During five-axis machining of impeller, the excessive local interference avoidance leads to inconsistency of cutter posture, low quality of machined surface and increase of processing time. Therefore, in order to impr...During five-axis machining of impeller, the excessive local interference avoidance leads to inconsistency of cutter posture, low quality of machined surface and increase of processing time. Therefore, in order to improve the efficiency of five-axis machining of impellers, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. By using an MC-space algorithm for interference avoidance, an MB-spline algorithm for continuous control was intended to create a five-axis machining tool path with excellent surface quality and economic feasibility. A five-axis cutting experiment was performed to verify the effectiveness of the continuity control. The result shows that the surface shape with continuous method is greatly improved, and the surface roughness is generally favorable. Consequently, the effectiveness of the suggested method is verified by identifying the improvement of efficiency of five-axis machining of an impeller in aspects of surface quality and machining time.展开更多
High accuracy contour error estimation and direct contour error control are two major approaches to reduce the contour error.However, two key factors make them complex for five-axis machine tools: the nonlinear kinema...High accuracy contour error estimation and direct contour error control are two major approaches to reduce the contour error.However, two key factors make them complex for five-axis machine tools: the nonlinear kinematics and the coupling between the tool position and orientation. In this study, by finding the reference point nearest to the current actual position, and interpolating the point with two neighboring reference points and using the distance ratio, a new contour error estimation method for five-axis machine tools is proposed, which guarantees high accuracy while depending on only the reference points. By adding a weighted contour error on the tracking error in the workpiece coordinate system, and specifying a desired second-order error dynamics based on the error variable, an effective contouring control method is proposed, which can alleviate the problem: when the contour error components are introduced into the controller, the contour errors increase instead in some regions of the tracking trajectory. A series of experiments are performed on a tilting-rotary-table(TRT) type five-axis machine tool. The results reveal that the proposed estimation method has high accuracy, and compared with the case without contour error control, the proposed control approach can reduce the contour error along the whole trajectory.展开更多
When the five-axis CNC system executes the 3D cutter radius compensation function,the angle between two adjacent radius compensation vectors might become very large and the linear axes would move too fast if the tool ...When the five-axis CNC system executes the 3D cutter radius compensation function,the angle between two adjacent radius compensation vectors might become very large and the linear axes would move too fast if the tool orientation vector is close to the surface normal.The reason that results in this phenomenon is analyzed based on building the transmission relationship between the cutter contact point and the cutter location point.By taking the square-end tool as an example,an optimization algorithm to control the undesired movements is advanced.For the singular area where sudden change exists,the number of interpolation cycles is determined by the cutter feedrate,the limit speeds of machine axes and the maximum allowable angle between radius compensation vectors of adjacent NC blocks.The radius compensation vector of each interpolation cycle is obtained by a kind of vector rotation method.By maintaining the perpendicularity between the radius compensation vector and the tool orientation vector,the rapid movements of the linear axes are eliminated.A trial-cut experiment is performed to verify the correctness and the effectiveness of the proposed algorithm.展开更多
To implement five-axis functions in CNC system, based on domestic system Lan Tian series, an improved design method for the system software structure is proposed in this paper. The numerical control kernel of CNC syst...To implement five-axis functions in CNC system, based on domestic system Lan Tian series, an improved design method for the system software structure is proposed in this paper. The numerical control kernel of CNC system is divided into the task layer and the motion layer. A five-axis transformation unit is integrated into the motion layer. After classifying five-axis machines into different types and analyzing their geometry information, the five-axis kinematic library is designed according to the abstract factory pattern. Furthermore, by taking CA spindle- tilting machine as an example, the forward and the inverse kinematic transformations are deduced. Based on the new software architecture and the five-axis kinematic library, algorithms of RTCP （rotation tool center point control） and 3D radius compensation for end-milling are designed and realized. The milling results show that, with five-axis functions based on such software struc- ture, the instructions with respect to the cutter＇s position and orientation can be directly carried out in the CNC system.展开更多
Well-designed tool orientation is crucial for the quality execution of five-axis machining with flat-end tools.Tool orientation can be specified in terms of tool inclination and tool tilt angles.For a given surface pa...Well-designed tool orientation is crucial for the quality execution of five-axis machining with flat-end tools.Tool orientation can be specified in terms of tool inclination and tool tilt angles.For a given surface path,these aspects need to be specified for each cutter contact point along the path,because poor tool orientation choice can cause large axial acceleration of the machine tool,leading to inferior quality of the machined surface.The rotation-minimizing frame aims to reduce unnecessary frame rotation during movement.This concept has been adopted to develop tool orientation methods that allow variation in the inclination angle,the tilt angle,and both the inclination and tilt angles.The intention is to reduce unnecessary rotation of the tool frame as the tool follows a specified path.Evaluation was conducted in the context of five-axis flat-end tool machining.Based on these methods,tool orientation was planned along surface paths of a torus,sphere,and dome.Changes in tool orientation were always smooth.From the perspective of reducing tool orientation changes and axial acceleration,it was demonstrated that simultaneous variation of the inclination and tilt angles based on rotation minimization provided the best results.展开更多
基金Work supported by the Second Stage of Brain Korea 21 ProjectsProject(RTI04-01-03) supported by the Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE) of Korea
文摘During five-axis machining of impeller, the excessive local interference avoidance leads to inconsistency of cutter posture, low quality of machined surface and increase of processing time. Therefore, in order to improve the efficiency of five-axis machining of impellers, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. By using an MC-space algorithm for interference avoidance, an MB-spline algorithm for continuous control was intended to create a five-axis machining tool path with excellent surface quality and economic feasibility. A five-axis cutting experiment was performed to verify the effectiveness of the continuity control. The result shows that the surface shape with continuous method is greatly improved, and the surface roughness is generally favorable. Consequently, the effectiveness of the suggested method is verified by identifying the improvement of efficiency of five-axis machining of an impeller in aspects of surface quality and machining time.
基金supported by the National Natural Science Foundation of China(Grant Nos.51535004&91748114)
文摘High accuracy contour error estimation and direct contour error control are two major approaches to reduce the contour error.However, two key factors make them complex for five-axis machine tools: the nonlinear kinematics and the coupling between the tool position and orientation. In this study, by finding the reference point nearest to the current actual position, and interpolating the point with two neighboring reference points and using the distance ratio, a new contour error estimation method for five-axis machine tools is proposed, which guarantees high accuracy while depending on only the reference points. By adding a weighted contour error on the tracking error in the workpiece coordinate system, and specifying a desired second-order error dynamics based on the error variable, an effective contouring control method is proposed, which can alleviate the problem: when the contour error components are introduced into the controller, the contour errors increase instead in some regions of the tracking trajectory. A series of experiments are performed on a tilting-rotary-table(TRT) type five-axis machine tool. The results reveal that the proposed estimation method has high accuracy, and compared with the case without contour error control, the proposed control approach can reduce the contour error along the whole trajectory.
基金supported by the National Basic Research Program of China under Grant No.2011CB302400the National Key Technology Research and Development Program of China under Grant No.2012BAF13B08
文摘When the five-axis CNC system executes the 3D cutter radius compensation function,the angle between two adjacent radius compensation vectors might become very large and the linear axes would move too fast if the tool orientation vector is close to the surface normal.The reason that results in this phenomenon is analyzed based on building the transmission relationship between the cutter contact point and the cutter location point.By taking the square-end tool as an example,an optimization algorithm to control the undesired movements is advanced.For the singular area where sudden change exists,the number of interpolation cycles is determined by the cutter feedrate,the limit speeds of machine axes and the maximum allowable angle between radius compensation vectors of adjacent NC blocks.The radius compensation vector of each interpolation cycle is obtained by a kind of vector rotation method.By maintaining the perpendicularity between the radius compensation vector and the tool orientation vector,the rapid movements of the linear axes are eliminated.A trial-cut experiment is performed to verify the correctness and the effectiveness of the proposed algorithm.
基金supported by the National Basic Research Program of China (No. 2011CB302400)the Important National Science & Technology Specific Projects (No. 2013ZX04007031).
文摘To implement five-axis functions in CNC system, based on domestic system Lan Tian series, an improved design method for the system software structure is proposed in this paper. The numerical control kernel of CNC system is divided into the task layer and the motion layer. A five-axis transformation unit is integrated into the motion layer. After classifying five-axis machines into different types and analyzing their geometry information, the five-axis kinematic library is designed according to the abstract factory pattern. Furthermore, by taking CA spindle- tilting machine as an example, the forward and the inverse kinematic transformations are deduced. Based on the new software architecture and the five-axis kinematic library, algorithms of RTCP （rotation tool center point control） and 3D radius compensation for end-milling are designed and realized. The milling results show that, with five-axis functions based on such software struc- ture, the instructions with respect to the cutter＇s position and orientation can be directly carried out in the CNC system.
文摘Well-designed tool orientation is crucial for the quality execution of five-axis machining with flat-end tools.Tool orientation can be specified in terms of tool inclination and tool tilt angles.For a given surface path,these aspects need to be specified for each cutter contact point along the path,because poor tool orientation choice can cause large axial acceleration of the machine tool,leading to inferior quality of the machined surface.The rotation-minimizing frame aims to reduce unnecessary frame rotation during movement.This concept has been adopted to develop tool orientation methods that allow variation in the inclination angle,the tilt angle,and both the inclination and tilt angles.The intention is to reduce unnecessary rotation of the tool frame as the tool follows a specified path.Evaluation was conducted in the context of five-axis flat-end tool machining.Based on these methods,tool orientation was planned along surface paths of a torus,sphere,and dome.Changes in tool orientation were always smooth.From the perspective of reducing tool orientation changes and axial acceleration,it was demonstrated that simultaneous variation of the inclination and tilt angles based on rotation minimization provided the best results.
