Optimization of 5-axis milling processes using process models

Productivity and part quality are extremely important for all machining operations, but particularly for 5-axis milling where the machine tool cost is relatively higher, and most parts have complex geometries and high quality requirements with tight tolerances. 5- axis milling, presents additional challenges in modeling due to more complex tool and workpiece interface geometry, and process mechanics. In this paper, modeling and optimization of 5-axis processes with cutting strategy selection are presented. The developed process models are used for cutting force predictions using a part-tool interface identification method which is also presented. Based on the model predictions and simulations, best cutting conditions are identified. Also, for finish process of a complex surface, machining time is estimated using three machining strategy alternatives. Results are demonstrated by example applications, and verified by experiments

Process simulation for 5-axis machining using generalized milling tool geometries

Multi-axis machining (especially 5-axis machining) is widely used in precision machining for automotive, aerospace and die-mold manufacturing. The goal in precision machining is to increase production while meeting high part quality needs which can be achieved through decision of appropriate process parameters considering machine tool constraints (such as power and torque), chatter-free operations and part quality. In order to predict and decide on optimal process parameters, simulation models are used. In the literature, individual tool geometries for multi-axis machining are examined in detailed with different modeling approaches to simulate cutting forces. In this study, a general numerical model for 5-axis machining is proposed covering all possible tool geometries. Tool envelope is extracted from CAD data, and helical flutes points are represented in cylindrical coordinates. Equal parallel slicing method is utilized to find cutter engagement boundaries (CEB) determining cutting region of the tool surface. for each axial level in the tool axis direction. For each level uncut chip thickness value is found and total forces are calculated by summing force values for each point along the cutting flutes. For arbitrary cases forces are simulated and obtained results are experimentally verified

Tool orientation effects on the geometry of 5-axis ball-end milling

5-axis ball-end milling has found application in various industries especially for machining of parts with complex surfaces. Additional two degree of freedoms, namely, lead and tilt angles make it possible to machine complex parts by providing extra flexibility in cutting tool orientation. However, they also complicate the geometry of the process. Knowledge of the process geometry is important for understanding of 5-axis ball-end milling operations. Although there are considerable amount of work done in 3-axis milling, the literature on 5-axis ball-end milling is limited. Some of the terminology used in 3-axis milling is not directly applicable to 5-axis ball end-milling. Hence some new process parameters and coordinate systems are defined to represent a 5-axis ball end-milling process completely. The engagement zone between the cutting tool and the workpiece is more involved due to the effects of lead and tilt angles. In this paper, effects of these angles on the process geometry are explained by presenting CAD models and analytical calculations

Application of multi sensor data fusion based on Principal Component Analysis and Artificial Neural Network for machine tool thermal monitoring

Due to the various heat sources on a machine tool, there exists a complex temperature distribution across its structure. This causes an inherent thermal hysteresis which is undesirable as it affects the systematic tool –to-workpiece positioning capability. To monitor this, two physical quantities (temperature and strain) are measured at multiple locations. This article is concerned with the use of Principal Component Analysis (PCA) and Artificial Neural Networks (ANN) to fuse this potentially large amount of data from multiple sources. PCA reduces the dimensionality of the data and thus reduces training time for the ANN which is being used for thermal modelling. This paper shows the effect of different levels of data compression and the application of rate of change of sensor values to reduce the effect of system hysteresis. This methodology has been successfully applied to the ram of a 5-axis gantry machine with 90 % correlation to the measured displacement

Kinematic Analysis of a Serial - Parallel Machine Tool: the VERNE machine

The paper derives the inverse and the forward kinematic equations of a serial - parallel 5-axis machine tool: the VERNE machine. This machine is composed of a three-degree-of-freedom (DOF) parallel module and a two-DOF serial tilting table. The parallel module consists of a moving platform that is connected to a fixed base by three non-identical legs. These legs are connected in a way that the combined effects of the three legs lead to an over-constrained mechanism with complex motion. This motion is defined as a simultaneous combination of rotation and translation. In this paper we propose symbolical methods that able to calculate all kinematic solutions and identify the acceptable one by adding analytical constraint on the disposition of legs of the parallel module

Workspace and Kinematic Analysis of the VERNE machine

This paper describes the workspace and the inverse and direct kinematic analysis of the VERNE machine, a serial/parallel 5-axis machine tool designed by Fatronik for IRCCyN. This machine is composed of a three-degree-of-freedom (DOF) parallel module and a two-DOF serial tilting table. The parallel module consists of a moving platform that is connected to a fixed base by three non-identical legs. This feature involves (i) a simultaneous combination of rotation and translation for the moving platform, which is balanced by the tilting table and (ii) workspace whose shape and volume vary as a function of the tool length. This paper summarizes results obtained in the context of the European projects NEXT ("Next Generation of Productions Systems")

Inverse kinematics of a 5-axis hybrid robot with non-singular tool path generation

This paper deals with non-singular tool path generation of a 5-axis hybrid robot named TriMule, which is designed for large part machining in situ. It is observed that at a singularity pose sudden changes occur in rotation of the C-axis and lengths of three telescopic legs. It is found that when the tool axis rotates about the axis normal to the plane expanded by the tool axis and the singular axis, the singular axis itself is forced to rotate simultaneously about the same axis in the opposite direction. This exploration enables the minimum rotation angle of the tool axis to be determined accurately for avoiding singularity and reducing machined surface errors caused by tool axis modification, leading to the development of an algorithm for non-singular tool path generation by modifying a partial set of the control points of B-splines. Both simulation and experiment on a prototype machine are carried out to verify the effectiveness of this approach

Workspace Analysis of the Parallel Module of the VERNE Machine

The paper addresses geometric aspects of a spatial three-degree-of-freedom parallel module, which is the parallel module of a hybrid serial-parallel 5-axis machine tool. This parallel module consists of a moving platform that is connected to a fixed base by three non-identical legs. Each leg is made up of one prismatic and two pairs of spherical joint, which are connected in a way that the combined effects of the three legs lead to an over-constrained mechanism with complex motion. This motion is defined as a simultaneous combination of rotation and translation. A method for computing the complete workspace of the VERNE parallel module for various tool lengths is presented. An algorithm describing this method is also introduced

A holistic integrated dynamic design and modelling approach applied to the development of ultraprecision micro-milling machines

Ultraprecision machines with small footprints or micro-machines are highly desirable for micro-manufacturing high-precision micro-mechanical components. However, the development of the machines is still at the nascent stage by working on an individual machine basis and hence lacks generic scientific approach and design guidelines. Using computer models to predict the dynamic performance of ultraprecision machine tools can help manufacturers substantially reduce the lead time and cost of developing new machines. Furthermore, the machine dynamic performance depends not only upon the mechanical structure and components but also the control system and electronic drives. This paper proposed a holistic integrated dynamic design and modelling approach, which supports analysis and optimization of the overall machine dynamic performance at the early design stage. Based on the proposed approach the modelling and simulation process on a novel 5-axis bench-top ultraprecision micro-milling machine tool – UltraMill – is presented. The modelling and simulation cover the dynamics of the machine structure, moving components, control system and the machining process, and are used to predict the overall machine performance of two typical configurations. Preliminary machining trials have been carried out and provided the evidence of the approach being helpful to assure the machine performing right at the first setup

Kinematic and Dynamic Analysis of the 2-DOF Spherical Wrist of Orthoglide 5-axis

This paper deals with the kinematics and dynamics of a two degree of freedom spherical manipulator, the wrist of Orthoglide 5-axis. The latter is a parallel kinematics machine composed of two manipulators: i) the Orthoglide 3-axis; a three-dof translational parallel manipulator that belongs to the family of Delta robots, and ii) the Agile eye; a two-dof parallel spherical wrist. The geometric and inertial parameters used in the model are determined by means of a CAD software. The performance of the spherical wrist is emphasized by means of several test trajectories. The effects of machining and/or cutting forces and the length of the cutting tool on the dynamic performance of the wrist are also analyzed. Finally, a preliminary selection of the motors is proposed from the velocities and torques required by the actuators to carry out the test trajectories