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
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 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
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
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 d...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.展开更多
Thermal errors in CNC machine tools,particularly those involving the spindle,significantly affect machining accuracy and performance.These errors,caused by temperature fluctuations in the spindle and surrounding compo...Thermal errors in CNC machine tools,particularly those involving the spindle,significantly affect machining accuracy and performance.These errors,caused by temperature fluctuations in the spindle and surrounding components,result in dimensional deviations that can lead to poor part quality and reduced precision in high-speed manufacturing processes.This paper explores thermal error modeling and compensation methods for the spindle of five-axis CNC machine tools.A detailed analysis of the heat generation,transfer mechanisms,and finite element analysis(FEA)is presented to develop accurate thermal error models.Compensation techniques,such as model-based methods,sensor-based methods,real-time compensation algorithms,and hybrid approaches,are critically reviewed.This study also discusses the challenges in real-time compensation and the integration of thermal error compensation with machine tool control systems.The objective is to provide a comprehensive understanding of thermal error phenomena and their compensation strategies,ultimately contributing to the enhancement of machining accuracy in advanced manufacturing applications.展开更多
Tracking interferometer based on bi-rotary milling head is a novel scheme to conduct volumetric accuracy measurement of a five-axis machine tool.The laser beam direction of the interferometer can be regulated to follo...Tracking interferometer based on bi-rotary milling head is a novel scheme to conduct volumetric accuracy measurement of a five-axis machine tool.The laser beam direction of the interferometer can be regulated to follow the retroreflector by moving the bi-rotary head.This is a low-cost implementation of multilateration measurement,and its measurement accuracy is mainly affected by the error motion of the rotary axes.This paper proposes an improved multilateration principle to identify the positionindependent geometric errors of rotary axis and laser beam,and minimize their impact on the measurement uncertainty.A closed-loop tracking interferometer system installed on the spindle is developed to perform the measurement with high tracking accuracy.The device can be installed on an ordinary five-axis machine tool without modifying the machine tool structure.The proposed scheme is conducive to improving the accuracy and practical application of the tracking interferometer based on birotary milling head.Experiments with the corresponding closed-loop tracking interferometer and uncertainty analysis are conducted to verify the performance of the proposed measurement scheme.展开更多
A compound machine tool was designed, which combined rotary ultrasonic assisted grinding, electrical discharge machining(EDM) and multi-axis milling. Experimental results indicated that its positioning accuracy was le...A compound machine tool was designed, which combined rotary ultrasonic assisted grinding, electrical discharge machining(EDM) and multi-axis milling. Experimental results indicated that its positioning accuracy was less than 5.6 μm and its repetitive positioning accuracy was less than 1.8 μm; the vibration amplitude of ultrasonic grinding system was uniform and stable, and the EDM system worked well and stably.A smooth surface of K9 optical glass component was achieved by the grinding method.展开更多
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
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
Vibration cutting has emerged as a promising method for creating surface functional microstructures.However,achieving precise tool setting is a time-consuming process that significantly impacts process efficiency.This...Vibration cutting has emerged as a promising method for creating surface functional microstructures.However,achieving precise tool setting is a time-consuming process that significantly impacts process efficiency.This study proposes an intelligent approach for tool setting in vibration cutting using machine vision and hearing,divided into two steps.In the first step,machine vision is employed to achieve rough precision in tool setting within tens of micrometers.Subsequently,in the second step,machine hearing utilizes sound pickup to capture vibration audio signals,enabling fine tool adjustment within 1μm precision.The relationship between the spectral intensity of vibration audio and cutting depth is analyzed to establish criteria for tool–workpiece contact.Finally,the efficacy of this approach is validated on an ultra-precision platform,demonstrating that the automated tool-setting process takes no more than 74 s.The total cost of the vision and hearing sensors is less than$1500.展开更多
The prediction of tool wear in CNC machine tools is a critical aspect of ensuring the efficient operation and longevity of manufacturing equipment.Tool wear significantly impacts machining accuracy,surface finish qual...The prediction of tool wear in CNC machine tools is a critical aspect of ensuring the efficient operation and longevity of manufacturing equipment.Tool wear significantly impacts machining accuracy,surface finish quality,and operational downtime,making its prediction essential for proactive maintenance strategies.This paper explores the integration of Digital Twin technology with tool wear prediction models to enhance the precision and reliability of wear forecasting in CNC machines.We review existing methodologies for tool wear prediction,including physics-based models,data-driven approaches,and hybrid models,with an emphasis on their strengths and limitations.Furthermore,the paper highlights the role of Digital Twin technology in creating real-time,virtual replicas of CNC machines that can dynamically monitor tool wear and provide actionable insights for optimization.By leveraging real-time data and advanced simulation techniques,Digital Twin-based prediction models offer significant improvements over traditional methods.The paper concludes by discussing future directions for integrating machine learning,deep learning,and real-time data analytics into the tool wear prediction process,ultimately contributing to the development of more intelligent and adaptive manufacturing systems.展开更多
In intelligentmanufacturing processes such as aerospace production,computer numerical control(CNC)machine tools require real-time optimization of process parameters to meet precision machining demands.These dynamic op...In intelligentmanufacturing processes such as aerospace production,computer numerical control(CNC)machine tools require real-time optimization of process parameters to meet precision machining demands.These dynamic operating conditions increase the risk of fatigue damage in CNC machine tool bearings,highlighting the urgent demand for rapid and accurate fault diagnosis methods that can maintain production efficiency and extend equipment uptime.However,varying conditions induce feature distribution shifts,and scarce fault samples limitmodel generalization.Therefore,this paper proposes a causal-Transformer-based meta-learning(CTML)method for bearing fault diagnosis in CNC machine tools,comprising three core modules:(1)the original bearing signal is transformed into a multi-scale time-frequency feature space using continuous wavelet transform;(2)a causal-Transformer architecture is designed to achieve feature extraction and fault classification based on the physical causal law of fault propagation;(3)the above mechanisms are integrated into a model-agnostic meta-learning(MAML)framework to achieve rapid cross-condition adaptation through an adaptive gradient pruning strategy.Experimental results using the multiple bearing dataset show that under few-shot cross-condition scenarios(3-way 1-shot and 3-way 5-shot),the proposed CTML outperforms benchmark models(e.g.,Transformer,domain adversarial neural networks(DANN),and MAML)in terms of classification accuracy and sensitivity to operating conditions,while maintaining a moderate level of model complexity.展开更多
The CNC machine tool is the fundamental equipment of the manufacturing industry,particularly in sectors where achieving high levels of accuracy is crucial.Geometric accuracy design is an important step in machine tool...The CNC machine tool is the fundamental equipment of the manufacturing industry,particularly in sectors where achieving high levels of accuracy is crucial.Geometric accuracy design is an important step in machine tool design and plays an essential role in determining the machining accuracy of the workpiece.Researchers have extensively studied methods to model,extract,optimize,and measure the geometric errors that affect the geometric accuracy of machine tools.This paper provides a comprehensive review of the state-of-the-art approaches and an overview of the latest research progress associated with geometric accuracy design in CNC machine tools.This paper explores the interrelated aspects of CNC machine tool accuracy design:modeling,analysis and optimization.Accuracy analysis,which includes geometric error modeling and sensitivity analysis,determines a machine tool’s output accuracy through its volumetric error model,given the known accuracy of its individual components.Conversely,accuracy allocation designs the accuracy of the machine tool components according to given output accuracy requirements to achieve optimization between the objectives of manufacturing cost,quality,reliability,and environmental impact.In addition to discussing design factors and evaluation methods,this paper outlines methods for verifying the accuracy of design results,aiming to provide a practical basis for ensuring that the designed accuracy is achieved.Finally,the challenges and future research directions in geometric accuracy design are highlighted.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
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 defi...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.展开更多
The effective monitoring of tool wear status in the milling process of a five-axis machining center is important for improving product quality and efficiency,so this paper proposes a CNN convolutional neural network m...The effective monitoring of tool wear status in the milling process of a five-axis machining center is important for improving product quality and efficiency,so this paper proposes a CNN convolutional neural network model based on the optimization of PSO algorithm to monitor the tool wear status.Firstly,the cutting vibration signals and spindle current signals during the milling process of the five-axis machining center are collected using sensor technology,and the features related to the tool wear status are extracted in the time domain,frequency domain and time-frequency domain to form a feature sample matrix;secondly,the tool wear values corresponding to the above features are measured using an electron microscope and classified into three types:slight wear,normal wear and sharp wear to construct a target Finally,the tool wear sample data set is constructed by using multi-source information fusion technology and input to PSO-CNN model to complete the prediction of tool wear status.The results show that the proposed method can effectively predict the tool wear state with an accuracy of 98.27%;and compared with BP model,CNN model and SVM model,the accuracy indexes are improved by 9.48%,3.44%and 1.72%respectively,which indicates that the PSO-CNN model proposed in this paper has obvious advantages in the field of tool wear state identification.展开更多
A new three dimensional simulation method is introduced to study the workspace of a 6 PSS (P denotes a prismatic kinematic pair, S denotes a spherical kinematic pair) parallel machine tool. This algorithm adopts the...A new three dimensional simulation method is introduced to study the workspace of a 6 PSS (P denotes a prismatic kinematic pair, S denotes a spherical kinematic pair) parallel machine tool. This algorithm adopts the method of numerical analysis to investigate the boundary points in a series of sections which form the surface of the workspace. That is, to study such points that have the largest polar radius on a certain section in a system of polar coordinates according to conditions of constraint. The constraint conditions considered in the article include the maximum and minimum displacements of each dieblock, the maximum and minimum angles of oscillation in each hinge. By converting the constraint inequalities into constraint equations, the largest polar radius corresponding to every constraint condition can be evaluated and the minimum one is used to decide the boundary point. This algorithm greatly simplifies the computational process and can be used to analyze any section of the workspace. It provides a theoretical basis for the structural design of such a machine tool.展开更多
A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC mac...A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.展开更多
Through analysis of the basic transformation of a typical body,the error transformations of the position vector and the displacement vector are employed,a general model for positioning errors of NC machine tools by us...Through analysis of the basic transformation of a typical body,the error transformations of the position vector and the displacement vector are employed,a general model for positioning errors of NC machine tools by using kinematics of the multi body system is discussed.By means of 8031 single chip system,intelligent error compensation controller has been developed.The results of experiments on XH714 machining center show that the positioning accuracy is enhanced effectively by more than 50%.展开更多
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 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.
文摘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.
文摘Thermal errors in CNC machine tools,particularly those involving the spindle,significantly affect machining accuracy and performance.These errors,caused by temperature fluctuations in the spindle and surrounding components,result in dimensional deviations that can lead to poor part quality and reduced precision in high-speed manufacturing processes.This paper explores thermal error modeling and compensation methods for the spindle of five-axis CNC machine tools.A detailed analysis of the heat generation,transfer mechanisms,and finite element analysis(FEA)is presented to develop accurate thermal error models.Compensation techniques,such as model-based methods,sensor-based methods,real-time compensation algorithms,and hybrid approaches,are critically reviewed.This study also discusses the challenges in real-time compensation and the integration of thermal error compensation with machine tool control systems.The objective is to provide a comprehensive understanding of thermal error phenomena and their compensation strategies,ultimately contributing to the enhancement of machining accuracy in advanced manufacturing applications.
基金supported by the National Natural Science Foundation of China(Grant No.51875357)the State Key Program of National Natural Science Foundation of China(Grant No.U21B2081)the National Defense Science and Technology Excellence Youth Foundation(Grant No.2020-JCJQ-ZQ-079)。
文摘Tracking interferometer based on bi-rotary milling head is a novel scheme to conduct volumetric accuracy measurement of a five-axis machine tool.The laser beam direction of the interferometer can be regulated to follow the retroreflector by moving the bi-rotary head.This is a low-cost implementation of multilateration measurement,and its measurement accuracy is mainly affected by the error motion of the rotary axes.This paper proposes an improved multilateration principle to identify the positionindependent geometric errors of rotary axis and laser beam,and minimize their impact on the measurement uncertainty.A closed-loop tracking interferometer system installed on the spindle is developed to perform the measurement with high tracking accuracy.The device can be installed on an ordinary five-axis machine tool without modifying the machine tool structure.The proposed scheme is conducive to improving the accuracy and practical application of the tracking interferometer based on birotary milling head.Experiments with the corresponding closed-loop tracking interferometer and uncertainty analysis are conducted to verify the performance of the proposed measurement scheme.
基金Supported by the National High Technology Research and Development Program of China("863" Program,No.2009AA044204)
文摘A compound machine tool was designed, which combined rotary ultrasonic assisted grinding, electrical discharge machining(EDM) and multi-axis milling. Experimental results indicated that its positioning accuracy was less than 5.6 μm and its repetitive positioning accuracy was less than 1.8 μm; the vibration amplitude of ultrasonic grinding system was uniform and stable, and the EDM system worked well and stably.A smooth surface of K9 optical glass component was achieved by the grinding method.
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 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the financial support for this research provided by the National Natural Science Foundation of China(Grant Nos.52275470,124115301,and 52105458)the Natural Science Foundation of Beijing(Grant No.3222009).
文摘Vibration cutting has emerged as a promising method for creating surface functional microstructures.However,achieving precise tool setting is a time-consuming process that significantly impacts process efficiency.This study proposes an intelligent approach for tool setting in vibration cutting using machine vision and hearing,divided into two steps.In the first step,machine vision is employed to achieve rough precision in tool setting within tens of micrometers.Subsequently,in the second step,machine hearing utilizes sound pickup to capture vibration audio signals,enabling fine tool adjustment within 1μm precision.The relationship between the spectral intensity of vibration audio and cutting depth is analyzed to establish criteria for tool–workpiece contact.Finally,the efficacy of this approach is validated on an ultra-precision platform,demonstrating that the automated tool-setting process takes no more than 74 s.The total cost of the vision and hearing sensors is less than$1500.
文摘The prediction of tool wear in CNC machine tools is a critical aspect of ensuring the efficient operation and longevity of manufacturing equipment.Tool wear significantly impacts machining accuracy,surface finish quality,and operational downtime,making its prediction essential for proactive maintenance strategies.This paper explores the integration of Digital Twin technology with tool wear prediction models to enhance the precision and reliability of wear forecasting in CNC machines.We review existing methodologies for tool wear prediction,including physics-based models,data-driven approaches,and hybrid models,with an emphasis on their strengths and limitations.Furthermore,the paper highlights the role of Digital Twin technology in creating real-time,virtual replicas of CNC machines that can dynamically monitor tool wear and provide actionable insights for optimization.By leveraging real-time data and advanced simulation techniques,Digital Twin-based prediction models offer significant improvements over traditional methods.The paper concludes by discussing future directions for integrating machine learning,deep learning,and real-time data analytics into the tool wear prediction process,ultimately contributing to the development of more intelligent and adaptive manufacturing systems.
基金the National Key Research and Development Program of China(Grant No.2022YFB3302700)the National Natural Science Foundation of China(Grant No.52375486)the Shanghai Rising-Star Program(Grant No.22QB1404200).
文摘In intelligentmanufacturing processes such as aerospace production,computer numerical control(CNC)machine tools require real-time optimization of process parameters to meet precision machining demands.These dynamic operating conditions increase the risk of fatigue damage in CNC machine tool bearings,highlighting the urgent demand for rapid and accurate fault diagnosis methods that can maintain production efficiency and extend equipment uptime.However,varying conditions induce feature distribution shifts,and scarce fault samples limitmodel generalization.Therefore,this paper proposes a causal-Transformer-based meta-learning(CTML)method for bearing fault diagnosis in CNC machine tools,comprising three core modules:(1)the original bearing signal is transformed into a multi-scale time-frequency feature space using continuous wavelet transform;(2)a causal-Transformer architecture is designed to achieve feature extraction and fault classification based on the physical causal law of fault propagation;(3)the above mechanisms are integrated into a model-agnostic meta-learning(MAML)framework to achieve rapid cross-condition adaptation through an adaptive gradient pruning strategy.Experimental results using the multiple bearing dataset show that under few-shot cross-condition scenarios(3-way 1-shot and 3-way 5-shot),the proposed CTML outperforms benchmark models(e.g.,Transformer,domain adversarial neural networks(DANN),and MAML)in terms of classification accuracy and sensitivity to operating conditions,while maintaining a moderate level of model complexity.
基金Supported by the National Natural Science Foundation of China(Grant Nos.52375448,52275440).
文摘The CNC machine tool is the fundamental equipment of the manufacturing industry,particularly in sectors where achieving high levels of accuracy is crucial.Geometric accuracy design is an important step in machine tool design and plays an essential role in determining the machining accuracy of the workpiece.Researchers have extensively studied methods to model,extract,optimize,and measure the geometric errors that affect the geometric accuracy of machine tools.This paper provides a comprehensive review of the state-of-the-art approaches and an overview of the latest research progress associated with geometric accuracy design in CNC machine tools.This paper explores the interrelated aspects of CNC machine tool accuracy design:modeling,analysis and optimization.Accuracy analysis,which includes geometric error modeling and sensitivity analysis,determines a machine tool’s output accuracy through its volumetric error model,given the known accuracy of its individual components.Conversely,accuracy allocation designs the accuracy of the machine tool components according to given output accuracy requirements to achieve optimization between the objectives of manufacturing cost,quality,reliability,and environmental impact.In addition to discussing design factors and evaluation methods,this paper outlines methods for verifying the accuracy of design results,aiming to provide a practical basis for ensuring that the designed accuracy is achieved.Finally,the challenges and future research directions in geometric accuracy design are highlighted.
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.
文摘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.
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The effective monitoring of tool wear status in the milling process of a five-axis machining center is important for improving product quality and efficiency,so this paper proposes a CNN convolutional neural network model based on the optimization of PSO algorithm to monitor the tool wear status.Firstly,the cutting vibration signals and spindle current signals during the milling process of the five-axis machining center are collected using sensor technology,and the features related to the tool wear status are extracted in the time domain,frequency domain and time-frequency domain to form a feature sample matrix;secondly,the tool wear values corresponding to the above features are measured using an electron microscope and classified into three types:slight wear,normal wear and sharp wear to construct a target Finally,the tool wear sample data set is constructed by using multi-source information fusion technology and input to PSO-CNN model to complete the prediction of tool wear status.The results show that the proposed method can effectively predict the tool wear state with an accuracy of 98.27%;and compared with BP model,CNN model and SVM model,the accuracy indexes are improved by 9.48%,3.44%and 1.72%respectively,which indicates that the PSO-CNN model proposed in this paper has obvious advantages in the field of tool wear state identification.
基金Ministerial Level Foundation(96J185 .1BQ0150) Fund for Reasearch on Doctoral Programs in Institutions of Higher Learning(1997000716)
文摘A new three dimensional simulation method is introduced to study the workspace of a 6 PSS (P denotes a prismatic kinematic pair, S denotes a spherical kinematic pair) parallel machine tool. This algorithm adopts the method of numerical analysis to investigate the boundary points in a series of sections which form the surface of the workspace. That is, to study such points that have the largest polar radius on a certain section in a system of polar coordinates according to conditions of constraint. The constraint conditions considered in the article include the maximum and minimum displacements of each dieblock, the maximum and minimum angles of oscillation in each hinge. By converting the constraint inequalities into constraint equations, the largest polar radius corresponding to every constraint condition can be evaluated and the minimum one is used to decide the boundary point. This algorithm greatly simplifies the computational process and can be used to analyze any section of the workspace. It provides a theoretical basis for the structural design of such a machine tool.
文摘A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.
文摘Through analysis of the basic transformation of a typical body,the error transformations of the position vector and the displacement vector are employed,a general model for positioning errors of NC machine tools by using kinematics of the multi body system is discussed.By means of 8031 single chip system,intelligent error compensation controller has been developed.The results of experiments on XH714 machining center show that the positioning accuracy is enhanced effectively by more than 50%.
