scholarly journals Sensitivity analysis of relationship between error motions and machined shape errors in five-axis machining center - Peripheral milling using square-end mill as test case -

2019 ◽  
Vol 60 ◽  
pp. 28-41 ◽  
Author(s):  
Zongze Li ◽  
Ryuta Sato ◽  
Keiichi Shirase ◽  
Yukitoshi Ihara ◽  
Dragan S. Milutinovic
Keyword(s):  
Sensitivity Analysis ◽  
Test Case ◽  
End Mill ◽  
Peripheral Milling ◽  
Machining Center ◽  
Shape Errors ◽  
Five Axis

Sensitivity Analysis Between Error Motions and Machined Shape Errors in Five-Axis Machining Centers: In Case of S-Shaped Machining Test by a Square End Mill

2019 ◽  
Author(s):  
Zongze Li ◽  
Ryuta Sato ◽  
Keiichi Shirase ◽  
Yukitoshi Ihara
Keyword(s):  
Sensitivity Analysis ◽  
Coordinate System ◽  
Complex Surface ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Machining Center ◽  
Shape Errors ◽  
Machining Test ◽  
Tool Motion ◽  
Five Axis

Abstract Five-axis machining center, combined three linear and two rotary axes, has been increasingly used in complex surface machining. However, as the two additional axes, the machined surface under table coordinate system is usually different from the tool motion under machine coordinate system, and as a result, it is very tough to predict the machined shape errors caused by each axes error motions. This research presents a new kind of sensitivity analysis method, to find the relationship between error motions of each axis and geometric errors of machined shape directly. In this research, the S-shaped machining test is taken as a sample to explain how the sensitivity analysis makes sense. The results show that the presented sensitivity analysis can investigate how the error motions affect the S-shaped machining accuracy and predicted the influence of error motions on certain positions, such as the reversal errors of the axes around motion reversal points. It can be proved that the presented method can help the five-axis machining center users to predict the machining errors on the designed surface of each axes error motions.

Sensitivity Analysis of Error Motions and Geometric Errors in the Case of Sphere-Shaped Workpiece

2020 ◽  
Author(s):  
Zongze Li ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Sensitivity Analysis ◽  
Machine Tools ◽  
End Milling ◽  
Geometric Errors ◽  
Machined Surface ◽  
Error Sources ◽  
Motion Error ◽  
Machining Center ◽  
Machining Errors ◽  
Five Axis

Abstract Motion error of machine tool feed axes influences the machined workpiece accuracy. However, the influences of each error sources are not identical; some errors do not influence the machined surface although some error have significant influences. In addition, five-axis machine tools have more error source than conventional three-axis machine tools, and it is very tough to predict the geometric errors of the machined surface. This study proposes a method to analyze the relationships between the each error sources and the error of the machined surface. In this study, a kind of sphere-shaped workpiece is taken as a sample to explain how the sensitivity analysis makes sense in ball-end milling. The results show that the method can be applied for the axial errors, such as motion reversal errors, to make it clearer to obverse the extent of each errors. In addition, the results also show that the presented sensitivity analysis is useful to investigate that how the geometric errors influence the sphere surface accuracy. It can be proved that the presented method can help the five-axis machining center users to predict the machining errors on the designed surface of each axes error motions.

scholarly journals Investigation on End-mill Cutter Location Based on Constant Feed-speed Vector at Cutting Point with a Five-axis Machining Center

2010 ◽  
Vol 76 (8) ◽  
pp. 912-917 ◽  
Author(s):  
Toshiki HIROGAKI ◽  
Eiichi AOYAMA ◽  
Keiji OGAWA ◽  
Tsugutoshi KAWAGUCHI ◽  
Takahiro HORIUCHI
Keyword(s):  
Feed Speed ◽  
End Mill ◽  
Machining Center ◽  
Mill Cutter ◽  
Five Axis ◽  
Cutting Point

scholarly journals Study on cutting trace shape control of machined surface by radius end mill with five-axis controlled machining center

2018 ◽  
Vol 84 (860) ◽  
pp. 17-00508-17-00508
Author(s):  
Toshiki HIROGAKI ◽  
Eiichi AOYAMA ◽  
Seigo NAKAMURA ◽  
Masahiro UENOYAMA
Keyword(s):  
Shape Control ◽  
End Mill ◽  
Machined Surface ◽  
Machining Center ◽  
Five Axis

A generalized cutting force model for five-axis milling processes

2017 ◽  
Vol 233 (1) ◽  
pp. 3-17 ◽  
Author(s):  
Qinghua Song ◽  
Zhanqiang Liu ◽  
Ganggang Ju ◽  
Yi Wan
Keyword(s):  
Chip Thickness ◽  
Milling Process ◽  
Normal System ◽  
Force Model ◽  
Sculptured Surfaces ◽  
End Mill ◽  
Peripheral Milling ◽  
Ball End Mill ◽  
Milling Cutter ◽  
Five Axis

A generalized mechanical model is proposed to predict cutting forces for five-axis milling process of sculptured surfaces with generalized milling cutter, which is considered as a revolution around tool axis of an arbitrary section curve composed of variable lines and curves. Solid-analytical-based method is presented and extended to precisely and efficiently identify the cutter–workpiece engagements between the generalized milling cutter and workpiece being machined. And the undeformed chip thickness is calculated with respect to pre-defined tool coordinate system, which is regarded as the transformation form of feed cross–feed normal system by lead and tilt angles. Although only two experimental validations (peripheral milling with cylinder end mill and multi-axis milling with ball end mill) are performed to estimate the robustness and flexibility of the method presented, it can be applied for an arbitrary mill geometry in multi-axis milling as well as three-axis milling, two-and-a-half-axis milling. Finally, a case study of aero-engine impeller five-axis milling with ball end mill is performed to further illustrate the validation of the model.

Interference-Free Multi-Axis NC Machining of Cylindrical Cam Using Enveloping Element

2009 ◽  
Vol 419-420 ◽  
pp. 333-336
Author(s):  
Jeng Nan Lee ◽  
Chih Wen Luo ◽  
Hung Shyong Chen
Keyword(s):  
Cutting Tool ◽  
Nc Machining ◽  
Model Material ◽  
Solid Model ◽  
End Mill ◽  
Generating Method ◽  
Collision Problem ◽  
Five Axis ◽  
Cutting Path ◽  
Cutting Simulations

To obtain the flexibility of choice of cutting tool and to compensate the wear of the cutting tool, this paper presents an interference-free toolpath generating method for multi-axis machining of a cylindrical cam. The notion of the proposed method is that the cutting tool is confined within the meshing element and the motion of the cutting tool follows the meshing element so that collision problem can be avoided. Based on the envelope theory, homogeneous coordinate transformation and differential geometry, the cutter location for multi-axis NC machining using cylindrical-end mill is derived and the cutting path sequences with the minimum lead in and lead out are planned. The cutting simulations with solid model are performed to verify the proposed toolpath generation method. It is also verified through the trial cut with model material on a five-axis machine tool.

Sensitivity Analysis of Geometric Errors for Five-Axis CNC Machine Tool Based on Multi-Body System Theory

2012 ◽  
Vol 271-272 ◽  
pp. 493-497
Author(s):  
Wei Qing Wang ◽  
Huan Qin Wu
Keyword(s):  
System Theory ◽  
Sensitivity Analysis ◽  
Machine Tool ◽  
Geometric Error ◽  
Machining Accuracy ◽  
Geometric Errors ◽  
Body System ◽  
Cnc Machine ◽  
Multi Body ◽  
Five Axis

Abstract: In order to determine that the effect of geometric error to the machining accuracy is an important premise for the error compensation, a sensitivity analysis method of geometric error is presented based on multi-body system theory in this paper. An accuracy model of five-axis machine tool is established based on multi-body system theory, and with 37 geometric errors obtained through experimental verification, key error sources affecting the machining accuracy are finally identified by sensitivity analysis. The analysis result shows that the presented method can identify the important geometric errors having large influence on volumetric error of machine tool and is of help to improve the accuracy of machine tool economically.

Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

2020 ◽  
Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Cutting Edge ◽  
Free Form ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
The Cost ◽  
Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

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