A novel method for evaluating the validity of dynamic accuracy test pieces for five-axis machine tools

Proceedings of the Institution of Mechanical Engineers, Part C:

Meng

Guan

et al. 2021

Self Cite

The existing studies on profile error analysis and machining accuracy measurement do not consider the impact of the theoretical errors on the machine tool accuracy measurement. Therefore, this study proposes an estimation method of the surface profile error based on the normal section plane, using the theoretical flank milled surface for comparison. This effectively improves the accuracy of profile error estimation. The theoretical flank milled surface is the surface machined by flank milling under ideal conditions. Hence, compared to the traditional analysis method based on the designed three-dimensional model of S-shaped test pieces, the calculated profile error of this method does not include theoretical errors, thereby eliminating the impact of theoretical errors on machine tool accuracy measurement and evaluation. First, an improved method for continuous parameterized dual spline interpolation was proposed. It simplifies the solution of the singular problem of the coefficient matrix of the spline basis function and obtains a continuous ideal machining tool axis trajectory surface with complete geometric characteristics. Next, a method for constructing the theoretical flank milled surface machined with a cylindrical milling tool using equidistant mapping characteristics was proposed; then, the differential transformation relationship at the cutting contact point of the curved surface under the influence of tool path errors was established. Furthermore, the normal section plane method based on the differentiation of the cutting contact point was proposed. The problem of solving the distance from a point to a surface is converted to the problem of solving the distance from a point to a curve in the normal section plane. This improves the accuracy of profile error estimation. The effectiveness of the method was verified by comparing the analysis results of the profile errors of a typical cylindrical surface with the point to surface and the point to curve methods.

Section: Generation Of the Ideal Flank Milled Surface Based On Equidistant Mappingmentioning

confidence: 99%

Section: The Impact Of Surface Cutting Contact Error On Profile Errormentioning

confidence: 99%

“…For the approximate solution of the distance from a point to surface (PTS), Ding 20 gave the solution of the nearest point vector from a PTS in the second-order Taylor estimation form:…”

Section: Examplementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

A normal section plane method for profile error analysis of five-axis machine tools based on the ideal tool flank milling surface

Proceedings of the Institution of Mechanical Engineers, Part C:

Meng

Guan

et al. 2021

Self Cite

“…CNC machine tool is one of the complex electromechanical products, improving its quality has been a research hotspot. [20][21][22][23] Due to the complex coupling relationships among quality characteristics, 11 the variation of a QC will affect others, which will lead to serious quality risk problems of CNC machine tool, such as processing efficiency and processing quality, and even personal safety. Actually, the decoupling analysis of QCs is very important to improve the stability of product quality.…”

Section: Case Studymentioning

confidence: 99%

Research on global coupling analysis and approximate decoupling of quality characteristics in the early design stage

Chen

Ran

Proceedings of the Institution of Mechanical Engineers, Part C:

et al. 2020

Due to the existence of coupling relationships, quality characteristics form a variation propagation process, which increases the risk possibility of product quality. In order to improve the robustness of quality characteristics, this paper proposes a fuzzy clustering-based key quality characteristics decoupling planning considering risk criticality. Firstly, based on the design structure matrix, a modular correlation matrix of key quality characteristics was established to quantify the coupling relationships among them. Secondly, according to the variation characteristics of quality characteristics, the variation propagation model is constructed to identify the potential quality risk. Thirdly, the fuzzy clustering algorithm is used to obtain the optimal control sequence of key quality characteristics. Finally, the computerized numerical control machine tool is taken as an actual case, the effectiveness and superiority of this method are verified by the comparison of the numerical result and method. This method provides a new indicator system solution for the coupling analysis of product design.

Kinematics and geometric features of the s-cone test piece: identifying the performance of five-axis machine tools using a new test piece

Osei

Int J Adv Manuf Technol

Ding

2023

The design of machine parts of different sizes and shapes has become relevant in the manufacturing industry which requires five-axis machine tools of high dynamic performance; different machining test pieces have been used to test and reflect the machine tool’s performance. The S-shaped is still under development and consideration of which a new test piece better than the S-shaped part has been recommended to be put forward making the NAS979 the only standardized test piece; however, it has some limitations. Hence, this study proposes a new test piece to objectively satisfy the demand for machine tools with higher dynamic performance, which shows much improvement over the standard NAS979 and is the best alternative to the S-shaped test piece, and it combines the geometric and kinematic features of both test pieces. Geometrically, it has non-uniform surface continuity, variable twist angle, and variable curvature; and the cutting tool moves in close and opened angles along the tool path; there is sudden rise and fall of axes’ velocity, acceleration, and jerk with much impact during machining which makes the S-cone test piece be machined by only five-axis machine tools with high dynamic performance, and has a better dynamic performance identification effect than the S-shaped test piece based on the trajectory test. Detailed work on the validation of the machine tool’s dynamic performance using the S-cone part will be captured next part of this study.