Dynamic Hybrid Modeling of the Vertical Z Axis in a High-Speed Machining Center: Towards Virtual Machining

2007 ◽  
Vol 129 (4) ◽  
pp. 780-788 ◽  
Author(s):  
Giovanni Tani ◽  
Raffaele Bedini ◽  
Alessandro Fortunato ◽  
Claudio Mantega
Keyword(s):  
High Speed ◽  
Experimental Tests ◽  
Pneumatic System ◽  
Mechanical Structure ◽  
Virtual Machining ◽  
Feed Drive ◽  
Machining Center ◽  
Dynamic Hybrid ◽  
Five Axis ◽  
Machine Head

This paper describes the modeling and simulation of the Z axis of a five axis machining center for high-speed milling. The axis consists of a mechanical structure: machine head and electro-mandrel, a CNC system interfaced with the feed drive, and a pneumatic system to compensate for the weight of the vertical machine head. These subsystems were studied and modeled by means of: (1) finite element method modeling of the mechanical structure; (2) a concentrated parameter model of the kinematics of the axis; (3) a set of algebraic and logical relations to represent the loop CNC-Z feed drive; (4) an equation set to represent the functioning of the pneumatic system; and (5) a specific analytical model of the friction phenomena occurring between sliding and rotating mechanical components. These modeled subsystems were integrated to represent the dynamic behavior of the entire Z axis. The model was translated in a computer simulation package and the validation of the model was made possible by comparing the outputs of simulation runs with the records of experimental tests on the machining center. The firm which promoted and financed the research now has a virtual tool to design improved machine-tool versions with respect to present models, designed by traditional tools.

Dynamic Hybrid Modeling of the Vertical Z Axis in an HSM Machining Center: Towards Virtual Machining

2005 ◽  
Author(s):  
Giovanni Tani ◽  
Raffaele Bedini ◽  
Alessandro Fortunato ◽  
Claudio Mantega
Keyword(s):  
High Speed ◽  
Dynamical Behavior ◽  
Experimental Tests ◽  
Pneumatic System ◽  
Fem Modeling ◽  
Mechanical Structure ◽  
Machining Center ◽  
Feed Drives ◽  
Five Axis ◽  
Machine Head

The paper describes the dynamical real-time simulation of the Z axis of a five axis machining center for high speed milling. The axis consists of a mechanical structure: machine head and electro-mandrel, a CNC Control System provided with feed drives and a Pneumatic System to compensate the weight of the entire vertical machine head. These three sub-systems have been studied and modeled by means of: • FEM modeling of the mechanical structure; • an equation set to represent the main functions of the CNC; • an equation set to represent the functioning of the Pneumatic System. These different modeling sub-systems have been integrated to obtain the entire actual dynamical behavior of the Z axis. A particular analysis was developed to represent the friction phenomena by a specific analytical model. Experimental activity was developed to test and validate the different modeling sub-systems, and other experimental tests were performed on the machining center to compare simulation outputs with experimental responses.

Energy Consumption of Feed Drive Systems Based on Workpiece Setting Position in Five-Axis Machining Center

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Ryuta Sato ◽  
Keiichi Shirase ◽  
Akio Hayashi
Keyword(s):  
Energy Consumption ◽  
Minimum Energy ◽  
Numerical Control ◽  
Total Energy Consumption ◽  
Feed Drive ◽  
Machining Center ◽  
Proposed Model ◽  
Energy Consumptions ◽  
Drive Systems ◽  
Five Axis

Energy consumption of numerical control (NC) machine tools is one of the key issues in modern industrial field. This study focuses on reducing the energy consumed by a five-axis machining center by changing only the workpiece setting position. Previous studies show that the movements along each axis in five-axis machining centers depend on the workpiece setting position, regardless of whether the same operation is performed. In addition, the energy consumptions required for the movements are different along each axis. From these considerations, an optimum workpiece setting position that can minimize the energy consumed during these motions is assumed to exist. To verify this assumption, in this study, the energy consumed by the feed drive systems of an actual five-axis machining center is first measured and then estimated using the proposed model in this study. The model for estimating the energy consumption comprises the friction, motor, and amplifier losses along each axis. The total energy consumption can be estimated by adding the energy consumptions along each axis. The effect of the workpiece setting position on the energy consumption is investigated by employing the cone-frustum cutting motion with simultaneous five-axis motions. The energy consumption that depends on the workpiece setting position is first measured and then estimated. The results confirm that the proposed model can estimate the energy consumption accurately. Moreover, the energy consumption is confirmed to depend on the workpiece setting position; the minimum energy consumption is found to be 20% lower than the maximum one.

Energy Consumption of Feed-Drive Systems That Depends on the Workpiece-Setting Position in a Five-Axis Machining Center

2017 ◽  
Author(s):  
Ryuta Sato ◽  
Yuta Inoue ◽  
Keiichi Shirase ◽  
Akio Hayashi
Keyword(s):  
Energy Consumption ◽  
Minimum Energy ◽  
Numerical Control ◽  
Total Energy Consumption ◽  
Feed Drive ◽  
Machining Center ◽  
Proposed Model ◽  
Energy Consumptions ◽  
Drive Systems ◽  
Five Axis

Energy consumption of numerical control (NC) machine tools is one of the key issues in modern industrial field. This study focuses on reducing the energy consumed by a five-axis machining center by changing only the workpiece-setting position. Previous studies show that the movements along each axis in five-axis machining centers depend on the workpiece-setting position, regardless of whether the same operation is performed. In addition, the energy consumptions required for the movements are different along each axis. From these considerations, an optimum workpiece-setting position that can minimize the energy consumed during these motions is assumed to exist. To verify this assumption, in this study, the energy consumed by the feed drive systems of an actual five-axis machining center is first measured and then estimated using the proposed model in this study. The model for estimating the energy consumption comprises the friction, motor, and amplifier losses along each axis. The total energy consumption can be estimated by adding the energy consumptions along each axis. The effect of the workpiece setting-position on the energy consumption is investigated by employing the cone-frustum cutting motion with simultaneous five-axis motions. The energy consumption that depends on the workpiece-setting position is first measured and then estimated. The results confirm that the proposed model can estimate the energy consumption accurately. Moreover, the energy consumption is confirmed to depend on the workpiece-setting position; the minimum energy consumption is found to be 20% lower than the maximum one.

Research on the Post-Processing Algorithm about Five-Axis High-Speed Machine Center

2011 ◽  
Vol 141 ◽  
pp. 460-464
Author(s):  
Wei Zhao ◽  
Tedros Alem Hadush ◽  
Qiong Yi He
Keyword(s):  
Control System ◽  
High Speed ◽  
Numerical Control ◽  
Processing Algorithm ◽  
Numerical Control System ◽  
Post Processing ◽  
Machine Center ◽  
Machining Center ◽  
Five Axis ◽  
High Speed Machine

Research on the post-processing algorithm with the DMC75VLinear 5-axis machining center and Heidenhain iTNC530 numerical control system. The formulae about angles B and C are proposed combined with the instruction of M128.The NC codes gotten from this method had been proved in the DMC75VLinea machine, so the post-processing algorithm is tested correctly and reliably.

Development of Table-on-Table-Type Five-Axis Machining Center: New Structure and Basic Characteristics

2011 ◽  
Vol 5 (2) ◽  
pp. 247-254 ◽  
Author(s):  
Naoshi Takayama ◽  
◽  
Hidehito Ota ◽  
Kensuke Ueda ◽  
Yoshimi Takeuchi ◽  
...  
Keyword(s):  
High Speed ◽  
Adjustment Process ◽  
Direct Drive ◽  
Rotary Axis ◽  
Advantages And Disadvantages ◽  
Machining Center ◽  
Wide Range ◽  
Drive Motor ◽  
Basic Characteristics ◽  
Five Axis

The demand for five-axis machining centers has been increasing rapidly, as companies seek “intensive processes” and “high accuracy.” However, it is generally more difficult for five-axis machining centers to achieve the same or higher accuracy than three-axis machining centers since it is necessary to have two more rotary feed axes besides the three linear feed ones. Many kinds of five-axis machining centers with various structures have been developed to date; an analysis of the advantages and disadvantages of major five-axis machining center structures was done first. As a result of this analysis, this paper focuses on the “table-on-table type” five-axis machining center. It is capable of accuracy because of its wide range of rotation for the rotary axis and its advantages in the adjustment process of the axis. and this paper proposes a five-axis machining center which has this construction. Furthermore, a new high-speed, highaccuracy, “table-on-table type” of five-axis machining center which uses a direct-drive motor for the rotary axis and a driven center of gravity for the linear axis has been developed based on this concept, and its accuracy has been verified.

Yaw Galloping of a TLWP Platform Under High Speed Currents by Analytical Methods and its Comparison With Experimental Results

2017 ◽  
Author(s):  
Francisco Lamas ◽  
Miguel A. M. Ramirez ◽  
Antonio Carlos Fernandes
Keyword(s):  
High Speed ◽  
Production Systems ◽  
Experimental Tests ◽  
Experimental Results ◽  
Analytical Methodology ◽  
New Approach ◽  
Laboratory Facilities ◽  
Polynomial Curve ◽  
Computational Fluid Dynamics Cfd ◽  
Cfd Analyses

Flow Induced Motions are always an important subject during both design and operational phases of an offshore platform life. These motions could significantly affect the performance of the platform, including its mooring and oil production systems. These kind of analyses are performed using basically two different approaches: experimental tests with reduced models and, more recently, with Computational Fluid Dynamics (CFD) dynamic analysis. The main objective of this work is to present a new approach, based on an analytical methodology using static CFD analyses to estimate the response on yaw motions of a Tension Leg Wellhead Platform on one of the several types of motions that can be classified as flow-induced motions, known as galloping. The first step is to review the equations that govern the yaw motions of an ocean platform when subjected to currents from different angles of attack. The yaw moment coefficients will be obtained using CFD steady-state analysis, on which the yaw moments will be calculated for several angles of attack, placed around the central angle where the analysis is being carried out. Having the force coefficients plotted against the angle values, we can adjust a polynomial curve around each analysis point in order to evaluate the amplitude of the yaw motion using a limit cycle approach. Other properties of the system which are flow-dependent, such as damping and added mass, will also be estimated using CFD. The last part of this work consists in comparing the analytical results with experimental results obtained at the LOC/COPPE-UFRJ laboratory facilities.

Dynamic Analysis of DVG 850 High-Speed Machining Center

2012 ◽  
Vol 487 ◽  
pp. 203-207
Author(s):  
Gong Xue Zhang ◽  
Xiao Kai Shen
Keyword(s):  
High Speed ◽  
Simulation Analysis ◽  
Response Analysis ◽  
Improved Method ◽  
Analysis Software ◽  
Element Analysis ◽  
Harmonic Response ◽  
Machining Center ◽  
Calculation Results ◽  
Harmonic Response Analysis

Purpose, with the application of workbench finite element analysis software, get the analysis results of DVG 850 high-speed vertical machining center via the modal analysis and harmonic response analysis. Use the calculation results for reference, put forward the improved method, and prove the credibility of the simulation analysis by testing DVG 850 prototype.

scholarly journals Additively Manufactured Parts Made of a Polymer Material Used for the Experimental Verification of a Component of a High-Speed Machine with an Optimised Geometry—Preliminary Research

Polymers ◽  
2020 ◽  
Vol 13 (1) ◽  
pp. 137
Author(s):  
Artur Andrearczyk ◽  
Bartlomiej Konieczny ◽  
Jerzy Sokołowski
Keyword(s):  
Polymer Material ◽  
High Speed ◽  
Numerical Models ◽  
Flow Analysis ◽  
Experimental Tests ◽  
Strength Analysis ◽  
Compressor Wheel ◽  
Operational Characteristics ◽  
3D Printed ◽  
Novel Method

This paper describes a novel method for the experimental validation of numerically optimised turbomachinery components. In the field of additive manufacturing, numerical models still need to be improved, especially with the experimental data. The paper presents the operational characteristics of a compressor wheel, measured during experimental research. The validation process included conducting a computational flow analysis and experimental tests of two compressor wheels: The aluminium wheel and the 3D printed wheel (made of a polymer material). The chosen manufacturing technology and the results obtained made it possible to determine the speed range in which the operation of the tested machine is stable. In addition, dynamic destructive tests were performed on the polymer disc and their results were compared with the results of the strength analysis. The tests were carried out at high rotational speeds (up to 120,000 rpm). The results of the research described above have proven the utility of this technology in the research and development of high-speed turbomachines operating at speeds up to 90,000 rpm. The research results obtained show that the technology used is suitable for multi-variant optimization of the tested machine part. This work has also contributed to the further development of numerical models.

Collision-Free Tool Path Generation for Five-Axis High Speed Machining

2011 ◽  
Vol 474-476 ◽  
pp. 961-966 ◽  
Author(s):  
Li Qiang Zhang ◽  
Min Yue
Keyword(s):  
Image Analysis ◽  
Collision Detection ◽  
High Speed ◽  
Tool Path ◽  
Geometric Model ◽  
High Speed Machining ◽  
Analysis Method ◽  
Geometric Information ◽  
Detection Approach ◽  
Five Axis

Collision detection is a critical problem in five-axis high speed machining. Using a combination of process simulation and collision detection based on image analysis, a rapid detection approach is developed. The geometric model provides the cut geometry for the collision detection and records a dynamic geometric information for in-process workpiece. For the precise collision detection, a strategy of image analysis method is developed in order to make the approach efficient and maintian a high detection precision. An example of five-axis machining propeller is studied to demonstrate the proposed approach. It has shown that the collision detection task can be achieved with a near real-time performance.

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