This paper describes A-B 7300 CNC machine tool rebuilding, mainly in PAL and AMP utilization of C-type software. It includes PAL program locating and analyzing, AMP capturing etc. After setting PAL and AMP, the greate...This paper describes A-B 7300 CNC machine tool rebuilding, mainly in PAL and AMP utilization of C-type software. It includes PAL program locating and analyzing, AMP capturing etc. After setting PAL and AMP, the greater part of the electrical rebuilding has been accomplished.展开更多
A method for improving accuracy of CNC machine tools through compensation for the thermal errors is studied. The thermal errors are obtained by 1 D ball array and characterized by an auto regressive model based on sp...A method for improving accuracy of CNC machine tools through compensation for the thermal errors is studied. The thermal errors are obtained by 1 D ball array and characterized by an auto regressive model based on spindle rotation speed. By revising the workpiece NC machining program, the thermal errors can be compensated before machining. The experiments on a vertical machining center show that the effectiveness of compensation is good.展开更多
A feedforward compensation naethod of the motion errors of NC machine tools imple- mented with software is proposed , with which the motion errors can be compensated whithout changing the original computer control sys...A feedforward compensation naethod of the motion errors of NC machine tools imple- mented with software is proposed , with which the motion errors can be compensated whithout changing the original computer control systems of the NC machine tools. The experimental results show that the circular interpolation profile machining errors decrease by a factor of 2/3 after com- pensated.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
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
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
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
With the aid of commercial finite element analysis software package ANSYS,investigations are made on the contributions of main components to stiffness of the main module for parallel machine tools,and it is found that...With the aid of commercial finite element analysis software package ANSYS,investigations are made on the contributions of main components to stiffness of the main module for parallel machine tools,and it is found that the frame is the main contributor.Then,influences of constraints,strut length and working ways of the main module have also been investigated.It can be concluded that when one of the main planes of the frame without linear drive unit is constrained,the largest whole stiffness can be acquired.And,the stiffness is much better when the main module is used in a vertical machine tool instead of a horizontal one.Finally,the principle of stiffness variation is summarized when the mobile platform reaches various positions within its working space and when various loads are applied.These achievements have provided critical instructions for the design of the main module for parallel machine tools.展开更多
Quick and accurate detecting the error of NC machine tool and performing the error compensation are important to improve the machining accuracy of NC machine tool. Currently, there are many methods for detecting the g...Quick and accurate detecting the error of NC machine tool and performing the error compensation are important to improve the machining accuracy of NC machine tool. Currently, there are many methods for detecting the geometric accuracy of NC machine tool. However, these methods have deficiencies in detection efficiency and accuracy as well as in versatility. In the paper, a method with laser tracker based on the multi-station and time-sharing measurement principle is proposed, and this method can rapidly and accurately detect the geometric accuracy of NC machine tool. The machine tool is controlled to move in the preset path in a 3D space or 2D plane, and a laser tracker is used to measure the same motion trajectory of the machine tool successively at different base stations. The original algorithm for multi-station and time-sharing measurement is improved. The space coordinates of the measuring point obtained by the laser tracker are taken as parameter values, and the initial position of each base point can be determined. The redundant equation concerning the base point calibration can be established by the distance information of the laser tracker, and the position of each base point is further determined by solving the equation with least squares method, then the space coordinates of each measuring point can be calibrated. The singular matrix does not occur in calculation with the improved algorithm, which overcomes the limitations of the original algorithm, that the motion trajectory of machine tool is in a 3D space and there exits height difference between the base stations. Adopting the improved algorithm can expand the application of multi-station and time-sharing measurement, and can meet the quick and accurate detecting requirements for different types of NC machine tool.展开更多
Although Markov chain Monte Carlo（MCMC） algorithms are accurate, many factors may cause instability when they are utilized in reliability analysis; such instability makes these algorithms unsuitable for widespread e...Although Markov chain Monte Carlo（MCMC） algorithms are accurate, many factors may cause instability when they are utilized in reliability analysis; such instability makes these algorithms unsuitable for widespread engineering applications. Thus, a reliability modeling and assessment solution aimed at small-sample data of numerical control（NC） machine tools is proposed on the basis of Bayes theories. An expert-judgment process of fusing multi-source prior information is developed to obtain the Weibull parameters＇ prior distributions and reduce the subjective bias of usual expert-judgment methods. The grid approximation method is applied to two-parameter Weibull distribution to derive the formulas for the parameters＇ posterior distributions and solve the calculation difficulty of high-dimensional integration. The method is then applied to the real data of a type of NC machine tool to implement a reliability assessment and obtain the mean time between failures（MTBF）. The relative error of the proposed method is 5.8020×10-4 compared with the MTBF obtained by the MCMC algorithm. This result indicates that the proposed method is as accurate as MCMC. The newly developed solution for reliability modeling and assessment of NC machine tools under small-sample data is easy, practical, and highly suitable for widespread application in the engineering field; in addition, the solution does not reduce accuracy.展开更多
Feedrate fluctuation caused by approximation errors of interpolation methods has great effects on machining quality in NURBS interpolation, but few methods can efficiently eliminate or reduce it to a satisfying level ...Feedrate fluctuation caused by approximation errors of interpolation methods has great effects on machining quality in NURBS interpolation, but few methods can efficiently eliminate or reduce it to a satisfying level without sacrificing the computing efficiency at present. In order to solve this problem, a high accurate interpolation method for NURBS tool path is proposed. The proposed method can efficiently reduce the feedrate fluctuation by forming a quartic equation with respect to the curve parameter increment, which can be efficiently solved by analytic methods in real-time. Theoretically, the proposed method can totally eliminate the feedrate fluctuation for any 2nd degree NURBS curves and can interpolate 3rd degree NURBS curves with minimal feedrate fluctuation. Moreover, a smooth feedrate planning algorithm is also proposed to generate smooth tool motion with considering multiple constraints and scheduling errors by an efficient planning strategy. Experiments are conducted to verify the feasibility and applicability of the proposed method. This research presents a novel NURBS interpolation method with not only high accuracy but also satisfying computing efficiency.展开更多
Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining qualit...Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.展开更多
Product customization is a trend in the current market-oriented manufacturing environment. However, deduction from customer requirements to design results and evaluation of design alternatives are still heavily relian...Product customization is a trend in the current market-oriented manufacturing environment. However, deduction from customer requirements to design results and evaluation of design alternatives are still heavily reliant on the designer＇s experience and knowledge. To solve the problem of fuzziness and uncertainty of customer requirements in product configuration, an analysis method based on the grey rough model is presented. The customer requirements can be converted into technical characteristics effectively. In addition, an optimization decision model for product planning is established to help the enterprises select the key technical characteristics under the constraints of cost and time to serve the customer to maximal satisfaction. A new case retrieval approach that combines the self-organizing map and fuzzy similarity priority ratio method is proposed in case-based design. The self-organizing map can reduce the retrieval range and increase the retrieval efficiency, and the fuzzy similarity priority ratio method can evaluate the similarity of cases comprehensively. To ensure that the final case has the based on grey correlation analysis is proposed to evaluate similar cases best overall performance, an evaluation method of similar cases to select the most suitable case. Furthermore, a computer-aided system is developed using MATLAB GUI to assist the product configuration design. The actual example and result on an ETC series machine tool product show that the proposed method is effective, rapid and accurate in the process of product configuration. The proposed methodology provides a detailed instruction for the product configuration design oriented to customer requirements.展开更多
Building cyber-physical system(CPS) models of machine tools is a key technology for intelligent manufacturing. The massive electronic data from a computer numerical control(CNC) system during the work processes of a C...Building cyber-physical system(CPS) models of machine tools is a key technology for intelligent manufacturing. The massive electronic data from a computer numerical control(CNC) system during the work processes of a CNC machine tool is the main source of the big data on which a CPS model is established. In this work-process model, a method based on instruction domain is applied to analyze the electronic big data, and a quantitative description of the numerical control(NC) processes is built according to the G code of the processes. Utilizing the instruction domain, a work-process CPS model is established on the basis of the accurate, real-time mapping of the manufacturing tasks, resources, and status of the CNC machine tool. Using such models, case studies are conducted on intelligent-machining applications, such as the optimization of NC processing parameters and the health assurance of CNC machine tools.展开更多
Machine tool thermal error is an important reason for poor machining accuracy. Thermal error compensation is a primary technology in accuracy control. To build thermal error model, temperature variables are needed to ...Machine tool thermal error is an important reason for poor machining accuracy. Thermal error compensation is a primary technology in accuracy control. To build thermal error model, temperature variables are needed to be divided into several groups on an appropriate threshold. Currently, group threshold value is mainly determined by researchers experience. Few studies focus on group threshold in temperature variable grouping. Since the threshold is important in error compensation, this paper arms to find out an optimal threshold to realize temperature variable optimization in thermal error modeling. Firstly, correlation coefficient is used to express membership grade of temperature variables, and the theory of fuzzy transitive closure is applied to obtain relational matrix of temperature variables. Concepts as compact degree and separable degree are introduced. Then evaluation model of temperature variable clustering is built. The optimal threshold and the best temperature variable clustering can be obtained by setting the maximum value of evaluation model as the objective. Finally, correlation coefficients between temperature variables and thermal error are calculated in order to find out optimum temperature variables for thermal error modeling. An experiment is conducted on a precise horizontal machining center. In experiment, three displacement sensors are used to measure spindle thermal error and twenty-nine temperature sensors are utilized to detect the machining center temperature. Experimental result shows that the new method of temperature variable optimization on optimal threshold successfully worked out a best threshold value interval and chose seven temperature variables from twenty-nine temperature measuring points. The model residual of z direction is within 3 μm. Obviously, the proposed new variable optimization method has simple computing process and good modeling accuracy, which is quite fit for thermal error compensation.展开更多
Thermal error monitoring technology is the key technological support to solve the thermal error problem of heavy-duty CNC （computer numerical control） machine tools. Currently, there are many review literatures intr...Thermal error monitoring technology is the key technological support to solve the thermal error problem of heavy-duty CNC （computer numerical control） machine tools. Currently, there are many review literatures intro- ducing the thermal error research of CNC machine tools, but those mainly focus on the thermal issues in small and medium-sized CNC machine tools and seldom introduce thermal error monitoring technologies. This paper gives an overview of the research on the thermal error of CNC machine tools and emphasizes the study of thermal error of the heavy-duty CNC machine tool in three areas. These areas are the causes of thermal error of heavy-duty CNC machine tool and the issues with the temperature moni- toring technology and thermal deformation monitoring technology. A new optical measurement technology called the ＂fiber Bragg grating （FBG） distributed sensing tech- nology＂ for heavy-duty CNC machine tools is introduced in detail. This technology forms an intelligent sensing and monitoring system for heavy-duty CNC machine tools. This paper fills in the blank of this kind of review articlesto guide the development of this industry field and opens up new areas of research on the heavy-duty CNC machine tool thermal error.展开更多
The milling-head machine tool is a sophisticated and high-quality machine tool of which the spindle system is made up of special multi-element structure.Two special mechanical configurations make the cutting performan...The milling-head machine tool is a sophisticated and high-quality machine tool of which the spindle system is made up of special multi-element structure.Two special mechanical configurations make the cutting performance of the machine tool decline.One is the milling head spindle supported on two sets of complex bearings.The mechanical dynamic rigidity of milling head structure is researched on designed digital prototype with finite element analysis(FEA)and modal synthesis analysis(MSA)for identifying the weak structures.The other is the ram structure hanging on milling head.The structure is researched to get dynamic performance on cutting at different ram extending positions.The analysis results on spindle and ram are used to improve the mechanical configurations and structure in design.The machine tool is built up with modified structure and gets better dynamic rigidity than it was before.展开更多
文摘This paper describes A-B 7300 CNC machine tool rebuilding, mainly in PAL and AMP utilization of C-type software. It includes PAL program locating and analyzing, AMP capturing etc. After setting PAL and AMP, the greater part of the electrical rebuilding has been accomplished.
文摘A method for improving accuracy of CNC machine tools through compensation for the thermal errors is studied. The thermal errors are obtained by 1 D ball array and characterized by an auto regressive model based on spindle rotation speed. By revising the workpiece NC machining program, the thermal errors can be compensated before machining. The experiments on a vertical machining center show that the effectiveness of compensation is good.
文摘A feedforward compensation naethod of the motion errors of NC machine tools imple- mented with software is proposed , with which the motion errors can be compensated whithout changing the original computer control systems of the NC machine tools. The experimental results show that the circular interpolation profile machining errors decrease by a factor of 2/3 after com- pensated.
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.
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%.
文摘With the aid of commercial finite element analysis software package ANSYS,investigations are made on the contributions of main components to stiffness of the main module for parallel machine tools,and it is found that the frame is the main contributor.Then,influences of constraints,strut length and working ways of the main module have also been investigated.It can be concluded that when one of the main planes of the frame without linear drive unit is constrained,the largest whole stiffness can be acquired.And,the stiffness is much better when the main module is used in a vertical machine tool instead of a horizontal one.Finally,the principle of stiffness variation is summarized when the mobile platform reaches various positions within its working space and when various loads are applied.These achievements have provided critical instructions for the design of the main module for parallel machine tools.
基金supported by National Hi-tech Research and Development Program of China (863 Program,Grant No. 2008AA042404)
文摘Quick and accurate detecting the error of NC machine tool and performing the error compensation are important to improve the machining accuracy of NC machine tool. Currently, there are many methods for detecting the geometric accuracy of NC machine tool. However, these methods have deficiencies in detection efficiency and accuracy as well as in versatility. In the paper, a method with laser tracker based on the multi-station and time-sharing measurement principle is proposed, and this method can rapidly and accurately detect the geometric accuracy of NC machine tool. The machine tool is controlled to move in the preset path in a 3D space or 2D plane, and a laser tracker is used to measure the same motion trajectory of the machine tool successively at different base stations. The original algorithm for multi-station and time-sharing measurement is improved. The space coordinates of the measuring point obtained by the laser tracker are taken as parameter values, and the initial position of each base point can be determined. The redundant equation concerning the base point calibration can be established by the distance information of the laser tracker, and the position of each base point is further determined by solving the equation with least squares method, then the space coordinates of each measuring point can be calibrated. The singular matrix does not occur in calculation with the improved algorithm, which overcomes the limitations of the original algorithm, that the motion trajectory of machine tool is in a 3D space and there exits height difference between the base stations. Adopting the improved algorithm can expand the application of multi-station and time-sharing measurement, and can meet the quick and accurate detecting requirements for different types of NC machine tool.
基金Supported by Research on Reliability Assessment and Test Methods of Heavy Machine Tools,China(State Key Science&Technology Project High-grade NC Machine Tools and Basic Manufacturing Equipment,Grant No.2014ZX04014-011)Reliability Modeling of Machining Centers Considering the Cutting Loads,China(Science&Technology Development Plan for Jilin Province,Grant No.3D513S292414)Graduate Innovation Fund of Jilin University,China(Grant No.2014053)
文摘Although Markov chain Monte Carlo（MCMC） algorithms are accurate, many factors may cause instability when they are utilized in reliability analysis; such instability makes these algorithms unsuitable for widespread engineering applications. Thus, a reliability modeling and assessment solution aimed at small-sample data of numerical control（NC） machine tools is proposed on the basis of Bayes theories. An expert-judgment process of fusing multi-source prior information is developed to obtain the Weibull parameters＇ prior distributions and reduce the subjective bias of usual expert-judgment methods. The grid approximation method is applied to two-parameter Weibull distribution to derive the formulas for the parameters＇ posterior distributions and solve the calculation difficulty of high-dimensional integration. The method is then applied to the real data of a type of NC machine tool to implement a reliability assessment and obtain the mean time between failures（MTBF）. The relative error of the proposed method is 5.8020×10-4 compared with the MTBF obtained by the MCMC algorithm. This result indicates that the proposed method is as accurate as MCMC. The newly developed solution for reliability modeling and assessment of NC machine tools under small-sample data is easy, practical, and highly suitable for widespread application in the engineering field; in addition, the solution does not reduce accuracy.
基金Supported by National Natural Science Foundation of China(Grant No.11290144)Innovation Foundation of BUAA for Ph D Graduates,China
文摘Feedrate fluctuation caused by approximation errors of interpolation methods has great effects on machining quality in NURBS interpolation, but few methods can efficiently eliminate or reduce it to a satisfying level without sacrificing the computing efficiency at present. In order to solve this problem, a high accurate interpolation method for NURBS tool path is proposed. The proposed method can efficiently reduce the feedrate fluctuation by forming a quartic equation with respect to the curve parameter increment, which can be efficiently solved by analytic methods in real-time. Theoretically, the proposed method can totally eliminate the feedrate fluctuation for any 2nd degree NURBS curves and can interpolate 3rd degree NURBS curves with minimal feedrate fluctuation. Moreover, a smooth feedrate planning algorithm is also proposed to generate smooth tool motion with considering multiple constraints and scheduling errors by an efficient planning strategy. Experiments are conducted to verify the feasibility and applicability of the proposed method. This research presents a novel NURBS interpolation method with not only high accuracy but also satisfying computing efficiency.
基金supported by the National Natural Science Foundation of China(Nos.52005413,52022082)Natural Science Basic Research Plan in Shaanxi Province of China(No.2021JM-054)the Fundamental Research Funds for the Central Universities(No.D5000220135)。
文摘Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.
基金Supported by State Science and Technology Support Program of China(Grant No.2012BAF12B08-04)Liaoning Provincial Key Scientific and Technological Project of China(Grant Nos.2011216010,2010020076-301)
文摘Product customization is a trend in the current market-oriented manufacturing environment. However, deduction from customer requirements to design results and evaluation of design alternatives are still heavily reliant on the designer＇s experience and knowledge. To solve the problem of fuzziness and uncertainty of customer requirements in product configuration, an analysis method based on the grey rough model is presented. The customer requirements can be converted into technical characteristics effectively. In addition, an optimization decision model for product planning is established to help the enterprises select the key technical characteristics under the constraints of cost and time to serve the customer to maximal satisfaction. A new case retrieval approach that combines the self-organizing map and fuzzy similarity priority ratio method is proposed in case-based design. The self-organizing map can reduce the retrieval range and increase the retrieval efficiency, and the fuzzy similarity priority ratio method can evaluate the similarity of cases comprehensively. To ensure that the final case has the based on grey correlation analysis is proposed to evaluate similar cases best overall performance, an evaluation method of similar cases to select the most suitable case. Furthermore, a computer-aided system is developed using MATLAB GUI to assist the product configuration design. The actual example and result on an ETC series machine tool product show that the proposed method is effective, rapid and accurate in the process of product configuration. The proposed methodology provides a detailed instruction for the product configuration design oriented to customer requirements.
基金support of the studies is from the National Major Scientific and Technological Special Project for "Development and comprehensive verification of complete products of open high-end CNC system, servo device and motor" (2012ZX04001012)
文摘Building cyber-physical system(CPS) models of machine tools is a key technology for intelligent manufacturing. The massive electronic data from a computer numerical control(CNC) system during the work processes of a CNC machine tool is the main source of the big data on which a CPS model is established. In this work-process model, a method based on instruction domain is applied to analyze the electronic big data, and a quantitative description of the numerical control(NC) processes is built according to the G code of the processes. Utilizing the instruction domain, a work-process CPS model is established on the basis of the accurate, real-time mapping of the manufacturing tasks, resources, and status of the CNC machine tool. Using such models, case studies are conducted on intelligent-machining applications, such as the optimization of NC processing parameters and the health assurance of CNC machine tools.
基金supported by Jiangsu Provincial Prospective Joint Research Foundation for Industry-University-Research of China (Grant No. BY2009102)Henan Provincial Major Scientific and Technological Projects of China (Grant No. 102102210050)
文摘Machine tool thermal error is an important reason for poor machining accuracy. Thermal error compensation is a primary technology in accuracy control. To build thermal error model, temperature variables are needed to be divided into several groups on an appropriate threshold. Currently, group threshold value is mainly determined by researchers experience. Few studies focus on group threshold in temperature variable grouping. Since the threshold is important in error compensation, this paper arms to find out an optimal threshold to realize temperature variable optimization in thermal error modeling. Firstly, correlation coefficient is used to express membership grade of temperature variables, and the theory of fuzzy transitive closure is applied to obtain relational matrix of temperature variables. Concepts as compact degree and separable degree are introduced. Then evaluation model of temperature variable clustering is built. The optimal threshold and the best temperature variable clustering can be obtained by setting the maximum value of evaluation model as the objective. Finally, correlation coefficients between temperature variables and thermal error are calculated in order to find out optimum temperature variables for thermal error modeling. An experiment is conducted on a precise horizontal machining center. In experiment, three displacement sensors are used to measure spindle thermal error and twenty-nine temperature sensors are utilized to detect the machining center temperature. Experimental result shows that the new method of temperature variable optimization on optimal threshold successfully worked out a best threshold value interval and chose seven temperature variables from twenty-nine temperature measuring points. The model residual of z direction is within 3 μm. Obviously, the proposed new variable optimization method has simple computing process and good modeling accuracy, which is quite fit for thermal error compensation.
基金Supported by National Natural Science Foundation of China(Grant No.51475343)International Science and Technology Cooperation Program of China(Grant No.2015DFA70340)
文摘Thermal error monitoring technology is the key technological support to solve the thermal error problem of heavy-duty CNC （computer numerical control） machine tools. Currently, there are many review literatures intro- ducing the thermal error research of CNC machine tools, but those mainly focus on the thermal issues in small and medium-sized CNC machine tools and seldom introduce thermal error monitoring technologies. This paper gives an overview of the research on the thermal error of CNC machine tools and emphasizes the study of thermal error of the heavy-duty CNC machine tool in three areas. These areas are the causes of thermal error of heavy-duty CNC machine tool and the issues with the temperature moni- toring technology and thermal deformation monitoring technology. A new optical measurement technology called the ＂fiber Bragg grating （FBG） distributed sensing tech- nology＂ for heavy-duty CNC machine tools is introduced in detail. This technology forms an intelligent sensing and monitoring system for heavy-duty CNC machine tools. This paper fills in the blank of this kind of review articlesto guide the development of this industry field and opens up new areas of research on the heavy-duty CNC machine tool thermal error.
基金supported by Funding Project for Academic Human Resources Development in Institutions of Higher Learning under the Jurisdiction of Beijing Municipality,China.
文摘The milling-head machine tool is a sophisticated and high-quality machine tool of which the spindle system is made up of special multi-element structure.Two special mechanical configurations make the cutting performance of the machine tool decline.One is the milling head spindle supported on two sets of complex bearings.The mechanical dynamic rigidity of milling head structure is researched on designed digital prototype with finite element analysis(FEA)and modal synthesis analysis(MSA)for identifying the weak structures.The other is the ram structure hanging on milling head.The structure is researched to get dynamic performance on cutting at different ram extending positions.The analysis results on spindle and ram are used to improve the mechanical configurations and structure in design.The machine tool is built up with modified structure and gets better dynamic rigidity than it was before.
