A dynamics-driven approach to precision machines design for micro-manufacturing and its implementation perspectives

Precision machines are essential elements in fabricating high quality micro products or micro features and directly affect the machining accuracy, repeatability and efficiency. There are a number of literatures on the design of industrial machine elements and a couple of precision machines commercially available. However, few researchers have systematically addressed the design of precision machines from the dynamics point of view. In this paper, the design issues of precision machines are presented with particular emphasis on the dynamics aspects as the major factors affecting the performance of the precision machines and machining processes. This paper begins with a brief review of the design principles of precision machines with emphasis on machining dynamics. Then design processes of precision machines are discussed, and followed by a practical modelling and simulation approaches. Two case studies are provided including the design and analysis of a fast tool servo system and a 5-axis bench-top micro-milling machine respectively. The design and analysis used in the two case studies are formulated based on the design methodology and guidelines

Improving the Dynamic Performance of Five-Axis CNC Machine Tool by using the Software-in-the-Loop (SIL) Platform

The paper presents the development and implementation of a Software-in-the-loop (SIL) platform allowing the real-time simulation of the hybrid model of five-axis CNC machine tool which is implemented in SIMULINK. The interfacing between dSPACE software and the feed drives models in SIMULINK is explined. The values for the simulated positioning errors between the position demand and simulated position of orthogonal trimming head for the gantry axis are in the order of microns so proposed SIL model is validated. The accurate SIL platform could be used to build and optimise the machining process models including CNC machine tools under cutting conditions and improve machines’ dynamic performance

Design of ultraprecision machine tools with application to manufacturing of miniature and micro components

Currently the underlying necessities for predictability, producibility and productivity remain big issues in ultraprecision machining of miniature/microproducts. The demand on rapid and economic fabrication of miniature/microproducts with complex shapes has also made new challenges for ultraprecision machine tool design. In this paper the design for an ultraprecision machine tool is introduced by describing its key machine elements and machine tool design procedures. The focus is on the review and assessment of the state-of-the-art ultraprecision machining tools. It also illustrates the application promise of miniature/microproducts. The trends on machine tool development, tooling, workpiece material and machining processes are pointed out

Contouring Accuracy Improvement Using an Adaptive Feedrate Planning Method for CNC Machine Tools

AbstractThe reduction of contour error plays an important role in achieving high accuracy machining. To reduce contour error, most of previous studies have focused on developing advanced control strategies. As an alternative strategy, contouring accuracy improvement using an adaptive feedrate planning method is proposed in this paper. First, a typical PID controller is adopted to build the contour error model, from which the feedrate can be scheduled in the contour error violated zones. Then, the relations between each constraint and the cutter tip feedrate are derived. After that, a linear programming model is applied to obtain the optimal feedrate profile on the sampling positions of the given tool path. Finally, illustrated examples are given to validate the feasibility and applicability of the proposed feedrate planning method. The comparison results show that the proposed method has a significant effect on improving contouring accuracy

RESEARCH OF ROBOTIC SYSTEM POSITIONING ACCURACY

Robotics is one of the technologies of the fourth industrial revolution, which has a wide range of applications, from household chores to manufacturing and healthcare to entertainment and space exploration. The purpose of the study is to determine and evaluate the repeatability and positioning accuracy indicators of the robotic system when reproducing the movements of the hand repeating a human hand. The article conducts a comparative analysis of the methods and software control algorithms for creating feedback of robotic system electromechanical control gears displacement, and provides the rationale for the choice of physical equipment for the technical experiment. This article describes the plan of stages of the experimental research, the research bench, presents the systematized results of the research, conclusions and suggestions for practical application