Analysis of Nonlinear Error Caused by Motions of Rotation Axes for Five-Axis Machine Tools with Orthogonal Configuration

Geng, C.; Wu, Yuhou; Qiu, Jian

doi:10.1155/2018/6123596

Cited by 13 publications

(7 citation statements)

References 26 publications

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“…Although five-axis CNC machines are more flexible in tool attitude changes, there is a nonlinear relationship between the position coordinates of the rotary axis and the tool attitude. This makes the actual machining trajectory deviate from the ideal linear machining trajectory, which results in unavoidable nonlinear errors [2] . For this reason, many researchers in related fields have conducted a lot of research on the reduction of nonlinear error, among which the most important methods to reduce nonlinear error are improved interpolation algorithms, linear encryption of cutter location points, cutter location correction method and real-time error compensation.…”

Section: Introductionmentioning

confidence: 99%

Nonlinear error compensation based on the optimization of swing cutter trajectory for five-axis machining

Chen

Tang

et al. 2022

Int J Adv Manuf Technol

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：In order to solve the problem of deviation between actual and theoretical machining paths due to the presence of rotation axis in five-axis machining, an interpolation algorithm based on the optimization of swing cutter trajectory and the method of corresponding nonlinear error compensation are proposed. Taking A-C dual rotary table five-axis machine tool as an example, the forward and reverse kinematic model of the machine tool is established according to the kinematic chain of the machine tool. Based on the linear interpolation of rotary axis, the generation mechanism of nonlinear error is analyzed, the modeling methods of cutter center point and cutter axis vector trajectory are proposed respectively, and the parameterized model of swing cutter trajectory is formed. The formula for the nonlinear error is obtained from the two-dimensional cutter center point trajectory. According to the established model of swing cutter trajectory, the synchronous optimization method of cutter center point trajectory and cutter axis vector trajectory is proposed, and the nonlinear error compensation mechanism is established. First, pre-interpolation is performed on the given cutter location data to obtain a model of the swing cutter trajectory for each interpolated segment.Then the magnitude of the nonlinear error is calculated based on the parameters of the actual interpolation points during formal interpolation, and the interpolation points with large errors are compensated for the nonlinear error. The simulation results show that the proposed method can effectively reduce the impact of nonlinear errors on machining, and is of high practical value for improving the accuracy of cutter position and the quality of complex free-form machining in five-axis machining.

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Section: Introductionmentioning

confidence: 99%

Nonlinear error compensation based on the optimization of swing cutter trajectory for five-axis machining

Chen

Tang

et al. 2022

Int J Adv Manuf Technol

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show abstract

“…Third, tool point position optimization method. This method reduces the nonlinear error by controlling the tool point trajectory [18][19][20][21][22]. Zhang et al [23] proposed the SSALI method to avoid tool positioning beyond the theoretical programming plane.…”

Section: Introductionmentioning

confidence: 99%

“…The relationship between the nonlinear error value and the angle of the rotating axis A and C are obtained according to the method used in Reference [22] to verify the correlation between the variation of the amplitude of the tool swing angle and the nonlinear error value as follows:…”

mentioning

confidence: 99%

Regionalized compensation method for nonlinear error control

Wei

Tang²,

Wang³

et al. 2022

Int J Adv Manuf Technol

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Although the five-axis machine tool presents excellent advantages of high-speed,efficiency, and -precision machining of complex curved surface parts (impeller and blade), its actual motion demonstrates nonlinear principle error due to the participation of the rotating axis. Traditional methods, such as linear interpolation, Rotation Tool Centre Point(RTCP), and tool point optimization, can effectively control nonlinear errors despite their limitations. A regional compensation optimization method is proposed in this study to solve nonlinear error problems effectively in five-axis machining of complex curved surface parts. First, feature points of the complex free-form surface are identified, and regions are divided to distinguish the compensation optimization algorithm of each interval. Second, JAVA language is applied to develop a special postprocessor with nonlinear error partition compensation module. Finally, the BV100 machine tool is used as the experimental platform, and a turbine blade is utilized as the specimen for simulation and cutting experiments. Results showed that the surface quality and contour accuracy of machined parts improved when the nonlinear error regional compensation optimization algorithm is used.

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“…They avoided the singular area by means of fixture redirecting workpiece. Geng et al [16] established a general calculation model for the nonlinear error of orthogonal machine tools and quantified the nonlinear error by the maximum deviation of the initial and final tool axis vectors relative to the reference plane. Geng et al [17] optimized the fractional velocity, fractional acceleration, and resultant velocity of each axis of the tool under the conditions of end and side milling based on the speed and acceleration constraints of each axis of the machine tool.…”

Section: Introductionmentioning

confidence: 99%

Post-processing of a nine-axis and five-linkage turn-milling composite machine tool

Wei¹,

Tang

Zhang³

et al. 2022

Preprint

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Post-processing is an important technology in transferring information between CAM software and CNC system. At present, the traditional five-axis machine tool cannot satisfy the requirements of high precision and efficiency in the manufacture of complex parts due to its single function. The auxiliary rotary spindle, auxiliary linear axis, and power tool rest are added on the basis of the traditional five-axis machine tool to solve the technical bottleneck problem. Thus, the machine tool with the composite function of turning and milling is established. The control of the motion chain and the numerical control system of the turn-milling composite machine tool is more complex than that of the traditional five-axis machine tool, and the development of the post-processing is also more difficult. This study investigates the development of post-processing of a nine-axis five-linkage turn-milling composite machine tool (PUMASMX2600ST). First, the kinematic chain and coordinate system of the turning and milling function are established, respectively, according to the function division of the machine tool, and the inverse kinematic model is solved by the kinematic coordinate transformation. Second, a special post-processing software with turning and milling functions is developed using Visual Basic language. Finally, a type of blade root milling tool is used as the specimen for simulation and actual cutting verification. Experiments show that the special processor is correct and reasonable, and it can satisfy the requirements of the machine tool.

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Analysis of Nonlinear Error Caused by Motions of Rotation Axes for Five-Axis Machine Tools with Orthogonal Configuration

Cited by 13 publications

References 26 publications

Nonlinear error compensation based on the optimization of swing cutter trajectory for five-axis machining

Nonlinear error compensation based on the optimization of swing cutter trajectory for five-axis machining

Regionalized compensation method for nonlinear error control

Post-processing of a nine-axis and five-linkage turn-milling composite machine tool

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