A generating milling method for a spur face gear using a five-axis computer numerical control milling machine

Energy consumption of computer numerical control (CNC) machines is significant and various empirical models have been developed to model the specific energy consumption (SEC) of CNC machines. However, most of the models are developed for specific machines and hence have limited applications in manufacturing industry. In this research, a general empirical SEC model for milling machine at certain power level is developed based on actual cutting experimental data. In this model, stand-by power and spindle power are used in the SEC model for the first time. The material removal rate (MRR) is used to represent the cutting parameter. The proposed model is fitted by the regression analysis and validated using experimental data. Results show that the proposed model can be applied on various milling machines with an average absolute residual ratio of 6%. The model is also validated through a series of cutting experiments on a machine center, with an accuracy of 91.5%, for the SEC calculation.

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Dynamic simulation based on dyna971 for computer numerical control boring and milling machine

Journal of Computer Applications ◽

10.3724/sp.j.1087.2013.02055 ◽

2013 ◽

Vol 33 (7) ◽

pp. 2055-2058

Author(s):

Youde WU ◽

Liuxian ZHU ◽

Bailin LI

Keyword(s):

Dynamic Simulation ◽

Computer Numerical Control ◽

Numerical Control ◽

Milling Machine ◽

Simulation Based

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Free-Form Flank Correction in Helical Gear Grinding Using a Five-Axis Computer Numerical Control Gear Profile Grinding Machine

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4006096 ◽

2012 ◽

Vol 134 (4) ◽

Cited By ~ 29

Author(s):

Yi-Pei Shih ◽

Shi-Duang Chen

Keyword(s):

Correction Method ◽

Computer Numerical Control ◽

Numerical Control ◽

Free Form ◽

Profile Grinding ◽

Wheel Profile ◽

Grinding Machine ◽

Tooth Flank ◽

Five Axis ◽

Gear Profile

To reduce form grinding errors, this paper proposes a free-form flank topographic correction method based on a five-axis computer numerical control (CNC) gear profile grinding machine. This correction method is applied not only to the five-axis machine settings (during grinding) but also to the wheel profile (during wheel truing). To achieve free-form modification of the wheel profile, the wheel is formulated as B-spline curves using a curve fitting technique and then normal correction functions made up of four-degree polynomials are added into its working curves. Additionally, each axis of the grinding machine is formulated as a six-degree polynomial. Based on a sensitivity analysis of the polynomial coefficients (normal correction functions and CNC machine settings) on the ground tooth flank and the topographic flank errors, the corrections are solved using the least squares method. The ground tooth flank errors can then be efficiently reduced by slightly adjusting the wheel profile and five-axis movement according to the solved corrections. The validity of this flank correction method for helical gears is numerically demonstrated using the five-axis CNC gear profile grinding machine.

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WebCAD: A computer aided design tool constrained with explicit ‘design for manufacturability’ rules for computer numerical control milling

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/095440502320193003 ◽

2002 ◽

Vol 216 (6) ◽

pp. 879-889 ◽

Cited By ~ 2

Author(s):

A Mohole ◽

P Wright ◽

C Séquin

Keyword(s):

Computer Aided Design ◽

Computer Numerical Control ◽

Design Tool ◽

Numerical Control ◽

Milling Machine ◽

Design Tools ◽

Cad System ◽

Computer Aided ◽

Cad Cam ◽

Aided Design

A key element in the overall efficiency of a manufacturing enterprise is the compatibility between the features that have been created in a newly designed part, and the capabilities of the downstream manufacturing processes. With this in mind, a process-aware computer aided design (CAD) system called WebCAD has been developed. The system restricts the freedom of the designer in such a way that the designed parts can be manufactured on a three-axis computer numerical control milling machine. This paper discusses the vision of WebCAD and explains the rationale for its development in comparison with commercial CAD/CAM (computer aided design/manufacture) systems. The paper then goes on to describe the implementation issues that enforce the manufacturability rules. Finally, certain design tools are described that aid a user during the design process. Some examples are given of the parts designed and manufactured with WebCAD.

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On-Machine Measurement and Error Compensation for 6061 Aluminum Alloy Hexagonal Punch Using a Turn-Milling Machine

Machines ◽

10.3390/machines9090180 ◽

2021 ◽

Vol 9 (9) ◽

pp. 180

Author(s):

Cheng-Hsien Kuo ◽

Po-Cheng Chen

Keyword(s):

Aluminum Alloy ◽

Error Compensation ◽

Machine Tools ◽

Numerical Control ◽

Cnc Machine Tools ◽

Milling Machine ◽

Tolerance Range ◽

Cnc Machine ◽

Rough Machining ◽

Five Axis

For machining parts with complex shapes, consisting of computer numerical control (CNC) machine tools, different CNC machine tools will be used according to the machining method. If the workpiece is removed for off-machine measurement after machining, when the size is incorrect, it will need to be returned to the CNC machine tool for secondary machining. In this case, the workpiece surface quality and machining accuracy will be affected, which is very time-consuming. On-machine measurement and complex machine center is a key to solve this problem. In the recent researches that the touch probe was integrated on three or five axis machine for error compensation and shape construction based on on-machine measurement, but turning-milling machine was rare. In addition, the most types of parts were thin-walled parts or thin web parts. In this study, a contact measurement system is integrated into a CNC combined turning-milling machine for on-machine measuring. Macro-programming is used to design the machining path of A6061-T6 aluminum alloy hexagonal punch, and the action of probe measurement is added to the machining path. As the measured data exceed the tolerance range, the calculated data are fed back to the controller for machining improvement by compensation. The finished hexagonal punch is measured in a 3D coordinate measuring machine and the error is compared. The experimental results show that the contact probe needs to be corrected before machining, and the size of the corrected workpiece can reach the tolerance range of ±0.01 mm. The size error of rough machining is larger than that of fined machining, and the size error of rough machining will increase with the length of the workpiece.

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