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
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
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
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
Machine tools,often referred to as the“mother machines”of the manufacturing industry,are crucial in developing smart manufacturing and are increasingly becoming more intelligent.Digital twin technology can promote m...Machine tools,often referred to as the“mother machines”of the manufacturing industry,are crucial in developing smart manufacturing and are increasingly becoming more intelligent.Digital twin technology can promote machine tool intelligence and has attracted considerable research interest.However,there is a lack of clear and systematic analyses on how the digital twin technology enables machine tool intelligence.Herein,digital twin modeling was identified as an enabling technology for machine tool intelligence based on a comparative study of the characteristics of machine tool intelligence and digital twin.The review then delves into state-of-the-art digital twin modelingenabled machine tool intelligence,examining it from the aspects of data-based modeling and mechanism-data dual-driven modeling.Additionally,it highlights three bottleneck issues facing the field.Considering these problems,the architecture of a digital twin machine tool(DTMT)is proposed,and three key technologies are expounded in detail:Data perception and fusion technology,mechanism-data-knowledge hybrid-driven digital twin modeling and virtual-real synchronization technology,and dynamic optimization and collaborative control technology for multilevel parameters.Finally,future research directions for the DTMT are discussed.This work can provide a foundation basis for the research and implementation of digital-twin modeling-enabled machine tool intelligence,making it significant for developing intelligent machine tools.展开更多
Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracer...Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracers to enable the rapid and high-precision measurement of geometric errors for gantry-type computer numerical control(CNC)machine tools.This method also improves on the existing measurement efficiency issues in the single-base station measurement method and multi-base station time-sharing measurement method.We consider a three-axis gantry-type CNC machine tool,and the geometric error mathematical model is derived and established based on the combination of screw theory and a topological analysis of the machine kinematic chain.The four-station laser tracers position and measurement points are realized based on the multi-point positioning principle.A self-calibration algorithm is proposed for the coordinate calibration process of a laser tracer using the Levenberg-Marquardt nonlinear least squares method,and the geometric error is solved using Taylor’s first-order linearization iteration.The experimental results show that the geometric error calculated based on this modeling method is comparable to the results from the Etalon laser tracer.For a volume of 800 mm×1000 mm×350 mm,the maximum differences of the linear,angular,and spatial position errors were 2.0μm,2.7μrad,and 12.0μm,respectively,which verifies the accuracy of the proposed algorithm.This research proposes a modeling method for the precise measurement of errors in machine tools,and the applied nature of this study also makes it relevant both to researchers and those in the industrial sector.展开更多
The dimensional accuracy of machined parts is strongly influenced by the thermal behavior of machine tools (MT). Minimizing this influence represents a key objective for any modern manufacturing industry. Thermally in...The dimensional accuracy of machined parts is strongly influenced by the thermal behavior of machine tools (MT). Minimizing this influence represents a key objective for any modern manufacturing industry. Thermally induced positioning error compensation remains the most effective and practical method in this context. However, the efficiency of the compensation process depends on the quality of the model used to predict the thermal errors. The model should consistently reflect the relationships between temperature distribution in the MT structure and thermally induced positioning errors. A judicious choice of the number and location of temperature sensitive points to represent heat distribution is a key factor for robust thermal error modeling. Therefore, in this paper, the temperature sensitive points are selected following a structured thermomechanical analysis carried out to evaluate the effects of various temperature gradients on MT structure deformation intensity. The MT thermal behavior is first modeled using finite element method and validated by various experimentally measured temperature fields using temperature sensors and thermal imaging. MT Thermal behavior validation shows a maximum error of less than 10% when comparing the numerical estimations with the experimental results even under changing operation conditions. The numerical model is used through several series of simulations carried out using varied working condition to explore possible relationships between temperature distribution and thermal deformation characteristics to select the most appropriate temperature sensitive points that will be considered for building an empirical prediction model for thermal errors as function of MT thermal state. Validation tests achieved using an artificial neural network based simplified model confirmed the efficiency of the proposed temperature sensitive points allowing the prediction of the thermally induced errors with an accuracy greater than 90%.展开更多
Machining is as old as humanity, and changes in temperature in both the machine’s internal and external environments can be of great concern as they affect the machine’s thermal stability and, thus, the machine’s d...Machining is as old as humanity, and changes in temperature in both the machine’s internal and external environments can be of great concern as they affect the machine’s thermal stability and, thus, the machine’s dimensional accuracy. This paper is a continuation of our earlier work, which aimed to analyze the effect of the internal temperature of a machine tool as the machine is put into operation and vary the external temperature, the machine floor temperature. Some experiments are carried out under controlled conditions to study how machine tool components get heated up and how this heating up affects the machine’s accuracy due to thermally induced deviations. Additionally, another angle is added by varying the machine floor temperature. The parameters mentioned above are explored in line with the overall thermal stability of the machine tool and its dimensional accuracy. A Robodrill CNC machine tool is used. The CNC was first soaked with thermal energy by gradually raising the machine floor temperature to a certain level before putting the machine in operation. The machine was monitored, and analytical methods were deplored to evaluate thermal stability. Secondly, the machine was run idle for some time under raised floor temperature before it was put into operation. Data was also collected and analyzed. It is observed that machine thermal stability can be achieved in several ways depending on how the above parameters are joggled. This paper, in conclusion, reinforces the idea of machine tool warm-up process in conjunction with a carefully analyzed and established machine floor temperature variation for the approximation of the machine tool’s thermally stability to map the long-time behavior of the machine tool.展开更多
In the context of intelligent manufacturing,machine tools,as core equipment,directly influence production efficiency and product quality through their operational reliability.Traditional maintenance methods for machin...In the context of intelligent manufacturing,machine tools,as core equipment,directly influence production efficiency and product quality through their operational reliability.Traditional maintenance methods for machine tools,often characterized by low efficiency and high costs,fail to meet the demands of modern manufacturing industries.Therefore,leveraging intelligent manufacturing technologies,this paper proposes a solution optimized for the diagnosis and maintenance of machine tool faults.Initially,the paper introduces sensor-based data acquisition technologies combined with big data analytics and machine learning algorithms to achieve intelligent fault diagnosis of machine tools.Subsequently,it discusses predictive maintenance strategies by establishing an optimized model for maintenance strategy and resource allocation,thereby enhancing maintenance efficiency and reducing costs.Lastly,the paper explores the architectural design,integration,and testing evaluation methods of intelligent manufacturing systems.The study indicates that optimization of machine tool fault diagnosis and maintenance in an intelligent manufacturing environment not only enhances equipment reliability but also significantly reduces maintenance costs,offering broad application prospects.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
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
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
With the development of modern information technology-and particularly of the new generation of artificial intelligence(AI)technology-new opportunities are available for the development of the intelligent machine tool...With the development of modern information technology-and particularly of the new generation of artificial intelligence(AI)technology-new opportunities are available for the development of the intelligent machine tool(IMT).Based on the three classical paradigms of intelligent manufacturing as defined by the Chinese Academy of Engineering,the concept,characteristics,and systemic structure of the IMT are presented in this paper.Three stages of machine tool evolution-from the manually operated machine tool(MOMT)to the IMT-are discussed,including the numerical control machine tool(NCMT),the smart machine tool(SMT),and the IMT.Furthermore,the four intelligent control principles of the IMT-namely,autonomous sensing and connection,autonomous learning and modeling,autonomous optimization and decision-making,and autonomous control and execution-are presented in detail.This paper then points out that the essential characteristic of the IMT is to acquire and accumulate knowledge through learning,and presents original key enabling technologies,including the instruction-domain-based analytical approach,theoretical and big-data-based hybrid modeling technology,and the double-code control method.Based on this research,an intelligent numerical control(INC)system and industrial prototypes of IMTs are developed.Three intelligent practices are conducted,demonstrating that the integration of the new generation of AI technology with advanced manufacturing technology is a feasible and convenient way to advance machine tools toward the IMT.展开更多
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.
基金co-supported by the Natural Science Foundation of Beijing(No.3214043)the Project of State Key Lab of Tribology of Tsinghua University(No.SKLT2021D16)the National Natural Science Foundation of China(No.51975319)。
文摘In order to satisfy the machining requirements of aero-engine casing in modern aviation industry, this paper investigates three main issues during the design and development process of a five-axis machine tool with high accuracy, stiffness and efficiency, including whole structure design,key components design, and supporting stiffness design. First, an appropriate structure of five-axis machine tool is determined considering the processing characteristics of aero-engine casing. Then, a dual drive swing head and a compact motorized spindle are designed with enough drive capability and stiffness, and related structure, assembly method, cooling technology, and performance simulation are given in detail. Next, a design method of supporting stiffness of guide is proposed through the deformation prediction of the spindle end. Based on above work, a prototype of machine tool is developed, and some experiments are carried out, including performance tests of swing head and motorized spindle, and machining of a simulated workpiece of aero-engine casing. All experimental results show that the machine tool has satisfactory accuracy, stiffness and efficiency, which meets the machining requirements of aero-engine casing. The main work can be used as references for engineers and technicians, which are meaningful in practice.
基金supported by the National 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 Tianjin Municipal University Science and Technology Development Foundation of China(Grant No.2021KJ176).
文摘Machine tools,often referred to as the“mother machines”of the manufacturing industry,are crucial in developing smart manufacturing and are increasingly becoming more intelligent.Digital twin technology can promote machine tool intelligence and has attracted considerable research interest.However,there is a lack of clear and systematic analyses on how the digital twin technology enables machine tool intelligence.Herein,digital twin modeling was identified as an enabling technology for machine tool intelligence based on a comparative study of the characteristics of machine tool intelligence and digital twin.The review then delves into state-of-the-art digital twin modelingenabled machine tool intelligence,examining it from the aspects of data-based modeling and mechanism-data dual-driven modeling.Additionally,it highlights three bottleneck issues facing the field.Considering these problems,the architecture of a digital twin machine tool(DTMT)is proposed,and three key technologies are expounded in detail:Data perception and fusion technology,mechanism-data-knowledge hybrid-driven digital twin modeling and virtual-real synchronization technology,and dynamic optimization and collaborative control technology for multilevel parameters.Finally,future research directions for the DTMT are discussed.This work can provide a foundation basis for the research and implementation of digital-twin modeling-enabled machine tool intelligence,making it significant for developing intelligent machine tools.
基金Supported by Natural Science Foundation of Shaanxi Province of China(Grant No.2021JM010)Suzhou Municipal Natural Science Foundation of China(Grant Nos.SYG202018,SYG202134).
文摘Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracers to enable the rapid and high-precision measurement of geometric errors for gantry-type computer numerical control(CNC)machine tools.This method also improves on the existing measurement efficiency issues in the single-base station measurement method and multi-base station time-sharing measurement method.We consider a three-axis gantry-type CNC machine tool,and the geometric error mathematical model is derived and established based on the combination of screw theory and a topological analysis of the machine kinematic chain.The four-station laser tracers position and measurement points are realized based on the multi-point positioning principle.A self-calibration algorithm is proposed for the coordinate calibration process of a laser tracer using the Levenberg-Marquardt nonlinear least squares method,and the geometric error is solved using Taylor’s first-order linearization iteration.The experimental results show that the geometric error calculated based on this modeling method is comparable to the results from the Etalon laser tracer.For a volume of 800 mm×1000 mm×350 mm,the maximum differences of the linear,angular,and spatial position errors were 2.0μm,2.7μrad,and 12.0μm,respectively,which verifies the accuracy of the proposed algorithm.This research proposes a modeling method for the precise measurement of errors in machine tools,and the applied nature of this study also makes it relevant both to researchers and those in the industrial sector.
文摘The dimensional accuracy of machined parts is strongly influenced by the thermal behavior of machine tools (MT). Minimizing this influence represents a key objective for any modern manufacturing industry. Thermally induced positioning error compensation remains the most effective and practical method in this context. However, the efficiency of the compensation process depends on the quality of the model used to predict the thermal errors. The model should consistently reflect the relationships between temperature distribution in the MT structure and thermally induced positioning errors. A judicious choice of the number and location of temperature sensitive points to represent heat distribution is a key factor for robust thermal error modeling. Therefore, in this paper, the temperature sensitive points are selected following a structured thermomechanical analysis carried out to evaluate the effects of various temperature gradients on MT structure deformation intensity. The MT thermal behavior is first modeled using finite element method and validated by various experimentally measured temperature fields using temperature sensors and thermal imaging. MT Thermal behavior validation shows a maximum error of less than 10% when comparing the numerical estimations with the experimental results even under changing operation conditions. The numerical model is used through several series of simulations carried out using varied working condition to explore possible relationships between temperature distribution and thermal deformation characteristics to select the most appropriate temperature sensitive points that will be considered for building an empirical prediction model for thermal errors as function of MT thermal state. Validation tests achieved using an artificial neural network based simplified model confirmed the efficiency of the proposed temperature sensitive points allowing the prediction of the thermally induced errors with an accuracy greater than 90%.
文摘Machining is as old as humanity, and changes in temperature in both the machine’s internal and external environments can be of great concern as they affect the machine’s thermal stability and, thus, the machine’s dimensional accuracy. This paper is a continuation of our earlier work, which aimed to analyze the effect of the internal temperature of a machine tool as the machine is put into operation and vary the external temperature, the machine floor temperature. Some experiments are carried out under controlled conditions to study how machine tool components get heated up and how this heating up affects the machine’s accuracy due to thermally induced deviations. Additionally, another angle is added by varying the machine floor temperature. The parameters mentioned above are explored in line with the overall thermal stability of the machine tool and its dimensional accuracy. A Robodrill CNC machine tool is used. The CNC was first soaked with thermal energy by gradually raising the machine floor temperature to a certain level before putting the machine in operation. The machine was monitored, and analytical methods were deplored to evaluate thermal stability. Secondly, the machine was run idle for some time under raised floor temperature before it was put into operation. Data was also collected and analyzed. It is observed that machine thermal stability can be achieved in several ways depending on how the above parameters are joggled. This paper, in conclusion, reinforces the idea of machine tool warm-up process in conjunction with a carefully analyzed and established machine floor temperature variation for the approximation of the machine tool’s thermally stability to map the long-time behavior of the machine tool.
文摘In the context of intelligent manufacturing,machine tools,as core equipment,directly influence production efficiency and product quality through their operational reliability.Traditional maintenance methods for machine tools,often characterized by low efficiency and high costs,fail to meet the demands of modern manufacturing industries.Therefore,leveraging intelligent manufacturing technologies,this paper proposes a solution optimized for the diagnosis and maintenance of machine tool faults.Initially,the paper introduces sensor-based data acquisition technologies combined with big data analytics and machine learning algorithms to achieve intelligent fault diagnosis of machine tools.Subsequently,it discusses predictive maintenance strategies by establishing an optimized model for maintenance strategy and resource allocation,thereby enhancing maintenance efficiency and reducing costs.Lastly,the paper explores the architectural design,integration,and testing evaluation methods of intelligent manufacturing systems.The study indicates that optimization of machine tool fault diagnosis and maintenance in an intelligent manufacturing environment not only enhances equipment reliability but also significantly reduces maintenance costs,offering broad application prospects.
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%.
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 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The authors would like to express special thanks to Prof.Ji Zhou from the Chinese Academy of Engineering.This paper is supported by the National Natural Science Foundation of China(51675204 and 51575210)the National Science and Technology Major Project of the Ministry of Science and Technology of China(2018ZX04035002-002).
文摘With the development of modern information technology-and particularly of the new generation of artificial intelligence(AI)technology-new opportunities are available for the development of the intelligent machine tool(IMT).Based on the three classical paradigms of intelligent manufacturing as defined by the Chinese Academy of Engineering,the concept,characteristics,and systemic structure of the IMT are presented in this paper.Three stages of machine tool evolution-from the manually operated machine tool(MOMT)to the IMT-are discussed,including the numerical control machine tool(NCMT),the smart machine tool(SMT),and the IMT.Furthermore,the four intelligent control principles of the IMT-namely,autonomous sensing and connection,autonomous learning and modeling,autonomous optimization and decision-making,and autonomous control and execution-are presented in detail.This paper then points out that the essential characteristic of the IMT is to acquire and accumulate knowledge through learning,and presents original key enabling technologies,including the instruction-domain-based analytical approach,theoretical and big-data-based hybrid modeling technology,and the double-code control method.Based on this research,an intelligent numerical control(INC)system and industrial prototypes of IMTs are developed.Three intelligent practices are conducted,demonstrating that the integration of the new generation of AI technology with advanced manufacturing technology is a feasible and convenient way to advance machine tools toward the IMT.
