An accurate, efficient envelope approach to modeling the geometric deviation of the machined surface for a specific five-axis CNC machine tool

Zhou, Yuansheng; Chen, Zezhong C.; Yang, Xujing

doi:10.1016/j.ijmachtools.2015.05.005

Cited by 41 publications

(13 citation statements)

References 56 publications

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“…Besides, there is still work to do in the field of tool path optimization when complex geometries are to be generated, especially for five-axis machining [22,23,24]. The compensation of the volumetric errors generated during the material removal, particularly when big parts are to be manufactured, is also a topic of research [25,26], as well as the analysis of the influence of the vibrations generated during the machining on the resulting surface accuracy [27]. Similarly, the main research areas within the laser-based additive processes are the development of control and monitoring systems that enable the enhancement of the process stability [28,29,30,31,32,33].…”

Section: Introductionmentioning

confidence: 99%

Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations

et al. 2018

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Hybrid machine tools combining additive and subtractive processes have arisen as a solution to increasing manufacture requirements, boosting the potentials of both technologies, while compensating and minimizing their limitations. Nevertheless, the idea of hybrid machines is relatively new and there is a notable lack of knowledge about the implications arisen from their in-practice use. Therefore, the main goal of the present paper is to fill the existing gap, giving an insight into the current advancements and pending tasks of hybrid machines both from an academic and industrial perspective. To that end, the technical-economical potentials and challenges emerging from their use are identified and critically discussed. In addition, the current situation and future perspectives of hybrid machines from the point of view of process planning, monitoring, and inspection are analyzed. On the one hand, it is found that hybrid machines enable a more efficient use of the resources available, as well as the production of previously unattainable complex parts. On the other hand, it is concluded that there are still some technological challenges derived from the interaction of additive and subtractive processes to be overcome (e.g., process planning, decision planning, use of cutting fluids, and need for a post-processing) before a full implantation of hybrid machines is fulfilled.

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Section: Introductionmentioning

confidence: 99%

Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations

et al. 2018

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“…Wu et al [7] reported the stiffness of a 5-DOF hybrid machine tool with actuation redundancy. Zhou et al [8] demonstrated that because the machined surface is part of the cutter envelope surface generated by the cutter motion, it is necessary to calculate the envelope surface to obtain the geometric deviation. Gegg et al [9] proposed a simplified mechanical model for a machine-tool system.…”

Section: Introduction mentioning

confidence: 99%

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2019

JMEA

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Owing to the increasing demand for improvement in production efficiency, there has been rapid development in the structure of the machine tool. Linear motors are used in machine tool feed systems, significantly improving their speed, acceleration, and accuracy. Additionally, the traditional machine tools have undergone structural changes. In this study, the polymer concrete structure of a linear motor machine tool is examined, including the static and dynamic characteristics analysis. This study adopted the finite element analysis (FEA) method to analyze the entire machine structure to improve the deformation and resonance of the machine tool. The FEA method was applied to machine tools in the design process, including static deformation analysis, modal analysis, transient analysis, and harmonic analysis. We conducted an analysis of the deformation of the machine caused by gravity acceleration and the cutting force by exploring the main factors that affect the cutting process of the machine. To further analyze the influence of vibrations on the processing quality, a transient response analysis was conducted, and the effect of the axial cutting force during machining was discussed. Furthermore, the harmonic analysis of the machine was performed. Finally, we optimized the structural design of the machine tool to eliminate unnecessary materials to reduce its weight.

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“…7 A geometric envelope approach with two major distinctions was proposed to calculate the envelope surface in five-axis milling. 8 From the literature review presented above, it can be seen that the cutting forces are the essential variables and links in milling process, especially for multi-axis milling process, which relate the material removal process to workpiece surface quality.…”

Section: Introductionmentioning

confidence: 99%

A generalized cutting force model for five-axis milling processes

Song

Liu

et al. 2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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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.

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An accurate, efficient envelope approach to modeling the geometric deviation of the machined surface for a specific five-axis CNC machine tool

Cited by 41 publications

References 56 publications

Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations

Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations

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A generalized cutting force model for five-axis milling processes

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