An integrated curvature surface inspection and prediction system for 5-axis synchronization machining

Abstract

There is an urgent demand for free form products in industry at the present time because of their superior appearance and the wide variety of functions they perform. Five-axis high-speed CNC machining technology has developed to satisfy this demand, but further improvement in surface quality metric inspection technology is the big challenge it now faces. In this study, the effects of jerk on the performance of five-axis synchronous high-speed CNC ball nose end mills on a freeform turbine mold were investigated. The relationships of characteristics of the images of 14 jerk-cluster finished workpieces with different jerk setting values were established, allowing surface texture features to be analyzed and surface roughness predicted. In addition, machine learning methods were integrated with the surface feature analysis to construct a virtual machining module that acts as a performance prediction system, merging the virtual machine tool functions, surface texture processor and AI roughness prediction processor. Using the geometric information of the workpiece, cutting parameters and machine tool parameters as inputs, product performance metrics combining surface roughness and machining time can be predicted as outputs of the system. The integrated system provides users with a way to evaluate manufacturing performance before performing actual operations and to reduce test time for cutting parameter development. The model is suitable for complex surface finishes as well as for the production of small batches with high parametric variance. In addition, the partial set of image processing and roughness prediction modules can be used alone as an effective intelligent surface quality inspection system.

Computational Numerical Control (CNC) Machines: A Systematic Review From 2015 To 2022

“…[10] CNC machining is a manufacturing process in which tools and machine work by means of a computer program, designed to move parts and tools by means of numerical data. [11] Since overall optimization is largely based on problem formulation, emphasis has been placed on defining optimization criteria as crucial elements to represent performance. [12] In order to optimize manufacturing with energy efficiency is that it resorted to an immune system enabled by Big Data, programming is a critical stage to minimize the life cycle cost in manufacturing.…”

“…The beams used can affect the performance of the whole machine, they are main components of the fiveaxis gantry machining center. [11] improved surface roughness through the application of the automated refrigerant supply system. [12] Energy savings of around 30% and improved productivity of more than 50% have been achieved by adopting I2 S in factories.…”

“…In the same way [4] and [9] they mainly talk about the performance of those machines which were instrumental in obtaining higher production; however, in [9] we find a limitation which is that the beams implemented can affect this performance of the whole machine. On the other hand, the article [11] mentions that by obtaining a better roughness on the surface it was essential to obtain a greater production that eventually led to a better performance. In the case of article [21] we found that a greater of the cutting tool in the ranges of 20% to 30%, plus a greater economic benefit.…”