A machining test to calibrate rotary axis error motions of five-axis machine tools and its application to thermal deformation test

Ibaraki, Soichi; Ota, Yusuke

doi:10.1016/j.ijmachtools.2014.07.005

Cited by 52 publications

(17 citation statements)

References 20 publications

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“…Monte Carlo simulation is a sampling experiment whose objective is to estimate the distribution of an outcome factor that depends on several probabilistic input factors [22]. Monte Carlo simulation was used to assess the uncertainties of various applications such as a life prediction model of a fishing net weaving machine component [23], rotary axis error calibration of five-axis machine tool [24], measurement uncertainty of an H-drive stage with air bearing in the semiconductor manufacturing industry [25], uncertainty on each of the eight link errors of a five-axis machine tools [26], verification of the effectiveness of the robust optimization approach for improving the machining accuracy retainability of the five-axis NC machine tool [27]. In this study, the Monte Carlo simulation technique was used to evaluate the tool life prediction uncertainty of the two drills.…”

Section: Methodsmentioning

confidence: 99%

Experimental and Simulation Study on Tool Life Models in Drilling of Forging Brass Using Uncoated-WC and AlCrN Coated-WC Tools

Timata¹,

Saikaew²

2019

Coatings

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Burr is an undesirable phenomenon occurring in drilling operation which is one of the essential operations in the machining industry since it is directly influencing the operating costs. Exit burr height (EBH) values as the function of drilling time during drilling the specific holes of the forging brass workpieces used for producing the water-valve components with the uncoatedtungsten carbide (WC) and the AlCrN coated-WC drills were discussed. The data sets of drilling time, corresponding to EBH values at the appropriate criterion were used to develop the tool life models in terms of cutting speed and feed rate using Taylor's equation. Monte Carlo simulation was adopted to study the uncertainty of cutting speed and feed rate on tool life predictions for sensitivity analysis. The results showed that drilling with a low feed rate decreased the averages of EBH. The predicted tool life values of the AlCrN coated-WC drills were higher than those of the uncoated-WC ones based on the results of tool life predictions. The appropriate operating condition of the cutting speed of 60 m/min and the feed rate of 0.2 mm/rev was recommended for manufacturers in the drilling of the forging brass workpieces using the AlCrN coated-WC drills. Moreover, the predicted tool life values for the uncoated-WC and the AlCrN coated-WC drills were about 600 and 800 min, respectively. This indicated that the AlCrN coated-WC drill increased tool life by 30%.

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Section: Methodsmentioning

confidence: 99%

Experimental and Simulation Study on Tool Life Models in Drilling of Forging Brass Using Uncoated-WC and AlCrN Coated-WC Tools

Timata¹,

Saikaew²

2019

Coatings

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“…In [19] a test workpiece is used to show the difference of measurable thermal induced errors with direct and indirect measurements systems for axes with ball screw drives. In [20] a test workpiece was developed to show the influence of thermal deformation on error motions of rotary axes in five-axis machine tools. Therefore more than one workpiece is required.…”

Section: State Of the Artmentioning

confidence: 99%

Generation of motion sequences for thermal load of machine tools

Höfer

Wiemer

2016

Prod. Eng. Res. Devel.

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An increase in the installed driving power is a typical method to improve machine tools' productivity. However, this measure also results in higher dissipation losses, which, in turn, cause an increase in thermally induced displacements on machine tools. To maintain or even increase machining accuracy, techniques that can compensate and correct thermally induced displacements have been engineered. To evaluate their effectiveness, a test workpiece and a motion sequence for the machine axes were developed, by means of which the machine tool can be warmed up in a defined manner to its thermal steady state. The paper introduces the conceptual design of the motion sequence and shows an example of its application.

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“…As reviewed in [1,2,3], numerous efforts have been reported on the measurement, modelling and compensation of thermal errors. On a five-axis machine tool, the thermal deformation often changes the position and the orientation of rotary axis average lines with respect to the tool's position and orientation [4]. The axis average line of a rotary axis represents the average position and orientation of the axis of rotation over its full rotation (the term in ISO 230-1 [5]).…”

Section: Introductionmentioning

confidence: 99%

“…(1) to (7) can be derived by using the rigid-body five-axis kinematic model, which has been used as the basis of many previous works, e.g. [4,8,9,10,14,15,16]. and C=-270.…”

mentioning

confidence: 99%

On-machine identification of rotary axis location errors under thermal influence by spindle rotation

Ibaraki

Inui

Hong

et al. 2019

Precision Engineering

Self Cite

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Position and orientation errors of rotary axis average lines are often among dominant error contributors in the fiveaxis kinematics. Although many error calibration schemes are available to identify them on-machine, they cannot be performed when a machine spindle is rotating. Rotary axis location errors are often influenced by the machine's thermal deformation. This paper presents the application of a non-contact laser light barrier system, widely used in the industry for tool geometry measurement, to the identification of rotary axis location errors, when the spindle rotates in the same speed as in actual machining applications. The effectiveness of the proposed scheme is verified by experimental comparison with the R-Test and a machining test. The uncertainty analysis is also presented.

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A machining test to calibrate rotary axis error motions of five-axis machine tools and its application to thermal deformation test

Cited by 52 publications

References 20 publications

Experimental and Simulation Study on Tool Life Models in Drilling of Forging Brass Using Uncoated-WC and AlCrN Coated-WC Tools

Experimental and Simulation Study on Tool Life Models in Drilling of Forging Brass Using Uncoated-WC and AlCrN Coated-WC Tools

Generation of motion sequences for thermal load of machine tools

On-machine identification of rotary axis location errors under thermal influence by spindle rotation

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