The effect of axis coupling on machine tool dynamics determined by tool deviation

Wang, Lei; Liu, Haitao; Lei, Yang; Zhang, Jun; Zhao, Wanhua; Lu, Bingheng

doi:10.1016/j.ijmachtools.2014.09.003

Cited by 33 publications

(20 citation statements)

References 22 publications

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“…Furthermore, machining forces result in vibration and elastic deformation of the machining tool and cause tool deviation. 53 Although, according to Figure 12, higher feed rate causes higher machining force, it is concluded that higher feed rates could lead to more tool deviation and vibration. Caprino and Tagliaferri 54 also claimed that by feed rate increment, damage pattern of delamination is affected by tool edge interaction, stepwise delamination, interlaminar crack and micro-sized deterioration.…”

Section: Resultsmentioning

confidence: 99%

Feasibility study of delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics

Baraheni

Amini

2017

Journal of Reinforced Plastics and Composites

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Glass fiber reinforced plastics are used in variety of industrial and constructional applications for their superb mechanical and physical properties. Delamination is one of the most important and prevalent damages in machining of glass fiber reinforced plastics. Diamond core drills have the capability of simultaneously drilling and grinding of fiber reinforced plastics, which results in hole quality improvement. Rotary ultrasonic-assisted drilling is the new machining process to drill holes on fiber reinforced plastics and has attracted increasing attention in recent years. In this paper, thrust force and delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics using diamond core drill have been investigated. A proper ultrasonic system for a core drill in ABAQUS was designed and fabricated. Influence of ultrasonic vibration and then tool grain size, fiber-volume fraction and machining parameters including spindle speed and feed rate on thrust force and delamination was investigated. Higher thrust force induces more delamination. As a result of the study, less delamination was achieved in ultrasonic-assisted mode by using a tool with larger grain size onto lower fiber-volume fraction composites. Additionally, experiments showed that lower spindle speed and higher feed rate induce more delamination.

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Section: Resultsmentioning

confidence: 99%

Feasibility study of delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics

Baraheni

Amini

2017

Journal of Reinforced Plastics and Composites

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“…The DCG technology is innovatively investigated by Mori Seiki. This twin ball screws structure could ensure the direction of drive forces close to the center of stage gravity, so that the vibration of machine tools could be decreased dramatically [2].…”

Section: Introductionmentioning

confidence: 99%

Dynamic Characteristics Analysis and Test of Dual-Driving Feed System Driven by Center of Gravity

Lü

Fan

Zhang

et al. 2018

Mathematical Problems in Engineering

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Dual-driving feed system (DDFS) driven by center of gravity (DCG) has been widely used in advanced manufacturing machine for its high rigidity and precision. However, the DCG technology requires that the joint force coincides with the center of gravity of the sliding stage. The dual-driving synchronization and tracking performance will be affected by the change of center of gravity of the sliding stage. Therefore, this paper proposes dynamic characteristics modeling, identification, and control scheme for DDFS driven by center of gravity (DCG). Firstly, a redundancy dynamic model including rotation and pitch vibration caused by the change of the position of center of gravity is presented for DDFS DCG based on the Lagrange method. The model parameters are identified by system identification experiment, and the predictive natural frequencies and vibration modes by the proposed dynamic model are compared by modal experiment. Moreover, the dynamic model-based cross-coupled sliding mode control (CCSMC) is proposed for DDFS DCG. Then, the proposed dynamic model-based CCSMC has been compared with normal cross-coupled sliding mode control (NCCSMC). Both the simulation and experimental results show that the proposed dynamic characteristics analysis and test scheme of DDFS DCG are validated effectively by comparisons.

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“…In order to reduce energy consumption, lightweight design and optimization techniques are applied to decrease the moving masses and improve the mass-to-payload ratio [8,9]. Over the last few decades, to improve the accuracy, stiffness, and dynamic performance of machine tools, various lightweight and optimization design methods and strategies have been investigated by many researchers at the early design stage; consequently, structural optimization and lightweight methods have been successfully applied in optimizing dynamical systems and lightweight machines [10][11][12][13][14][15][16][17][18].…”

Section: Introductionmentioning

confidence: 99%

“…Wu et al [17] presented an optimization approach for the concept design of machine tools; the results showed that the principal dimensions of all structural parts could be determined while minimizing the weight of the machine and maintaining sufficient stiffness. In order to analyze the dynamic behavior and tool deviations, a dynamic model of a 3-axis gantry milling machine considering axis coupling effects was proposed by Wang et al [18]. Sandwich structures are commonly used materials for lightweight designs, and their mechanical behaviors are based on their structural features: They are built from two layers, i.e., a stiff and strong skin layer, and a compliant and lightweight core layer [19].…”

Section: Introductionmentioning

confidence: 99%

Design Optimization Approach of a Large-Scale Moving Framework for a Large 5-Axis Machining Center

et al. 2018

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The traditional machine tool design method with metal materials makes large-scale moving structures very heavy, which seriously impacts dynamic performance and results in significant energy consumption. Using sandwich structures of composite materials to replace metal materials is an important strategy for lightweight large-scale moving structures. However, this kind of substitution is generally believed to be difficult because foam-filled sandwich structures usually show nonlinear characteristics and must balance the moving mass, material costs, and structural stiffness. In the present study, we proposed a design optimization approach for a large-scale moving framework in a large 5-axis machining center (L5AMC) considering large dimensions in the x, y, and z work space and high machining speed with the aim of minimizing the displacements of the milling head. An improved approach, named the 3-step design optimization, was executed to obtain the optimum framework structures to solve the contradiction between the moving mass, material costs, and structural stiffness. This approach was based on multi-objective optimization and finite element analysis. The structural stiffness of the framework after optimization increased by 89% compared with before optimization although the mass increased by 6% and the material costs increased by 9%. A finite element simulation under four given operational loads showed that the displacements of the milling head were all less than the design requirement of 0.25 mm. The results indicated that the proposed 3-step design optimization approach for the optimal design of a large-scale moving framework was feasible and successful. A 40 m × 6 m × 4 m L5AMC prototype was manufactured, and the actual verification results indicated that the large-scale moving framework fully met the design requirements of the L5AMC and reduced energy consumption.

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The effect of axis coupling on machine tool dynamics determined by tool deviation

Cited by 33 publications

References 22 publications

Feasibility study of delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics

Feasibility study of delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics

Dynamic Characteristics Analysis and Test of Dual-Driving Feed System Driven by Center of Gravity

Design Optimization Approach of a Large-Scale Moving Framework for a Large 5-Axis Machining Center

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