Analysis of NC Data for Machining Test of Cone-Frustum under Simultaneous Five-Axis Control

Abstract

NC data for machining the cone-frustum by means of five-axis machining centers with a tilting rotary table are analyzed in detail. The cone-frustum is machined by using a milling cutter at simultaneous five-axis control for inspecting the machining accuracy. However, the NC data have to be changed corresponding to the setting position of the workpiece on the rotary table. Thus, the moving range and velocity of each axis are analyzed by changing the apex angle and center position of the cone. It is found from the analyzed results that the larger apex angle gives the larger moving range and the higher velocity to all axes. When the center position moves along the Y-direction, every reversal point independently appears on a circular path. Therefore, it is recommended to offset the center position of the cone frustum along Y-direction to give the large moving ranges and the high velocities to the axes.

Sensitivity Analysis in Ball Bar Measurement of Three-Dimensional Circular Movement Equivalent to Cone-Frustum Cutting in Five-Axis Machining Centers

“…The errors of the X, Y, and A axes are only detected by the ball bar, though the five axes are simultaneously moved. As reported previously by Bossoni (13) and the present authors (9) , the travel ranges of these axes for a half apex angle of 45° are larger than those for a half apex angle of 15°. The sensitivity coefficients of the Y and A axes are small (except around 0° and 180°), though the sensitivity coefficient of the X axis is slightly larger than that for a half apex angle of 15°, as shown in Fig.…”

“…Journal of Advanced Mechanical Design, Systems, and Manufacturing of the cone-frustum for a half apex angle of 15° and its center is located 50 mm away from the centerline of the rotary table in the Y direction. For this test condition, as previously reported (9) , the reversal positions of the axes can be detected separately on the circular trajectory, and interference with the ball bar itself does not occur.…”

“…In addition, the authors have analyzed in detail the numerically controlled (NC) data that create a tool path for the two cone-frustums with half apex angles of 15° and 45° ( 9) , which are the test conditions for checking the accuracy in ISO/DIS 10791-6 (1) . This NC data can actually be used for five-axis MCs having a tilting rotary table.…”

Indirect Measurement of Volumetric Accuracy for Three-Axis and Five-Axis Machine Tools: A Review

“…Its inclusion in ISO/CD 10791-7:2011 [156] is currently under discussion in ISO TC39/SC2. Some researchers present sensitivity analysis of location errors of rotary axes on the geometric accuracy of the machined cone frustum workpiece, with a particular interest in the influence of workpiece location and orientation [157][158][159]. Matsushita et al [160] presented the identification of all location errors from finished cone frustum workpieces when they are machined at three different positions.…”