Five-axis trajectory generation considering synchronisation and nonlinear interpolation errors

This paper presents a novel real-time interpolation technique for 5-axis machine tools to attain higher speedand accuracy. To realize computationally efficient real-time interpolation of 6DOF tool motion, a joint workpiece-machine coordinate system interpolation scheme is proposed. Cartesian motion of the tool centre point (TCP) isinterpolated in the workpiece coordinate system (WCS), whereas tool orientation is interpolated in the machinecoordinate system (MCS) based on the finite impulse response (FIR) filtering. Such approach provides several ad-vantages: i) it eliminates the need for complex real-time spherical interpolation techniques, ii) facilitates efficientuse of slower rotary drive kinematics to compensate for the dynamic mismatch between Cartesian and rotary axesand achieve higher tool acceleration, iii) mitigates feed fluctuations while interpolating near kinematic singulari-ties. To take advantage of such benefits and realize accurate joint WCS-MCS interpolation scheme, tool orientationinterpolation errors are analysed. A novel approach is developed to adaptively discretize long linear tool movesand confine interpolation errors within user set tolerances. Synchronization errors between TCP and tool orienta-tion are also characterized, and peak synchronization error level is determined to guide the interpolation parameterselection. Finally, blending errors during non-stop continuous interpolation of linear toolpaths are modelled andconfined. Advantages of the proposed interpolation scheme are demonstrated through simulation studies and vali-dated experimentally. Overall, proposed technique can improve cycle times up to 10% while providing smooth and accurate non-stop real-time interpolation of tool motion in 5-axis machining.

Tool-Path Planning Method For Kinematics Optimization of Blade Machining On Five-Axis Machine Tool

Planning tool-paths on free-form surfaces is a widely discussed issue. However, traditional methods of generating paths capable of meeting all the requirements of blade machining remain challenging. In this study, a new iso-parametric path-planning strategy based on a novel parameterization method combined with the conformal transformation theory was proposed. The proposed method could adapt to the curvature characteristics of the blade surface, improving the kinematic performance of the machining process, reducing multi-axis coordinated motion control complexity, and improving machining quality. The proposed method was then compared with three traditional methods. The influence of the tool-path on the kinematic performance of the machine tool was quantitatively examined based on the kinematics models of two different machine tools. A large cutting depth milling experiment was conducted to verify that kinematics optimization could improve machining quality. The proposed method provides a more reasonable path-planning approach for blade machining on a five-axis machine tool, which is of great significance in reducing the cost of blade machining and the risks of blade failure. Moreover, it is of great significance for the large-scale automated production of blades.

Study on the tool setting method of micro-milling tool based on in-line holography

Aiming at the various shortcomings of existing tool setting methods, this paper proposes a coaxial holographic tool setting method for tiny tools. Based on the research and analysis of the principle of holographic imaging and the key issues of holographic images, a set of holographic tool setting detection device for micro milling tool was built, and the micro milling tool measurement was carried out on the five-axis machining center using standard tools. experiment. Experimental results show that the tool setting device can efficiently perform tool setting detection of micro-milling tool. Compared with the measurement results of the high-precision external presetting instrument, the relative error of the contact tool setting instrument is 0.033%, and the relative error of the holographic tool setting prototype is 0.007%, which is more effective in realizing the tool setting of tiny tools. Detection. This result verifies the feasibility of the coaxial holographic tool setting method for micro tool, that is, holographic measurement can be used for high-precision tool setting of micro milling tool.

Visual Measurement and Calibration of Geometric Errors of Rotating Axes for Five-axis Platform

In this paper, a method for identifying and decoupling geometric errors of rotation axes using vision measurement is proposed. Based on screw theory and exponential product formula, identification equations of position-dependent geometric errors (PDGEs) and position-independent geometric errors (PIGEs) of the rotation axes are established. The mapping relationships between the error twist and geometric errors are established. The error model provides the coupling mechanism of PDGEs and PIGEs. Furthermore, a progressive decoupling method is proposed to separate PDGEs and PIGEs without additional assumptions. The pose parameters, required for solving the identification equations, are obtained by visual measurement. Then, the error terms of PIGEs and PDGEs are determined. Lastly, the error calibration of the rotation axes is investigated, thus providing an average rotary table orientation error reduction of 28.1% compared to the situation before calibration.

Analysis of Dynamic Characteristics for Machine Tools Based on Dynamic Stiffness Sensitivity

Dynamic parameters are the intermediate information of the entirety of machine dynamics. The differences between components have not been combined with the structural vibration in the cutting process, so it is difficult to directly represent the dynamic characteristics of the whole machine related to spatial position. This paper presents a method to identify sensitive parts according to the dynamic stiffness-sensitivity algorithm, which represents the dynamic characteristics of the whole machine tool. In this study, two experiments were carried out, the simulation verification experiment (dynamic experiment with variable stiffness) and modal analysis experiment (vibration test of five-axis gantry milling machine). The key modes of sensitive parts obtained by this method can represent the position-related dynamic characteristics of the whole machine. The characteristic obtained is that the inherent properties of machine-tool structure are independent of excitation. The method proposed in this paper can accurately represent the dynamic characteristics of the whole machine tool.

Nonlinear Error Compensation Based on the Optimization of Swing Cutter Trajectory for Five-Axis Machining

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.