5-axis Machining Research Articles

Optimization of cutting parameters based on surface partitioning

With the rapid development of science and technology, five-axis CNC machine tools are widely used in the field of complex surface parts processing and manufacturing, so the part geometry model of the complex surface becomes more and more complex. Most traditional machining methods use fixed cutting parameters to calculate and generate five-axis machining toolpaths. If the fixed cutting parameters are used to generate the 5-axis machining toolpaths, the optimal cutting condition will not be obtained in some parts, and the generated machining toolpaths will be less adaptable. In this paper, the complex surface is partitioned and the cutting parameters are optimally adjusted to different parts of the workpiece during the cutting process to respond to the change in the cutting state.

Measurement Of Aluminium Alloy 6061 Diameter Results Using Profile Projector

The writing of this study was conducted to measure the circle of variations of aluminum alloy 6061 with a diameter of 20mm, 25mm and 30mm, respectively the speed on the CNC frais engine is different, among others, low speed 500 Rpm, medium speed 700 Rpm and high speed of 1000 Rpm. In addition, the results of frais CNC 3 Axis machine are validated using Profile Projector measuring tool that has a higher accuracy rate compared to other measuring instruments.The purpose of the study was to determine the effect of CNC engine speed with low, medium and high speeds on the dimensions of diameters of 20mm, 25mm and 30mm. and to find out the results of the deviation measure and accuracy of the hole work process by using frais CNC machine and Digital Caliper measuring instrument and Profile Projector.The result of this study was that the variation values of sample measurements using Varnier Caliper Digital and Profile Projector were heavily influenced by machine speed, and the result of the average deviation value was very pharmaceutical. Keywords: Measurement of aluminum alloy diameter 6061, frais CNC machine Results 3 Axis with speeds of 500, 700, and 1000 Rpm, with Profile Projector measurement

Understanding the effect of microstructural texture on the anisotropic elastic properties of selective laser melted Ti-24Nb-4Zr-8Sn

Due to their low Young's Modulus, high strength and suitability for additive manufacturing, non-toxic beta-type titanium alloys are emerging as next-generation biomaterials. We present novel experimental results that demonstrate significant variation of Young's Modulus with direction for selective laser melted (SLM) biocompatible Ti-24Nb-4Zr-8Sn (Ti2448). Grain orientation data for SLM-processed Ti2448 is measured using electron backscatter diffraction. By assuming the grain orientations are fixed relative to the axes of the SLM build machine, the measured grain orientation data is used to generate a detailed microstructural finite element model of the polycrystalline SLM-processed material. The computational model provides excellent predictions of the anisotropic properties of SLM-processed Ti2448, indicating that preferential grain orientations that form during SLM processing of Ti2448 cause the experimentally measured variation of the Young's Modulus. The results show that computational models are able to accurately predict the anisotropic Young's Modulus of polycrystalline materials, and, in the context of biocompatible Ti2448 show how to tailor the modulus of SLM components by choosing the build orientation.

Modified tool radius compensation in the Archimedes' spiral tool path for high speed machining of circular geometry

A key role in HSM (High Speed Machining) is played by the NC program code, which guides the tool along a programmed path without jumps in velocity and acceleration. The commonly used CAM (Computer Aided Manufacturing) software offers many operations for dynamic machining, but the generated code is difficult to edit. An alternative is to use parameterized technology cycles. Unfortunately, the circular pocket cycle available on the Siemens Sinumerik 840D controller was not designed for HSM machining. The purpose of the article is to program an Archimedes' spiral using modified tool radius compensation. The parametric NC code was implemented on the Siemens Sinumerik 840D controller as a technology cycle. The obtained trajectory of the tool meets the curvature continuity condition (C2 continuity). The algorithm uses 3 NC program blocks to define the spiral, regardless of its length. Tool positions are calculated directly by the interpolator during the tool's circular motion (G2/G3). Spiral step is achieved by an additional contour offset (OFFN function), and also by multiple repetitions of circles (TURN function). The change in the effective tool radius value during active tool radius compensation (G41/G42) moves the tool away from the contour along the length of the entire NC block. Several spiral programming variants that are used in cycles were analyzed to identify the feed rate drops at joining points between program blocks. During the process, the trajectory and feed rate were recorded using the Sinumerik Trace function. A problem with the Siemens Sinumerik controller was identified when machine axes exceed the acceleration limit. Synchronized actions were implemented to reduce the feed rate, with the acceleration and jerk limit that are specified in the part program being taken into account. The presented cycle, with the graphical user interface, highlights the potential for HSM milling. The conducted experiment shows the need to supplement the Siemens Sinumerik controller with Archimedes' spiral interpolation. New technology cycles will increase productivity and open up new possibilities, such as tapered threads milling.

An integrated trajectory smoothing method for lines and arcs mixed toolpath based on motion overlapping strategy

Smoothing the discretized toolpaths generated by CAM systems is vital for CNC options in improving the quality of machined surfaces. One discretized toolpath from CAM is commonly represented in the form of a series of linear and arc segments. The linear segment smoothing method has been extensively investigated. However, for linear and arc joint segments, which are in the form of G01 and G02/03 mixing modes, efficient smoothing strategies are still lacking. In this study, an integrated toolpath smoothing method based on motion overlapping strategy is proposed to improve the continuities of the mixture of G01 and G02/03 codes. To satisfy the requests of the kinematic limitations and high efficiency, heuristic algorithms are used to seek optimum kinematic parameters. Meanwhile, we also introduce a variable jerk-limited feedrate profile in the motion overlapping strategy to further reduce the machining time. Simulations on various toolpaths are performed to validate the effectiveness of the proposed method compared with the classical FIR and B-spline methods. The machining experiment executed on a 3-axis machine tool with a real-time CNC system also demonstrates the applicability of the proposed method.

Hierarchical design, dimensional synthesis, and prototype validation of a novel multi-spindle 5-axis machine tool for blisk machining

Hierarchical design, dimensional synthesis, and prototype validation of a novel multi-spindle 5-axis machine tool for blisk machining

Five-Axis Trochoidal Sweep Scanning Path Planning for Free-Form Surface Inspection

Freeform surface inspection is a vital process in manufacturing, and the newly emerged five-axis continuous sweep scanning technology is one of the most efficient and accurate means for free-form surface inspection. The key in employing the five-axis inspection technology is to plan an effective and efficient sweep scanning path respecting both the inspection surface and the properties of the inspection device. Current sweep scanning paths suffer from the oscillating pattern that forces the high-speed stylus of the five-axis inspection device to swing back and forth frequently, which imposes excessive kinematic loading on the probe head, and in turn, undermines the inspection stability and efficiency. In this paper, we present a new trochoidal sweep scanning path for freeform surface inspection. The proposed method is novel in that the generated inspection path is a smooth trochoidal-shaped curve on the surface without causing any oscillation during a sweep scanning process. The kinematic performance of the probe head is significantly improved, which enables much better inspection stability and efficiency. Both computer simulation and physical inspection experiments of the proposed method have been conducted, whose results convincingly validate the feasibility and superiority of the proposed trochoidal sweep scanning path over the traditional oscillating sweep scanning path in terms of inspection stability and efficiency. Note to Practitioners—This work is motivated by the high requirements on the stability and efficiency of the newly emerged five-axis sweep scanning technology for freeform surface inspection. A novel trochoidal sweep scanning path is generated to make the original heavy-loaded rotary axes of the five-axis inspection machine move smoothly without needing frequent acceleration and deceleration as suffered from a traditional five-axis oscillating sweep scanning path. The kinematic loads of the five-axis inspection device are significantly reduced based on the proposed sweep scanning path; thus, the inspection machine could afford a higher sweep velocity of inspection, and the inspection stability and efficiency could be improved considerably as well. Compared with a traditional oscillating sweep scanning path, in our tests, the proposed method can improve the inspection efficiency by more than 20%, while the maximal kinematic loads (e.g., the velocity and jerk of the C-axis) can be reduced by 55%-85%. With superior inspection efficiency and stability, the proposed trochoidal sweep scanning path can be utilized for accurate and efficient inspection of large freeform surfaces like those in the aerospace and automotive industries.

PERANCANGAN 3D PRINTING CARTESIAN BERBASIS FUSED DEPOSITION MODELLING DENGAN UKURAN 200 X 200 X 200 mm

The technology of adding manufacturing or 3D printing is one of the main issues in the concept of technology 4.0. The construction design of the 3D printing machine and the deflection of its construction significantly affect the accuracy of the dimension and shape the printed product. The study aims to obtain a construction design of a cartesian type 3 D printing machine based on fused deformation modelling, and to verify the maximum value of the deflection of the machine axis. The study method used VDI222, calculation analysis, and Finite Element Analysis (FEA) simulation using CAE Solidworks software to verify the strength and deflection of the machine design construction. The study results show the construction design of 3D printing machine has been obtained according to the requirement. The verified maximum deflection value is 0.036 mm, hence the maximum error in the dimensions and shape of the printed product for each layer will still be within the standard tolerance. In addition, its maximum deflection value is verified within the radial clearance value of each determined machine axis bearing.

Efficient compensation method of 5-axis machine tools based on a novel representation of the volumetric error

Efficient compensation method of 5-axis machine tools based on a novel representation of the volumetric error

Perancangan dan Pembuatan Prototype Mesin CNC Laser Engravir Dengan Mikrokontroler sebagai Komunikasi Wireless

To support the creative economy, creative ideas are needed which are then transformed into concrete reality. One of the concrete creative ideas is art craftsmen, for example, painting, sculpture, three-dimensional art, sculpture and many more. The promising craft today is the souvenir craft, which has various forms and functions. In this research, the authors specialize in the craft of engraved souvenirs where most of these craftsmen still work on their crafts using conventional media. The purpose of this research is to design and manufacture a prototype CNC Laser Engraver machine with a microcontroller with wireless data communication which is expected to help improve the quality of the production of souvenir craftsmen. The method used is an experimental method in the form of designing, manufacturing and testing the mechanical work of each linear axis of the CNC Laser Engraver machine. With this research it is hoped that a control system scheme for a prototype CNC Laser Engraver machine can be obtained, to be applied to a real CNC Laser Engraver machine. From the results of testing this machine prototype, some data was obtained, namely a machine with three axes of motion, a microcontroller for wireless communication, a laser module with a diode capacity of 1000 mW and a maximum work area of 38 mm x 38 mm x 20 mm, which can help small industries and businesses. small and medium enterprises in the production process of various forms of creative carvings for various materials

In the Right Gear

Subcontractor Sovereign Gears Ltd has invested in its machining with the addition of a 5-axis machining centre

Characterization and uncertainty analysis of volumetric error variation with temperature

An artefact-based fast and automated volumetric error mapping solution for medium size 3-axis machine tools that enables the calibration of a 1m3 workspace in less than 1 h is proposed for characterizing how temperature variations affect the volumetric accuracy of the machine without a priori knowledge of the temperature variations. A continuous measurement during seven days is performed on a machine affected by different heat sources and a volumetric error variation model is identified. Residual errors remaining from the identification process are used to estimate the uncertainties of individual parameters and motion errors, and Monte Carlo simulations are used to propagate them to the TCP. This model is used to understand how the volumetric positioning error of the machine changes over time and how it is generated within the kinematic chain of the machine.

Straightness Geometric Error Assessment for CNC Milling Machine

The straightness movement error of the machine tools axis contributes significantly to the straightness of the workpiece machining feature. This paper focuses on the assessment study of CNC machine tools’ straightness geometric error for obtaining recommendation information to improve machine geometric accuracy. A research method by determining measurement parameters according to ISO 230 procedure, no-load measurement of straightness vertical-horizontal geometric error using a laser interferometer, collecting data, data analysis. Data analysis calculates positional straightness deviation, mean positional deviation, systematic positional deviation, repeatability, and accuracy of straightness movement for each machine axis, and generating error compensation values for improving machine geometric error. The travelled distance of the X, Y, and Z-axis CNC milling machine tested is about 1100 mm, 560 mm, and 520 mm. The assessment result shows mean deviation straightness horizontal of X, Y, and Z-axis is 4.14 μm, 3.41μm, and 0.95 μm. The mean deviation straightness vertical of X, Y, and Z-axis is 3.75 μm, 2.63 μm, and 2.30 μm. Finally, the assessment outcome is generating error compensation values of each axis. It could be recommendation information for setting back error compensation parameter on CNC controller, hence the mean deviation of straightness geometric error machine tools to be less than 1 μm.

Measurement and identification of translational static stiffness in workspace of a machine tool

This work presents a measurement for the identification of translational quasi-static stiffness of machine tool using Stiffness Workspace System (SWS). The novelty of this work is a significant modification of the SWS. The changes in measurement procedure and data analysis as well as new technical solutions are described in detail. A methodology for generalised translational static stiffness determination is presented. The major purpose of this paper is to provide the information about quasi-static stiffness values that characterise a typical machine tool. The measurement procedure is implemented in a case study on a 5-axis machining centre. Measurement results were used to determine the generalised translational stiffness indicators of points in the workspace. Then, the static stiffness distribution on the XY plane over machining space was estimated. The obtained results confirm the importance of analyses of static stiffness distribution as they point out areas where some possible changes occur. In the conclusion of the paper the utility value of the information of translational static stiffness is emphasised.

A novel surface residual stress monitoring method based on the power consumption of machine tool: A case study in 5-axis machining

The machining-induced residual stress significantly influences the service performance of machined parts and should be well monitored. However, the direct measurement method is time-consuming and only can be conducted after machining. Meanwhile, the existing prediction method rarely considers the effects of real-time factors on the machining parameters and cannot meet the requirement of online residual stress monitoring. Therefore, a novel surface residual stress monitoring method is proposed based on the easily measured online factor (power consumption of the 5-axis machine tool is used in the paper). Firstly, the power consumption of the machine tool (Pt) is used to model the mean effective cutting power (Pe¯). Secondly, the relationship between the surface residual stress in the feed direction (Rsx) and Pe¯ is established. Thirdly, Rsx is predicted based on Pt by combining these two models. Finally, a novel surface residual stress monitoring method based on Pt is proposed. The effectiveness of the proposed method is validated by various experiments, and the mean prediction error rate is only 9.5 %. From the case study, when the power consumption of machine power increases at a fixed spindle speed, Rsx changes from tensile stress to compressive stress. It provides a new method and platform for controlling the surface residual stress and greatly benefits the high-performance manufacturing of complex parts.

CAM model parameterisation methodology and its further unification in Siemens NX environment

The paper describes the methodology of mathematical CAD model parameterisation for the subsequent development of the control program (CP) in Siemens NX 2206, which allows in the process of changing the parametric CAD model to adapt not only the 3D model, but also to rebuild the control program, thereby significantly reducing the time for CP development. The application of methods of parametrisation of models in the article is shown in an example of simulators of blades of 3 stages. As a result, a parametric CAD model of the blade simulator, tooling for the product installation on the machine tool, for 3-axis CNC milling machining, automatically changing for each stage of the simulator were developed. A simulator manufacturing process based on the parametric model was developed and successfully implemented. The report formulated the basic provisions and rules for the design of single-type models for the subsequent development of universal control programmes for CNC machines.

Intelligent feedrate optimization using a physics-based and data-driven digital twin

Intelligent manufacturing machines envisioned for the future must be able to autonomously select process parameters that maximize their speed while adhering to quality specifications. Accordingly, this paper proposes a framework and methodology for using a physics-based and data-driven digital twin of a feed drive to maximize feedrate while respecting kinematic and contour error limits. To correct for inaccuracies introduced by unmodeled dynamics and disturbances, the data-driven model is updated on-the-fly using sensor feedback. Experiments on a 3-axis CNC machine tool prototype are used to demonstrate up to 35% cycle time reduction without violating error tolerances compared to the status quo.

A modeling study of grinding force for axial feed machining of Si3N4-diamond grinding wheel endface based on specific chip energy

A modeling study of grinding force for axial feed machining of Si3N4-diamond grinding wheel endface based on specific chip energy

A modelling study of grinding force for axial feed machining of Si<SUB align="right">3N<SUB align="right">4-diamond grinding wheel end-face based on specific chip energy

A modelling study of grinding force for axial feed machining of Si<SUB align="right">3N<SUB align="right">4-diamond grinding wheel end-face based on specific chip energy

Drives’ stiffness of 5-axis machine designs: Evaluation and comparison by Schur complement eigenvalues

Drives’ stiffness of 5-axis machine designs: Evaluation and comparison by Schur complement eigenvalues