Multi-axis Machine Research Articles

A Method for Generating Toolpaths in the Manufacturing of Orthosis Molds with a Five-Axis Computer Numerical Control Machine

This paper proposes a new algorithm for the automatic generation of toolpaths for machining complex geometric positions, such as molds used in orthosis production. The production of individualized orthoses often requires the use of multi-axis machining systems, such as five-axis machines or industrial robots. Typically, complex and expensive CAD/CAM systems are used to generate toolpaths for these machines, requiring the definition of a machining strategy for each surface. While this approach can achieve a reliable and high-quality machining process, it is very time-consuming and makes it challenging to meet the criteria for rapid production of orthopedic aids. Given that their production is a custom-made process using individual shapes as inputs, the toolpath generation process becomes even more demanding. To address these challenges, this paper proposes an algorithm suitable for the automatic generation of toolpaths for such complex positions. The proposed algorithm has been tested and has proven to be robust and applicable.

Deep learning-based topology optimization for multi-axis machining

This paper presents a novel framework that integrates topology optimization (TO) and deep learning (DL) to generate high-performance structures suitable for multi-axis machining. Within the proposed framework, DL is built on the pix2pix network, with the conditional channel used to determine the tool shape and feed direction in multi-axis machining. This DL model will be trained using our own generated dataset on TO for multi-axis machining. Then, users can customize tool dimensions and machining orientations of the multi-axis machining operation and specify the design boundary and loading conditions as input. The DL model will rapidly generate a near-optimized structure, which subsequently serves as the starting point for further optimization. Ultimately, a topology-optimized structure that meets the tailored requirements is apt for multi-axis machining and can be finalized with only a few iterations. 2D and 3D numerical examples for heat conduction problems are studied to prove the effectiveness of the proposed method, validating improved structural performance and optimization efficiency compared to conventional TO for multi-axis machining.

Simulation of Motion Nonlinear Error Compensation of CNC Machine Tools With Multi-Axis Linkage

In order to solve the problem of nonlinear error for a dual rotary table five-axis CNC machine tool due to the linkage of rotary and translational axes, the simulation of motion nonlinear error compensation for a multi-axis linkage CNC machine tool is proposed. The adjacent points in the tool position file are selected as the tool position points for building the model, and then the nonlinear error model resolved by the harmonic function is established according to the error distribution in the classical post-processing. The nonlinear error between the two tool position points is quickly predicted by the analytical expression of this model, and the real-time error compensation of the intermediate interpolation points is realized. Finally, MALTLAB simulation analysis is performed on the tool position file of an impeller part machining to verify the effectiveness of the proposed algorithm. The experimental results show that it can be seen from the distribution curve of the nonlinear error that it is about 10% after compensation as before compensation, thus verifying the effectiveness of the nonlinear error compensation mechanism. The correctness of the nonlinear error analysis and compensation method and the effectiveness of post-processing are verified.

Analysis of models of measurement and correction of volumetric error of three-axis metal-cutting machine tool

The paper considers the improvement of the quality of products of machined production in connection with the quality of machining of various products and, accordingly, with the accuracy of the equipment used. It is noted that geometrical errors, which account for up to 40 % of the total error of a multi-axis, especially three-axis, metal-cutting machine tool, have the greatest influence on the accuracy of product machining. In order to improve the quality of product machining, it is necessary to correct its parameters according to the measurement information received during machine tool operation, for which the methods of mathematical modelling are used. Models of the volumetric error of a three-coordinate metal-cutting machine tool are developed, taking into account the summands of the first (linear) and second (quadratic) order of smallness. A comparative analysis of the developed models is carried out. The results of experiments on measurement of volumetric errors of the STAN S500 complex and their correction on the basis of the nonlinear theoretical model are given. It is found that in the range of angular errors 0–2.5′ the consideration of quadratic terms of the model in addition to linear ones does not lead to a significant reduction of the volumetric error. It is shown that when processing measurement information of multi-axis metal-cutting machines it is sufficient to limit the consideration of components of the volumetric error not higher than the first order of smallness. The research results are useful for the acceptance and periodic control of the volumetric error of metal-cutting machines, as well as for the programme reduction of the volumetric error.

FRKVF: High-accuracy motion interpolation for polishing operations using fourth-order Runge-Kutta and velocity flexibility planning

Traditional interpolation algorithms often fail to meet the precision requirements of ultra-precision machining when applied to super-precision polishing machines. Moreover, the processing of fused silica glass optical components is frequently threatened by mechanical impacts due to their fragility. In order to address this issue, this paper proposes a high-precision motion interpolation method based on fourth-order Runge-Kutta and velocity-flexible planning. This method is designed for open-architecture small multi-axis optical polishing machines to polish quartz glass. The algorithm initially employs composite Simpson's rule to calculate the lengths of sub-paths within the polishing trajectory. Based on these length values, flexible velocity planning is executed to ensure the smooth continuity of velocity, acceleration, and jerk during motion interpolation. This reduces the risk of mechanical impacts that could damage the components during the machining process. The introduction of the adaptive fourth-order Runge-Kutta method significantly enhances the parameter point calculation accuracy of NURBS curves. The incorporation of adaptive principles also maintains a higher processing speed, thereby greatly improving processing efficiency. This method comprehensively addresses both the precision of curve interpolation and execution efficiency. Finally, experimental validation is conducted on an open-architecture small multi-axis optical polishing machine. The proposed method based on FRKVF not only mitigates mechanical impacts resulting from discontinuous acceleration, thereby ensuring the machining quality of optical components, but also satisfies the high-precision requirements for processing fused silica optical elements.

Chatter Stability of Orthogonal Turn-Milling Process in Frequency and Discrete-Time Domains

Abstract As the industry seeks better quality and efficiency, multitasking machine tools are becoming increasingly popular owing to their ability to create complex parts in one setup. Turn-milling, a type of multi-axis machining, combines milling and turning processes to remove material through simultaneous rotations of the cutter and workpiece with the translational feed of the tool. While turn-milling can be advantageous for large parts made of hard-to-cut materials, it also offers challenges in terms of surface form errors and process stability. Because tool eccentricity and workpiece rotation lead to more complexity in process mechanics and dynamics, traditional milling stability models cannot predict the stability of turn-milling processes. This study presents a mathematical model based on process mechanics and dynamics by incorporating the unique characteristics of the orthogonal turn-milling process to avoid self-excited chatter vibrations. A novel approach was employed to model time-varying delays considering the simultaneous rotation of the tool and workpiece. Stability analysis of the system was performed in both the discrete-time and frequency domains. The effects of eccentricity and workpiece speed on stability diagrams were demonstrated and validated through experiments. The results show that the tool eccentricity and workpiece speed alter the engagement geometry and delay in the regeneration mechanism, respectively, leading to significant stability diagram alterations. The proposed approach offers a comprehensive framework for the stability of orthogonal turn-milling and guidance for the selection of process conditions to achieve stable cuts with enhanced productivity.

Hybrid Path Generation Method for Multi-Axis Laser Metal Deposition of Overhanging Thin-Walled Structures.

Additive manufacturing has advantages over other traditional manufacturing technologies for the fabrication of complex thin-walled parts. Previous correlation path strategies, when applied to laser metal deposition processes, suffer from contour deposition transboundary and surface "scar" type overstacking. Therefore, this paper proposes a hybrid path generation method for the laser metal deposition process. First, the topological logic of the STL model of the part is restored to reduce redundant calculations at the stage of obtaining the layered contour. Then, the path points are planned on the basis of the offset contours in a helical upward trend to form a globally continuous composite path in space considering the melt channel width. Finally, vectors that adaptively fit to the model surface are generated for the path points as tool orientations and they are optimized by smoothing the rotation angles. The results of experiments conducted on a multi-axis machine equipped with a laser metal deposition module show that the path generated by the proposed method is not only capable of thin-walled structures with overhanging and curved surface features but also improves the surface imperfections of the part due to sudden changes in the angle of rotation while ensuring the boundary dimensions.

Integrated decision of production scheduling and condition-based maintenance planning for multi-unit systems with variable replacement thresholds

In practice, production scheduling and maintenance planning are two popular technologies that are interdependent, but they are most often performed independently. In this study, we have developed an integrated model for coordinating single-machine scheduling and condition-based maintenance planning. Firstly, we build upon existing scheduling research that often views the system as a whole and further consider the degradation and maintenance of multiple units within the system during the scheduling process. Secondly, in contrast to traditional degradation modeling which usually assumes a single threshold to trigger maintenance/replacement, we also consider the variability of replacement thresholds caused by the heterogeneity of scheduling tasks. Based on this foundation, we propose an integrated policy that considers both scheduling and condition-based maintenance. Furthermore, we have developed an integrated decision model for multi-unit systems. The model aims to minimize the total weighted expected completion time over the entire scheduling time horizon. Moreover, the genetic algorithm was employed to optimize the integrated model. Finally, we present an example of an SA adjustable multi-axis machine and conduct a sensitivity analysis of key parameters to validate the integration policy.

Full pose measurement system for industrial robots kinematic calibration based on a sensorized spatial linkage mechanism

This paper presents a low-cost pose measuring device capable of simultaneously measuring all six coordinates (3 translations and 3 rotations) of a rigid body with respect to a given reference frame. The proposed system consists of a mechanical chain of rigid bodies and two encoders. The mechanism is a spatial four-bar linkage system with a symmetrical Revolute-Spherical-Spherical-Revolute (RSSR) kinematic structure, where two encoders measure the rotation of the revolute joints. The mechanism is investigated theoretically and solved kinematically using a numerical estimation method. The uncertainty of the pose determination, caused by the repeatability of the sensors, is estimated, as well as the achievable measurement range. A low uncertainty is achieved by a suitable design of the proposed kinematic chain. The mechanism is easy to realize with low tolerances and the correct definition of the length of the links allows a quite large workspace. The system can be profitably used in the calibration of robots or multi-axis machine tools where the actual pose of the gripper or spindle must be measured over the workspace of the machine. An experimental prototype is described, and the first experimental results are reported.

Introducing a novel sheet test specimen for biaxial stretching under uniaxial loading

This paper introduces a novel sheet test specimen that plastically deforms under biaxial stretching when subjected to uniaxial loading in conventional testing machines. The specimen was designed using finite element simulation and consists of a two-dimensional reticular structure with interconnected arms in the form of triangles that converge at the center and are connected to full-width sheets at the specimen's ends. Accumulation of damage at the center is ensured through spherical cups that are milled at opposite sheet surfaces. Experimental strain loading paths obtained by digital image correlation confirm the capability of the novel sheet test specimen to provide biaxial stretching strain paths. This is achieved under friction-independent conditions and without requiring complicated multiaxial setups and machines, provided appropriate values of the inner and outer angles of the interconnected arms are used.

Multi-axis near-dry Electrical Discharge machining using inconel 718 alloy

ABSTRACT In the current research work, in-house developed and fabricated multi-axis near-dry Electrical Discharge Machine (near-dry EDM) has been used having different tool positions, i.e. tool electrodes in horizontal position (Case-I) and vertical positions (Case-II) as a novel machining techniques in hard-to-reach places and also to improve the process performance. Design of Experiment tool has been used with three process parameters: voltage, discharge current, and pulse-on-time for experimentation purposes. In order to maximize Material Removal Rate (MRR), it was necessary to compare and enhance these parameters in both cases, i.e. Case-I, and Case-II. The machining process is significantly influenced by the vertical tool positions, as indicated by the largest percentage contribution in the Analysis of Variance results. The voltage has the least influence, while the pulse-on time is relatively less. In contrast, for the horizontal tool position, the voltage proved the most prominent factor in terms of influence, while the current ranked second in significance. Conversely, the pulse-on time exhibited the least impact among the three factors. The highest MRR 2.45 mm3/min was achieved in the vertical tool position while in horizontal machining, the highest MRR 0.144 mm3/min was observed. These findings provide valuable insights into the multi-axis near-dry EDM with proposed methodology.

Accurate error compensation method for multi-axis parallel machine via singularized jacobi geometric parameter correction and coupling error evaluation

The Jacobian model is a prevalent tool for error compensation in multi-axis parallel mechanisms. However, discrepancies between the model's nominal and actual geometrical parameters, combined with equivalent replacements and high-order rounding in the modeling process, lead to equation solving challenges and modeling errors. These inaccuracies result in residual errors in the Jacobian model compensation. To address these problems, this paper proposes an optimal Jacobian correction approach. This is based on a geometrical parameter singularized Jacobian correction model, and a module for the evaluation of coupling errors for multi-axis parallel mechanisms was incorporated. Instead of relying on iterative processes, a singularized geometrical error solution method (SESM) was developed. Through this method, precise derivation of the Jacobian correction parameters is ensured, effectively addressing the indefinite equation challenge and partial posture non-solution problem. Moreover, modeling errors resulting from equivalent infinitesimal replacements and the overlooking of high-order minor values are compensated for by the SESM. It was observed that varying singularized geometrical parameters in the Jacobian model can produce different coupling effects and compensation outcomes. Therefore, a sensitivity-based error predictive evaluation method (EPEM) was introduced. By this method, the optimal correction parameter of the Jacobian model across the entire workspace is identified, ensuring precise pose error compensation. The proposed method was validated using a three-axis parallel mechanism. Through these tests, its superior efficacy was revealed. In comparison to the traditional uncorrected Jacobian compensation, reductions in position and orientation errors by 64.93% and 55.29%, respectively, were achieved. This method provides a new approach for error modeling, equation solving, and parameter correction for multi-axis mechanism error compensation and precision equipment development.

Enhancing machining efficiency of Ti-6Al-4V through multi-axial ultrasonic vibration-assisted machining and hybrid nanofluid minimum quantity lubrication

Ti-6Al-4V offers a balance of good strength with lightweight properties. Yet, Ti-6Al-4V poses machining challenges, including low thermal conductivity, chemical adhesion to cutting tools, and chip removal difficulties. To improve machining efficiency, Ultrasonic Vibration-Assisted Machining (UVAM) has emerged as a promising approach. UVAM has demonstrated reduced tool wear, cutting forces, and improved surface quality compared to Conventional Machining (CM). Additionally, Minimum Quantity Lubrication (MQL) methods offer sustainable coolant alternatives, with recent research focusing on Nanofluid-MQL (NMQL) and Hybrid Nanofluid-MQL (HNMQL) for enhanced performance. Although there exists a body of literature showcasing the promising effects of UVAM and MQL methods individually, comprehensive investigations into the synergistic effects of these methodologies remain limited. This study addresses these critical research gaps by conducting a systematic examination of combined application of multi-axial UVAM and HNMQL. Specifically, it delves into the comparison of different vibration directions within UVAM, evaluates the effectiveness of UVAM when combined with cutting fluids incorporating Al2O3 and CuO nanoparticles in NMQLs and HNMQLs, and contrasts these novel approaches with conventional machining methods. The study unfolds in three distinct stages. The first stage examines the ultrasonic cutting mechanism and its combined application with the MQL technique. In the second stage, the study investigates the physical properties of the cutting fluids, including contact angle and surface tension. The final stage encompasses slot milling operations, where an array of parameters such as cutting forces, surface roughness, surface topography, surface texture, and the occurrence of burr formations are rigorously analyzed. The results demonstrate that the combination of multi-axial UVAM with HNMQL yields substantial advantages over traditional machining methods. Notably, it leads to a remarkable reduction in cutting forces (up to 37.6 %) and surface roughness (up to 37.4 %). Additionally, this combination engenders the production of highly homogeneous and uniform surface textures, characterized by minimal surface defects and a significantly diminished occurrence of burr formations. These findings underscore the potential of multi-axial UVAM combined with HNMQL as a promising approach in enhancing the machining of Ti-6Al-4V, thus offering a pathway to enhance the efficiency and precision of aerospace component manufacturing processes.

Multi-axis CNC finishing and surface roughness prediction of TC11 titanium alloy open integral micro impeller

The titanium alloy open integral micro impeller has a strong material strength and high removal rate in the field of multi-axis CNC machining. The flow channel is tiny and the blades are thin and highly twisted. It is difficult to control the surface accuracy and prone to overcutting and undercutting. The NX2212 software post-processing module plans two distinct blade finishing process routes and verifies them using virtual machine tool simulation, taking into account the technical challenges of micro impeller machining. Following verification, the tool path machining code is imported into MATLAB for data fitting. The workpiece surface working condition is determined based on the simulation findings, the blade surface roughness value is calculated, and a physical simulation model of blade finishing is created in the finite element analysis software. The outcomes demonstrate how well the “segmented and sub-regional cutting” processing method may raise blade accuracy. The leading and trailing edges of the blade both had surface roughness increases of 4.86% and 4.19%. The surface morphology of the micro impeller is measured using a white light interferometer, and it is CNC machined using two distinct process methods. The findings demonstrate that there is a significant difference between the value calculated by the finite element analysis software and the surface roughness value measured experimentally which together make up less than 5%. An investigation of the impact of cutting parameters on the surface roughness of micro-structure components is carried out using a three factor, three-level BBD experiment that is founded on the second-order response surface method. The findings indicate that the feed per tooth influences surface roughness more significantly than cutting depth and cutting speed for a reasonable range of cutting parameters; Surface roughness will rise with lower or higher cutting speeds; Raising the feed per tooth and the cutting speed simultaneously may reduce surface roughness; Surface roughness can be accurately predicted and controlled using the second-order response surface method.

Моделирование скругления острых кромок наклонных охлаждающих отверстий лопаток турбин методом электроэрозионного фрезерования на многоосевых станках с ЧПУ

The article views efficiency improving issues, quality and accuracy of sharp edge smoothing for numerous angular fans in the turbine blades of gas turbine engines made of heat-resistant nickel alloys and used in modern growing passenger aviation transport based on the development of ED milling new technology for modern multi-axis CNC machines with a rotating hollow electrode and a high-pressure fluidsupply of a special flush through the electrode body. An automated process for sharp edge machining has been developed for the production of more than 200 differently placed angular fans with a diameter of 0,45…0,6 mm in one blade instead of labor-intensive manual benchwork, where various needles, abrasive and metal rotary files are used. It is found that modeling and the development of special software resulted in a uniform radius of smoothing with high accuracy due to automatic ED milling operation along the entire trailing edge of each angular hole in the turbine blades at a multi-axis machining electro discharge center. The use of a rounded edge of the outlet ports provides more efficient cooling of the turbine blades and higher performance of gas turbine engines. At the same time, it is found that with a significant efficiency improving in blade sharp edge machining, a higher quality of the rounded edge surfaces in the holes is ensured. The results of the conducted research are recommended for the adoption of technologies in the aircraft engine industry.

Fast extraction of cutter-workpiece engagement for milling force prediction in multi-axis machining

The paper proposes a fast extraction method for cutter-workpiece engagement (CWE), which greatly facilitates the milling force prediction during multi-axis machining. One of the key cores of the method is to reconstruct the nearby cut-off material of workpiece using a set of past neighboring cutter location points (CLPs), and obtain the CWE entity through local Boolean operation among the current tool, workpiece blank, and reconstructed entity. Moreover, by performing 2-dimensional (2D) image mapping, the engagement boundary of CWE entity will be quickly obtained. Combining with the analytical formula of instantaneous undeformed chip thicknesses (IUCTs), the composite IUCT for tool side and bottom cutting edges during actual immersion is further derived. Finally, accurate and fast prediction of milling force with consideration of tool attitude, corner feature and bottom cutting effect is achieved. The results reveal that the method can predict milling force with an excellent performance of first-order computation complexity.

Determination and Analysis of Working Diameters and Working Angle of the Torus Cutter Blade in Multi-axis Machining in the Aspect of Tool Wear

The aim of this study is to provide a theoretical and experimental analysis of the multi-axis milling process by the torus milling cutter of nickel-based superalloy parts in terms of surface quality and tool wear. In the analytical part, using, among other things, matrix calculus and trigonometric relationships, mathematical models were developed to describe the relationships between the tool axis orientation and the geometric parameters of the cutting layer at the contact point. On this basis, mathematical relationships for contact diameter and effective diameter were derived. The basis for these considerations is the very rarely considered working angle of the cutter blade. In part of the experimental study, machining tests were carried out for selected kinematic variants of multi-axis cutting. Based on the results obtained, it was found that as the tool axis inclination angle increases, the contact diameter increases. The effective diameter at the upper characteristic point of the cutting layer increases up to a certain angle of inclination, after which it begins to decrease. The rotational angle of the tool axis does not affect any of the diameters, but it does affect the displacement of the contact point, the values of the working angle of the tool blade and the feed-related component decrease. The result of this displacement is a change from climb milling to conventional milling, which has significantly degraded surface quality and tool life. The best results of the machining test were obtained when only the angle of inclination of the tool axis was used. It was concluded that the parameter tool blade working angle can be a control variable in a multi-axis milling process and has a major impact on the physical aspects of the cutting process.

Construction and Implementation of an Integrated Teaching Model for CNC Lathe, CNC Milling, and Multi-Axis Machining

Construction and Implementation of an Integrated Teaching Model for CNC Lathe, CNC Milling, and Multi-Axis Machining

Mathematical modeling and simulation of generation milling process to manufacture complex face gear surface through multi-axis machine kinematics

Manufacturing of face gear is a complex process, due to its varying geometry, hence the application is not wide as conventional gear geometry. The developments in analytical tools and kinematics of the CNC machine tools motivate researchers to explore the manufacturing process and associated applications. This article presents an efficient method for the generation milling of spur face gear utilizing a nutating head multi-axis CNC machine tool where the tool swings about an arbitrary axis in an inclined plane. The mathematical model of the disk milling cutter and face gear geometry were derived from the shaper geometry by applying the theory of gearing, equation of meshing and coordinate transformation. The cutter location (CL) data was evaluated by aligning the tool orthogonal unit vector and the tooth surface normal vector at the contact point by calculating the appropriate transformation matrices. The evaluation of machine coordinates on a multi-axis CNC milling machine was analyzed with respect to the machine pivot point and the axes movement during generation milling for the face gear drive was studied on the nutating head machine. The NC data is derived from the CL data using the inverse kinematics and the machining simulation was carried out using suitable software. The tooth surface deviation of a maximum of 43.5 μm was observed between the simulated model and the theoretical model, which is well within the requirement of roughing. The generation milling process with the proposed machine configuration is concluded as a profound face gear manufacturing technique.

Research on CNC programming and machining process based on CAD/CAM technology

Abstract Focusing on CNC process data, this paper provides an in-depth analysis, characterization and mining of macro machining processes by associating CAD and CAM models. The article introduces a Bayesian inference method to construct an association relationship between the manufacturing features of the query part and the macroscopic process of the manufactured part, which avoids the need for a direct similarity comparison between the geometry of the query part and the part to be manufactured. In addition, the study calculated the overall similarity between the query part and the CNC programming process data instances through the guidance of the process skeleton, thus realizing the precise evaluation from the CNC programming perspective. The algorithm for generating tool trajectories in multi-axis CNC programming is analyzed. By selecting representative surfaces and performing tool processing calculations, this study explores the process planning and tool parameter selection of usual parts of surfaces in multi-axis CNC programming machining. It optimizes the nonlinear error in tool trajectory processing by combining CAD/CAM technology. The results show that the optimized process proposed in this paper significantly improves the machining efficiency by 36.94%. In the cutting at tool corners, the maximum cutting force generated by the optimized machining process is only 190.3N, which is only 67.2% of the leading cutting force of the Cimatron process. In addition, when the engagement frequency is 780 Hz, the optimized process proposed in this paper has the smallest vibration amplitude, which is only 21.4% of the Cimatron strategy. Therefore, this study significantly improves the machining efficiency while ensuring the machining quality, which has important practical application value.