5-Axis adaptive flank milling of flexible thin-walled parts based on the on-machine measurement

Huang, Nuodi; Bi, Qinsheng; Wang, Yuhan; Sun, Chao

doi:10.1016/j.ijmachtools.2014.04.004

Cited by 121 publications

(33 citation statements)

References 24 publications

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“…To increase accuracy in 5-axis machining operations of impeller blades, optimized strategy for finishing operations in the final step of the machining process is presented by Chaves-Jacob et al [4]. The machining operations errors in 5-Axis adaptive flank milling of thin walled impeller blades is analyzed and decreased by Huang et al [5] to develop the process of machining operations of flexible parts. To analyze an decrease the deflection error in milling thin-walled impeller blade, an advanced method to predict the deflection error is investigated by Liu et al [6].…”

Section: -Review Of Research Work In the Deflection Errors Of Thin mentioning

confidence: 99%

Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Soori

Asmael

2020

Preprint

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To enhance accuracy as well as efficiency in process of machining operations, the virtual machining systems are developed. Free from surfaces of sophisticated parts such as turbine blades, airfoils, impellers, and aircraft components are produced by using the 5-axis CNC machine tools which can be analyzed and developed by using virtual machining systems. The machining operations of thin walled structures such as impeller blades are with deflection errors due to cutting forces and cutting temperatures. The flexibility of thin walled impeller blades can cause machining defects such as overcut or undercut. So, the desired accuracy in the machined impeller blades can be achieved by decreasing the deflection error in the machining operations. To minimize the deflection of machined impeller blades, optimized machining parameters can be obtained. An application of virtual machining system in predicting and minimizing the deflection errors of 5-Axis CNC machining operations of impeller blades is presented in the study to increase accuracy and efficiency in process of part production. The finite element analysis is applied to obtain the deflection error in machined impeller blades. In order to minimize the deflection error of impeller blades in the machining operations, the optimization methodology based on the Genetic algorithm is applied. The impeller is machined by using the 5-axis CNC machine tool in order to validate the developed virtual machining system in the study. Then, the machined impeller is measured by using the CMM machines to obtain the deflection error. As a result, the deflection error of in machining operations of impeller by using 5-Axis CNC machine tools can be decreased in order to enhance accuracy and efficiency of part manufacturing.

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Section: -Review Of Research Work In the Deflection Errors Of Thin mentioning

confidence: 99%

Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Soori

Asmael

2020

Preprint

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“…Furthermore, the geometric errors of the machine tool and mounted laser scanner are also nonignorable error sources. Much research work has been conducted to investigate the errors of multi-axis machine tools [28,29]. In order to calibrate the developed measuring system, two surfaces, one consisting of a slope, plane and convex sphere, and the other composed of a plane and a larger convex sphere were machined in the fly-cutting machine and then measured by the laser scanner.…”

Section: Configuration and Calibration Of The Measurement Systemmentioning

confidence: 99%

Fiducial-aided on-machine positioning method for precision manufacturing of optical freeform surfaces

Wang¹,

Cheung²,

Ren³

et al. 2018

Opt. Express

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There are still significant challenges in the accurate positioning of optical freeform surfaces on the machine tool and the measurement instrument due to the high accuracy requirement and their complex shapes. This paper proposes a Fiducial-aided On-machine Positioning method (FAOPM) that combines on-machine measurement and off-machine measurement to precisely position optical freeform surfaces during the precision manufacturing cycle including rough machining, fine machining, measurement, and error compensation. The FAOPM makes use of fiducials which are firstly measured on a coordinate measuring machine with nanometric accuracy to generate a Fiducial-aided Computer Aided Design (FA-CAD) of the designed optical surface, then the developed on-machine measuring device obtains the accurate positions of the fiducials after remounting in the machining coordinate system. Finally the relative position of the workpiece is identified so that the associated cutting paths and compensation tool path can be easily generated. Several optical freeform surfaces were experimentally machined to prove the capability of the proposed method. The results indicate that the positions of the workpiece during the precision manufacturing and measurement cycle were precisely achieved and the form accuracy of the optical freeform surfaces was remarkable improved based on the FAOPM.

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“…For the multi-cut process (MCP), the trend of the cutting deviation is estimated using the probing data, then the multitool path is modified using the discrete compensation vectors computed according to the cutting compliance model. On the base of 3-axis tool path iterative compensation, the cutting force-induced errors of flexible thin-walled parts were adaptively decreased based on OMM by the modifying 5-axis flank milling toolpath [11]. In order to obtain a precision assemble of radio-frequency quadrupoles (RFQs) cavity, the measured values were fed back to offset the final cut depths and achieve the required vane-tips machining accuracy [14].…”

Section: Literature Reviewmentioning

confidence: 99%

Integration strategy of on-machine measurement (OMM) and numerical control (NC) machining for the large thin-walled parts with surface correlative constraint

Liu

Wang

Zhang

et al. 2015

Int J Adv Manuf Technol

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There is a kind of large thin-walled parts in aerospace industry, the machining target surface of which is tightly associated with another specific surface (named correlative surface). And it is always the primary machining objective. However, the preformed correlative surface is significantly different from its original design model due to large profile and thickness errors. Thus, part-referenced machining is necessary to ensure the correlative constraint accuracy. In this article, an integration strategy of OMM and NC machining for the large thin-walled parts with surface correlative constraint is systematically developed. Generally, the integration process consists of correlative constraint analysis, on-machine measurement, machining target surface redesign, and NC machining. Firstly, an isoplanar-based on-machine scanning method is presented for large surface profile information extraction. Then, a unified target surface redesign model is established according to surfaces accompanying relation analysis. Further, to compensate stress-induced monotonic structural deformation, a partitioned measuring and machining approach has been employed. Finally, the liquid rocket engine nozzle as a typical part was employed to verify the validation of the proposed strategy. Coolant channel machining experiments were conducted on a special dual-spindle machine tools. For a nozzle with machining area about 8 m 2 , the correlative accuracy could be controlled in the range of ±0.1 mm. It has been proved that incorporating dimensional metrology feedback to machining process could consistently improve machining quality and efficiency of large thin-walled parts.

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5-Axis adaptive flank milling of flexible thin-walled parts based on the on-machine measurement

Cited by 121 publications

References 24 publications

Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Fiducial-aided on-machine positioning method for precision manufacturing of optical freeform surfaces

Integration strategy of on-machine measurement (OMM) and numerical control (NC) machining for the large thin-walled parts with surface correlative constraint

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