 5-axis high speed machining is proposed in this paper.Firstly,the voltage contours are calculated to satisfy the machining parameters in the mapping parametric domain by means of the electrostatic field model of partial differential equations.Secondly,the mapping rules are constructed and the machining trajectory is planned out in the standard parametric domain in order to map and generate the spiral trajectory in the corresponding parametric domain.Finally,this trajectory is mapped onto the parametric surface for the obtainment of the spiral tool path.This spiral tool path can realize the machining of complicated parametric surface and trimmed surface without tool retractions.The above-mentioned algorithm has been implemented in several simulations and validated successfully through the actual machining of a complicated cavity.The results indicate that this method is superior to the existing machining methods to realize the high speed machining of the complicate-shaped cavity based on parametric surface and trimmed surface.
基金Supported by National Natural Science Foundation of China(Grant Nos.52075076,U1908231)National Key R&D Program of China(Grant No.2019YFA0705304)。
文摘A sudden increase in the radial depth(SIRD)is a distinctive phenomenon in plunge milling.It is typically characterized by a sharp increase in cutting force at the end of the axial feed of the tool,accompanied by harsh machine vibration sounds,which can negatively impact the reliability of plunge milling.This paper proposes an optimization method to eliminate SIRD in five-axis plunge milling.Initially,a five-axis plunge milling experiment and an analysis of the spatial position relationship between the plunge tools and the workpiece revealed that the cause of SIRD is unreasonable tool path planning.Subsequently,using the cutter position and cutter axis vector as variables,an SIRD discrimination model was developed for adjacent cutter positions and extended to multiple cutter positions.Optimizing the plunge milling tool path is considered a multivariate optimization problem that involves determining the cutter point and cutter axis vector.The SIRD discrimination model was used as a constraint function to aid in solving for the variables.The simulation and experimental results indicate that with the remaining volume of material as the optimization target,the optimized plunge milling tool path results in a residual material volume that is less than 60%of the gradually decreasing plunge depth.This optimization decreases the subsequent semi-finishing time of the workpiece and enhances machining efficiency.Additionally,it does not rely on operator experience and facilitates efficient automated optimization of the tool path to exclude SIRD.
基金supported by the National Natural Science Foundation of Chin-China Aerospace Science and Technology Corporation on Advance Manufacturing(No.U1537209)National Natural Science Foundation of China(No.51775278)Jiangsu Province Outstanding Youth Fund of China(No.BK20140036).
文摘In order to ensure machining stability,curvature continuity and smooth cutting force are very important so as to meet the constraints of both cutting force and kinematics of machine tools.For five-axis flank milling,it is difficult to meet both of the constraints because tool path points and tool axis vectors interact with each other.In this paper,multiple relationships between tool path points and tool axis vectors with cutting force and kinematics of machine tools are established,and the strategies of corner-looping milling and clothoidal spirals are combined so as to find feasible solutions under both of the constraints.Tool path parameters are iterated by considering the maximum cutting force and the feasible range of the tool axis vector,and eventually a curvature continuity five-axis flank milling tool path with smooth cutting force is generated.Machining experimental results show that the conditions of cutting force are satisfied,vibration during the process of machining is reduced,and the machining quality of the surface is improved.
基金Supported by National Natural Science Foundation of China(Grant No.51305244)Shandong Provincal Natural Science Foundation of China(Grant No.ZR2013EEL015)
文摘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.
基金financially supported by the Major National S&T Program of China(2017ZX04002001)the Major National S&T Program of China(2016ZX04004004)the National Natural Science Foundation of China(51675301)。
文摘In five-axis flank milling operations,the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements,especially in aeronautical manufacturing.To focus on motion problems in milling operations,this paper presents a new model that utilizes elliptical paths as cutting edge trajectories on 3D surface topography machined by peripheral milling.First,the cutter parallel axis offset and location angle are considered,which change the location of the ellipse center and intersection point of the cutting edges.Then,through the proposed model,the predicted surface topography is obtained,and the factors that affect the development tendency of roughness are analyzed.Next,the effects of the cutter location position(CLP)geometric parameters,cutter parallel axis offset and curvature on the roughness are evaluated by a numerical simulation.Finally,machining tests are carried out to validate the model predictions,and the results show that the surface topography predictions correspond well with the experimental results.
基金Supported by National Nature Science Foundation of China(Grant No.51175461)Science Fund for Creative Research Groups of National Natural Science Foundation of China(Grant No.51221004)Program for Zhejiang Leading Team of S&T Innovation of China(Grant No.2009R50008)
文摘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.
基金the National Natural Science Foundation of China(No.51675439)。
文摘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.
基金Work supported by the Second Stage of Brain Korea 21 ProjectsProject(RTI04-01-03) supported by the Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE) of Korea
文摘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.
基金the CNC Equipment Development for Key Structure Integrated Manufacturing by LAW(No.ZB-ZBYZ-03-11-2190)the Shanghai Aerospace Fund(No.HTJ10-20)
文摘A novel five-axis real-time interpolation algorithm for 3[PP]S-XY hybrid mechanism is proposed in this paper. In the algorithm, the five-axis tool path for controlling this hybrid mechanism is separated into two sub-paths. One sub-path describes the movement of 3[PP]S parallel kinematic mechanism module, and the other one describes the movement of XY platform. A pair of cubic Bezier curves is employed to smooth the corners in those two sub-paths. Based on the homogenous Jacobian matrix of 3[PP]S mechanism, a relationship between the position errors of every driving joint in hybrid mechanism and the position deviation of the tool tip center point at the moving platform is established. This relationship is used to estimate the approximation error for the corners smoothing according to the accuracy requirement of tool tip center in interpolation. Due to the high computational efficiency of this corner smoothing method, it is integrated into the look-ahead module of computer numerical control(CNC) system to perform online tool path smoothing. By performing the speed planning based on a floating window scheme, a jerk limited S-shape speed profile can be generated efficiently. On this basis, a realtime look-ahead scheme, which is comprised of path-smoothing and feedrate scheduling, is developed to acquire a speed profile with smooth acceleration. A monotonic cubic spline is employed for synchronization between those two smoothed sub-paths in tool path interpolation. This interpolation algorithm has been integrated into our own developed CNC system to control a 3PRS-XY experimental instrument(P, R and S standing for prismatic,revolute and spherical, respectively). A club shaped trajectory is adopted to verify the smoothness and efficiency of the five-axis interpolator for hybrid mechanism control.
文摘为探究配筋率和复合层厚度对ECC-NC(Engineered Cementitious Composites to Normal Concrete)复合梁抗弯性能的影响,设计了5根ECC-NC复合梁,通过四点弯曲试验,开展了ECC-NC复合梁抗弯性能研究,分析了复合梁破坏模式和裂缝发展规律,探讨了配筋率和复合层厚度对结构承载能力、韧性及延性的影响。研究结果表明:与普通混凝土梁相比,ECC-NC复合梁破坏模式不同,能有效发挥ECC材料特性,具有较好的抗弯性能;相同配筋率下,受拉区ECC层厚度增加,ECC-NC复合梁的抗弯承载力增强有限,弯剪区裂缝数量增多,延性增强,刚度退化缓慢,最佳复合层厚度为0.3h~0.5h;ECC层具有替代部分纵筋作用,受压与受拉区同时设置ECC层能极大地提高抗弯承载能力、延性及结构韧性;基于响应面法,配筋率对ECC-NC抗弯性能影响最大,最大配筋率与复合层厚度有关,0~0.5h呈负相关,0.5h~h间呈正相关,受压区设置ECC可提高界限配筋率,高配筋率有利于提高抗弯刚度,减缓裂缝扩展;弯曲荷载下,截面符合平截面假定,变形协调;基于条带法,建立了ECC-NC复合梁抗弯承载能力计算方法,与试验结果及已有文献数据校核,平均误差在6%以内,吻合度较高,可为工程应用提供理论支撑。ECC替代普通混凝土,不仅提高了结构抗弯承载力,还延缓了裂缝扩展,改善了复合梁带裂缝工作性能和抗裂性能,且抗弯性能较为优越。
基金financed with the means of Basic Scientific Research Youth Program of Education Department of Liaoning Province,No.LJKQZ2021185Yingkou Enterprise and Doctor Innovation Program (QB-2021-05).
文摘A spindle fault diagnosis method based on CNN-SVM optimized by particle swarm algorithm(PSO)is proposed to address the problems of high failure rate of electric spindles of high precision CNC machine tools,while manual fault diagnosis is a tedious task and low efficiency.The model uses a convolutional neural network(CNN)model as a deep feature miner and a support vector machine(SVM)as a fault state classifier.Taking the electric spindle of a five-axis machining centre as the experimental research object,the model classifies and predicts four labelled states:normal state of the electric spindle,loose state of the rotating shaft and coupling,eccentric state of the motor air gap and damaged state of the bearing and rolling body,while introducing a particle swarm algorithm(PSO)is introduced to optimize the hyperparameters in the model to improve the prediction effect.The results show that the proposed hybrid PSO-CNN-SVM model is able to monitor and diagnose the electric spindle failure of a 5-axis machining centre with an accuracy of 99.33%.In comparison with the BP model,SVM model,CNN model and CNN-SVM model,the accuracy of the model increased by 10%,6%,4%and 2%respectively,which shows that the fault diagnosis model proposed in the paper can monitor the operation status of the electric spindle more effectively and diagnose the type of electric spindle fault,so as to improve the maintenance strategy.
