The objectives of the present research are to investigate relationships between kinematic motion deviations of machine tools and geometric tolerances of their components, to propose mathematical models representing kinematic motion deviations of five-axis machining centers, and to apply the models to analysis of the kinematic motion deviations of five-axis machining centers. A set of models is proposed to represent kinematic motion deviations of both the linear tables and the rotary tables, based on the geometric tolerances of the guide-ways connecting the components. By combing the models, three models of the five-axis machining centers are developed and applied to the analysis of the standard deviations of the shape generation motions of the tools and the workpieces. The proposed models provides us with a systematic method to analyze and to estimate the kinematic motion deviations of the five-axis machining centers, based on the geometric tolerances of the guide-ways connecting the components.
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The kinematic motion deviations of the five-axis machining centers are deeply influenced by the geometric deviations of the components, such as guide-ways and bearings. A systematic design method is required for specifying suitable geometric tolerances of the guide-ways, in order to improve the kinematic motion deviations of five-axis machining centers. The objective of the present research is to establish a computer-aided design system for specifying a suitable set of the geometric tolerances of the guide-ways considering the trade-off between the requirements on the kinematic motion deviations and the ease of the manufacturing processes. A mathematical model was proposed in the previous papers to represent the standard deviations of the shape generation motions, based on the tolerance values of the guide-ways of the five-axis machining centers. A systematic method is proposed here, by applying an optimization method, to determine a suitable set of the tolerance values of all the guide-ways under the constraints on the kinematic motion deviations between the tools and the workpieces. The method is applied to some design problems of the geometric tolerances of the guide-ways included in the five-axis machining centers.
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