A Machining Test to Reflect Dynamic Machining Accuracy of Five-Axis Machine Tools

2012 ◽  
Vol 622-623 ◽  
pp. 414-419 ◽  
Author(s):  
Wen Ping Mou ◽  
Zhi Yong Song ◽  
Zhi Ping Guo ◽  
Li Min Tang
Keyword(s):  
Machine Tools ◽  
Tool Path ◽  
Industrial Applications ◽  
Machining Accuracy ◽  
Surface Machining ◽  
The Real ◽  
Machining Test ◽  
Five Axis ◽  
Kinematic Errors

NAS (National Aerospace Standard) 979 is the only standard well known in industry describing a five-axis machining test for measuring kinematic errors of five-axis machine tools. As it cannot reflect the tool path characteristics of typical ruled surface machining, five-axis machine tools which passed the NAS test may not have the ability to satisfy the requirement of the real industrial applications. To fill this gap between the NAS test and the real industrial applications, an “S” machining test is proposed in this paper. The case study shows that the proposed machining test is feasible and practicable.

A pyramid-shaped machining test to identify rotary axis error motions on five-axis machine tools: software development and a case study

2017 ◽  
Vol 94 (1-4) ◽  
pp. 227-237 ◽  
Author(s):  
Soichi Ibaraki ◽  
Shota Tsujimoto ◽  
Yu Nagai ◽  
Yasutaka Sakai ◽  
Shigeki Morimoto ◽  
...  
Keyword(s):  
Software Development ◽  
Machine Tools ◽  
Rotary Axis ◽  
Machining Test ◽  
Five Axis

Machining of Free-Form Surface Method and Implementation Research with Ball-End Cutter

2011 ◽  
Vol 697-698 ◽  
pp. 244-248
Author(s):  
Ke Hua Zhang ◽  
Li Min ◽  
Dong Hui Wen
Keyword(s):  
Tool Path ◽  
Computer Hardware ◽  
Free Form ◽  
Machining Accuracy ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
Tool Position ◽  
Five Axis

A new tool path generation method based on Z-buffer method is proposed for free-form surface machining by using ball-end cutters. Firstly, to avoid ball-end mill cutting the workpiece, we make the cutter shaft which is perpendicular to machining surface tilt angle θ, then determine the examining area and then judge there is or not a interference occurring between ball-end mill and examining area, if there is, then make a adjustment for cutter shaft. The discretized points within the examining area are efficiently read in and stored directly by the computer hardware; no extra searching and iterative methods are needed. Simulation results show that, comparing with the traditional algorithm, the tool-position calculation time is shorter, and the phenomenon of workpiece squeezed and scratched is less in this algorithm. It meets the basic needs of five axis machining accuracy. Finally we make a practical machining experiment for cutter location generated.

scholarly journals Triple parametric tool path interpolation for five-axis machining with three-dimensional cutter compensation

2018 ◽  
Vol 10 (9) ◽  
pp. 168781401879822
Author(s):  
Chuanjun Li ◽  
Bin Zhang ◽  
XueLei Wang ◽  
Qiang Liu ◽  
Huan Liu
Keyword(s):  
Tool Path ◽  
Interpolation Method ◽  
Three Dimensional ◽  
Machining Accuracy ◽  
Great Success ◽  
Surface Machining ◽  
Smooth Motion ◽  
Simultaneous Interpolation ◽  
Five Axis ◽  
Parametric Interpolation

Parametric interpolation obtains a great success in three-axis surface machining with smooth motion, high accuracy, and high machining efficiency, but does not go well in five-axis surface machining due to lack of appropriate and efficient methods of tool path generation, interpolation, and three-dimensional cutter compensation. This article proposes a triple parametric tool path interpolation method for five-axis machining with three-dimensional cutter compensation, which proposes an appropriate triple parametric tool generation method for realizing the three-dimensional cutter compensation in five-axis parametric interpolation. A triple parametric interpolation algorithm is also proposed to realizing the simultaneous interpolation of the source data, which ensures the primitivity and maintains the accuracy. The proposed three-dimensional cutter compensation can compensate the errors caused by minor changes in cutter size, thus machining accuracy can be improved. Finally, illustrated example verifies the feasibility and applicability of the proposed methods.

scholarly journals Influence of Tool Length and Profile Errors on the Inaccuracy of Cubic-Machining Test Results

2021 ◽  
Vol 5 (2) ◽  
pp. 51
Author(s):  
Zongze Li ◽  
Hiroki Ogata ◽  
Ryuta Sato ◽  
Keiichi Shirase ◽  
Shigehiko Sakamoto
Keyword(s):  
Machine Tools ◽  
Test Accuracy ◽  
Test Results ◽  
Machining Error ◽  
Tool Profile ◽  
Machining Test ◽  
The Difference ◽  
Side Error ◽  
Profile Errors ◽  
Five Axis

A cubic-machining test has been proposed to evaluate the geometric errors of rotary axes in five-axis machine tools using a 3 × 3 zone area in the same plane with different tool postures. However, as only the height deviation among the machining zones is detected by evaluating the test results, the machining test results are expected to be affected by some error parameters of tool sides, such as tool length and profile errors, and there is no research investigation on how the tool side error influences the cubic-machining test accuracy. In this study, machining inaccuracies caused by tool length and tool profile errors were investigated. The machining error caused by tool length error was formulated, and an intentional tool length error was introduced in the simulations and actual machining tests. As a result, the formulated and simulated influence of tool length error agreed with the actual machining results. Moreover, it was confirmed that the difference between the simulation result and the actual machining result can be explained by the influence of the tool profile error. This indicates that the accuracy of the cubic-machining test is directly affected by tool side errors.

Research on Five-Axis Dual-NURBS Adaptive Interpolation Algorithm for Flank Milling

2010 ◽  
Vol 443 ◽  
pp. 330-335 ◽  
Author(s):  
Yu Han Wang ◽  
Jing Chun Feng ◽  
Sun Chao ◽  
Ming Chen
Keyword(s):  
Tool Path ◽  
Flank Milling ◽  
Interpolation Algorithm ◽  
Machining Time ◽  
Surface Machining ◽  
Tool Axis ◽  
Scanning Area ◽  
Nurbs Interpolation ◽  
Milling Method ◽  
Five Axis

In order to exploit the advantages of five-axis flank milling method for space free surface machining to the full, a definition of non-equidistant dual-NURBS tool path is presented first. On this basis, the constraint of velocity of points on the tool axis and the constraint of scanning area of the tool axis are deduced. Considering both of these constraints, an adaptive feed five-axis dual-NURBS interpolation algorithm is proposed. The simulation results show that the feedrate with the proposed algorithm satisfies both of the constraints and the machining time is reduced by 38.3% in comparison with the constant feed interpolator algorithm.

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.

A Real-Time C3 Continuous Tool Path Smoothing and Interpolation Algorithm for Five-Axis Machine Tools

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Qin Hu ◽  
Youping Chen ◽  
Xiaoliang Jin ◽  
Jixiang Yang
Keyword(s):  
Coordinate System ◽  
Real Time ◽  
Machine Tools ◽  
Tool Path ◽  
Maximum Deviation ◽  
Interpolation Algorithm ◽  
Tool Orientation ◽  
Path Smoothing ◽  
Tip Position ◽  
Five Axis

Abstract Local corner smoothing method is commonly adopted to smooth linear (G01) tool path segments in computer numerical control (CNC) machining to realize continuous motion at transition corners. However, because of the highly non-linear relation between the arc-length and the spline parameter, and the challenge to synchronize the tool tip position and tool orientation, real-time and high-order continuous five-axis tool path smoothing and interpolation algorithms have not been well studied. This paper proposes a real-time C3 continuous corner smoothing and interpolation algorithm for five-axis machine tools. The transition corners of the tool tip position and tool orientation are analytically smoothed in the workpiece coordinate system (WCS) and the machine coordinate system (MCS) by C3 continuous PH splines, respectively. The maximum deviation errors of the smoothed tool tip position and the tool orientation are both constrained in the WCS. An analytical synchronization algorithm is developed to guarantee the motion variance of the smoothed tool orientation related to the tool tip displacement is also C3 continuous. The corresponding real-time interpolation method is developed with a continuous and peak-constrained jerk. Simulation results verify that the maximum deviation errors caused by the tool path smoothing algorithm are constrained, and continuous acceleration and jerk of each axis are achieved along the entire tool path. Comparisons demonstrate that the proposed algorithms achieve lower amplitude and variance of acceleration and jerk when compared with existing methods. Experiments show that the proposed five-axis corner smoothing and interpolation algorithms are serially executed in real-time with 0.5-ms cycle.

Research on Rotary and Tilting Table Five-Axis Milling Post-Processing Software Star-Fpost

2011 ◽  
Vol 403-408 ◽  
pp. 2962-2966
Author(s):  
Lian Xia ◽  
Jiang Han ◽  
Hu Li
Keyword(s):  
Machine Tools ◽  
Tool Path ◽  
Object Oriented ◽  
Simulation Environment ◽  
Post Processing ◽  
Source File ◽  
Processing Software ◽  
Five Axis ◽  
The Mathematical Model ◽  
Tilting Table

Based on the MIRON UCP800 rotary and tilting table five-axis machine, this paper studies the mathematical model of Five-Axis machining and derives the algorithm formula of Six-Coordinate axis vector into five-axis AC rotary and tilting table. The Post-Processing process of turning the source file to the machine tool path code is fulfilled by using coordinate transformation matrix; with reading the cutting location file line by line, a dedicated five-axis milling post-processing software through adapting the Keyword-Triggered method is developed by using object-oriented program in the paper. First completing construction of Five-Axis machine tools mode in the VERICUT simulation environment, then manufacturing the whole shaft by ternary simulation of impeller machining in NX, and the simulation results shows that the function of Post-Processing software Star-Fpost. The software can provide the actual processing of information for MIKRON UCP800 five-axis machine tools.

S1301-1-1 Machining Tests to Identify Kinematic Errors on Five-axis Machine Tools

2009 ◽  
Vol 2009.4 (0) ◽  
pp. 221-222
Author(s):  
Takeyuki Iritani ◽  
Soichi Ibaraki ◽  
Masahiro Sawada ◽  
Tetsuya Matsushita
Keyword(s):  
Machine Tools ◽  
Five Axis ◽  
Kinematic Errors
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