Investigation of Motion Control of Liner Axes and a Rotary Axis Under Constant Feed Speed Vector at Milling Point With a Five-Axis Machining Center

2013 ◽  
Author(s):  
Yuma Maruyama ◽  
Takayuki Akai ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa
Keyword(s):  
Surface Roughness ◽  
Present Report ◽  
Sudden Change ◽  
Machining Accuracy ◽  
Feed Speed ◽  
Motion Error ◽  
Rotary Axis ◽  
Machining Center ◽  
Five Axis ◽  
Cutting Point

Recently, a novel manufacturing technology has spread out with a five-axis machining center. It is especially important to keep the surface roughness on an entire machined surface constant. Thus, we proposed a novel method for maintaining a constant feed speed vector at the cutting point between the end-mill tool and the workpiece surface by controlling two linear axes and a rotary axis with a five-axis machining center. In the present report, we focused on machining the combined inner and outer radius curvature and investigating the influence of synchronous control error between the linear axes and rotary axis on the machining accuracy and surface roughness. As a result, we determined that it is possible to suppress sudden change in the synchronous motion error by accurately aligning the motion direction of the linear and rotary axes and the feed speed vector at milling point at the contact point of the inner and outer circles.

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

Motion Tuning Method of Linear Axes and Rotary Axis Under a Constant Cutting Speed Vector at End-Milling Point With a Five-Axis Controlled Machining Center

2015 ◽  
Author(s):  
Takamaru Suzuki ◽  
Takakazu Ikegami ◽  
Takayuki Akai ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Quality ◽  
End Milling ◽  
High Surface ◽  
Cutting Speed ◽  
Surface Shape ◽  
Feed Speed ◽  
Shape Error ◽  
Rotary Axis ◽  
Machining Center ◽  
Five Axis

Recently It is difficult to maintain the high surface quality ingenerating curved surface shape under five-axis controlled end-milling. In this study, we aimed at maintaining feed speed vector at milling point by controlling two linear axes and a rotary axis with a five-axis machining center, to improve machined surface quality and suggested a method for solving shape error of machined workpiece considering differences of three axes’s sarvo characteristics. As the results, it could be seen that shape error greatly decreased based on the proposed method.

scholarly journals Improved Method for Synchronizing Motion Accuracy of Linear and Rotary Axes Under Constant Feed Speed Vector at End Milling Point – Investigation of Motion Error Under NC-Commanded Motion –

2019 ◽  
Vol 13 (5) ◽  
pp. 679-690 ◽  
Author(s):  
Takamaru Suzuki ◽  
Kazuki Yoshikawa ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Takakazu Ikegami ◽  
...  
Keyword(s):  
End Milling ◽  
Research Work ◽  
Free Form ◽  
Machining Accuracy ◽  
Feed Speed ◽  
Shape Error ◽  
Control Coefficient ◽  
Machined Surface ◽  
Motion Error ◽  
Rotary Axis

A 5-axis machining center (5MC) is noted for its synchronous control capability, making it a feasible tool for quickly and accurately machining complicated three-dimensional surfaces such as propellers and hypoid gears as it is equipped with a direct-drive (DD) motor in the rotary axis. The current research work identified the necessity of improving both the accuracy of the machined shape and the consistency of the free-form machined surface. A method for maintaining the feed speed vector at the milling point by controlling two linear axes and the rotary axis of a 5MC to improve the quality of the machined surface was investigated. Additionally, a method was proposed for reducing the shape error of machined workpieces by considering differences in the servo characteristics of the three axes. The shape error was significantly reduced by applying the proposed method using a precedent control coefficient determined via calculations. To maintain the feed speed vector at the milling point in the machining of complex shapes, rapid velocity change in each axis is often required, leading to inaccuracy caused by torque saturation at a DD motor in the rotary axis. The results of this study indicate that torque saturation can be evaluated via simulation and that the machining accuracy and consistency can be improved by accounting for these errors using the proposed precedent control coefficient method.

scholarly journals Improvement of machined accuracy under constant feed speed at milling point with a five axis controlled machining center considering approach path

2020 ◽  
Vol 86 (889) ◽  
pp. 20-00175-20-00175
Author(s):  
Takamaru SUZUKI ◽  
Shoya IWAMA ◽  
Toshiki HIROGAKI ◽  
Eiichi AOYAMA
Keyword(s):  
Feed Speed ◽  
Machining Center ◽  
Five Axis

Optimization of Cutting Conditions for Surface Roughness in VMC 5-Axis

2019 ◽  
Vol 969 ◽  
pp. 631-636 ◽  
Author(s):  
Ramesh Rudrapati ◽  
Arun Patil
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Metal Cutting ◽  
Advanced Materials ◽  
Milling Parameters ◽  
Machining Center ◽  
Machining Economics ◽  
Parameters Selection ◽  
Quality Response ◽  
Five Axis

Vertical machining center (VMC) five-axis is advanced metal cutting process which used tomachine advanced materials for creating parts for industries like die, automotive, aerospace, machinerydesign, etc. Input parameters selection very important in VMC-five axis to obtain better surface finishon milled part and enhanced machining economics. In the present work, experimental analysis has beenplanned to study the significances of milling parameters on quality response, surface roughness (Ra) ofD3 steel. The experiments have been planned on D3 steel in VMC five axis as per Box-Behnken designof response surface methodology (RSM). Modeling and optimization have been done by hybrid RSMand Jaya optimization algorithm. The factor effects on Ra has been studied by analysis of signal-tonoise ratio. The concluding remarks has been drawn from the study

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.

Experimental study on the surface roughness of micromilled Elgiloy™

2011 ◽  
Vol 225 (11) ◽  
pp. 2138-2143 ◽  
Author(s):  
P Zhang ◽  
B Wang ◽  
Y Liang ◽  
M J Jackson
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Surface Topography ◽  
Industrial Applications ◽  
Depth Of Cut ◽  
Mean Deviation ◽  
Machining Accuracy ◽  
Feed Speed ◽  
3D Surface ◽  
Axial Depth

Elgiloy™ is a cobalt-based alloy with excellent physical and chemical performance, and is used widely in medical and industrial applications. The machining accuracy, surface topography, and surface damaged layer play an important role in the use of the alloy for specific applications. In this paper, an experimental study on the surface roughness of precision micromilling of Elgiloy is accomplished by using a super-fine-grained tungsten carbide milling cutter. The surface topography of the surface of the slots milled is achieved with different values of feed speed and axial depth of cut. Three-dimensional (3D) measurement results are considered to reflect the surface topography based on a comparison of the difference between two-dimensional (2D) and 3D surface roughness measurements. The arithmetic mean deviation of the slots’ 3D surface is achieved by using a white light interferometric profilometer. By using analysis of variance (ANOVA), the factors of feed speed, axial depth of cut, and their interaction are proven to be the most important factors relating to the magnitude of surface roughness.

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