An approach to optimize the machining accuracy retainability of multi-axis NC machine tool based on robust design

Cai, Ligang; Zhang, Ziling; Cheng, Qiang; Liu, Zhifeng; Gu, Peihua; Yin, Qin

doi:10.1016/j.precisioneng.2015.09.001

Cited by 42 publications

(20 citation statements)

References 34 publications

(35 reference statements)

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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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“…(2) e key geometric errors are identified by conducting a variance-based sensitivity analysis [38]; however, the variance is only a probabilistic statistical feature of geometric error terms as random variables and is inadequate to describe the uncertainty of a model input and output based only on variance-based analysis in the case of multidimensional output. Previous studies have focused mainly on geometric error analysis based on the method of variance analysis from the perspective of the precision design of machine tools [21,23,38]; more research on the quantitative relationship and the degree of relative importance of geometric error for determining the key geometric error terms is needed. (3) e results of sensitivity analysis and accuracy retentivity analysis are rarely directly applied in error compensation of machine tools from the view of improving compensation accuracy [39].…”

Section: Motivations and Potential Applicationsmentioning

confidence: 99%

“…e analysis of geometric error terms has been an active research topic in the past 3 years due to the implementation of both offline error compensation and real-time error compensation [6,20]. e fundamental reason is that the precision of the machine tool can be further enhanced by analysing the correlation effect and nonlinear characteristics of geometric error terms [21,22]. Evaluation or analysis of geometric error sources is fundamentally important, whether for error compensation or precision design for improving machine tool accuracy retentivity [23].…”

Section: Introductionmentioning

confidence: 99%

A Recognition Methodology for the Key Geometric Errors of a Multi‐Axis Machine Tool Based on Accuracy Retentivity Analysis

2019

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This paper proposes a recognition methodology for key geometric errors using the feature extraction method and accuracy retentivity analysis and presents the approach of optimization compensation of the geometric error of a multiaxis machine tool. The universal kinematics relations of the multiaxis machine tool are first modelled mathematically based on screw theory. Then, the retentivity of geometric accuracy with respect to the geometric error is defined based on the mapping between the constitutive geometric errors and the time domain. The results show that the variation in the spatial error vector is nonlinear while considering the operation time of the machine tool and the position of the motion axes. Based on this aspect, key factors are extracted that simultaneously consider the correlation, similarity, and sensitivity of the geometric error terms, and the results reveal that the effect of the position-independent geometric errors (PIGEs) on the error vectors of the position and orientation is greater than that of the position-dependent geometric errors (PDGEs) of the linear and rotary axes. Then, the fruit fly optimization algorithm (FOA) is adopted to determine the compensation values through multiobjective tradeoffs between accuracy retentivity and fluctuation in the geometric errors. Finally, an experiment on a four-axis horizontal boring machine tool is used to validate the effectiveness of the proposed approach. The experimental results show that the variations in the precision of each test piece are lower than 25.0%, and the maximum variance in the detection indexes between the finished test pieces is 0.002 mm when the optimized parameters are used for error compensation. This method not only recognizes the key geometric errors but also compensates for the geometric error of the machine tool based on the accuracy retentivity analysis results. The results show that the proposed methodology can effectively enhance the machining accuracy.

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“…Geometric error budget of machine tool is an important aspect of precision design 6 based on the total position accuracy of a given machine or mechanism to determine the accuracy of its main components. The machining geometric error budget directly determines the technical quality of product and affects the manufacturing cost.…”

Section: Introductionmentioning

confidence: 99%

A new geometric error budget method of multi-axis machine tool based on improved value analysis

Cheng

Dong

Liu

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part C:

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The improvement of the accuracy grade of main components in the production process through balancing between function and cost helps to improve the overall accuracy of machine tools. Therefore, this paper presents an improved value analysis method and uses the method of global sensitivity analysis and geometric error correlation analysis to analyze and optimize the error parameters of a 4-axis machining tool based on the proposed method. The geometric error modeling of the 4-axis machine tool was established by using the homogeneous transformation matrices (HTMs). By using global sensitivity analysis, the degree of influence of each error parameter on the accuracy of machine tool was obtained, and functional coefficient and cost coefficient of value analysis were gained by correlation analysis. An optimization model for geometric error budget of machine tool was established according to the improved value analysis theory, and the machining accuracy of machine tool was optimized according to the improved value analysis method.

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An approach to optimize the machining accuracy retainability of multi-axis NC machine tool based on robust design

Cited by 42 publications

References 34 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

A Recognition Methodology for the Key Geometric Errors of a Multi‐Axis Machine Tool Based on Accuracy Retentivity Analysis

A new geometric error budget method of multi-axis machine tool based on improved value analysis

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