符合阿贝原则的数控机床几何误差建模

为提高现有数控机床空间误差分析方法的准确度,本文基于阿贝原则对齐次转换矩阵(HTM)几何误差补偿模型进行优化。首先,推导出XYFZ型三轴机床适用的HTM几何误差补偿模型并给出模型正确使用的前提条件;然后,基于阿贝原则分析了三轴机床的空间误差传递机理,指出阿贝误差对机床定位精度的影响,给出理论计算公式并在机床运动轴上进行实验验证;最后,基于阿贝原则和布莱恩原则对现有的HTM几何误差补偿模型进行优化,采用该模型拟合体对角线空间误差,并与实测机床体对角线误差进行对比验证。现有HTM几何补偿模型可将机床空间误差由41.15μm补偿至16.37μm,补偿率为60.22%;优化后的补偿模型可将机床空间误差补偿至5.32μm,补偿率为87.07%,提高了26.85%。实验结果表明,优化后的补偿模型更加合理,进一步改善了空间误差的补偿精度。     

Local toolpath smoothing for five-axis machine tools

When five axis CNC machine tools follow series linear toolpath segments, the drives experience velocity, acceleration and jerk discontinuities at the block transition points. The discontinuities result in fluctuations on machine tool motions which lead to poor surface quality. This paper proposes to insert quintic and septic micro-splines for the tool tip and tool-orientation, respectively, at the adjacent linear toolpath segments. Optimal control points are calculated for position and orientation splines to achieve C³ continuity at the junctions while respecting user-defined tolerance limits. The geometrically smoothed corners are traveled at a smoothly varying feed with cubic acceleration trajectory profile. The proposed method is experimentally demonstrated to show improvements in motion smoothness and tracking accuracy in five-axis machining of free-form surfaces found in dies, molds and aerospace parts.     

A new approach to contour error control in high speed machining

High speed machining technology attempts to maximize productivity through the use of high spindle speeds and axis traverse rates. The technology is dependent upon the development of suitable mechanical hardware, electrical drives and associated control software to ensure that all components are used to maximum advantage. The role of the control software is particularly demanding since one needs to maximize traverse rates while providing the necessary accuracy, and indeed providing a margin of safety to deal with unexpected changes in process, or system parameters. There have been relatively few improvements in commercial CAD or CAM systems that would help machine tool users to take maximum advantage of high speed machining; rather the majority of the approaches have been undertaken at the machine tool controller level. This paper uses circular interpolation and corner tracking to compare several such control techniques, (Cross Coupled Control (CCC), Zero Phase Error Tracking Control (ZPETC), and Realtime Frequency Modulated Interpolation (FMI)), each of which have been proposed in the literature order to improve machining accuracy. None of these approaches are found to be universally successful when used alone and the authors, in this paper, examine the use of these systems in combination. Particular attention is focused upon an extension of a simplified version of cross coupled control together with Frequency Modulated Interpolation. It is shown that the combined system performs extremely well, and is easily actuated at high frequencies with conventional hardware. A custom built high speed x-y table is used to confirm system performance with multiple constraints present.     

基于模糊故障树的数控龙门铣床加工误差分析与试验

针对数控龙门铣床加工中出现的平面度误差问题进行研究与改进,分析工艺系统因素产生的误差,建立加工平面误差的模糊故障树,通过下行法对其进行简化分析,定性分析影响加工平面度误差的最小割集,运用模糊隶属函数定量分析顶事件的发生概率及底事件的发生概率重要度,确定主要因素为工作台形位误差、定位元件误差、热变形等。使用激光测量技术对安装的工作台平面进行矩形布点测量,根据采集数据建立基于最小二乘法的数学模型,运用Matlab软件定性分析平面度的评定,并对超差区域进行改进,最终实现了机床装配与使用要求。     

基于模糊数和AHP的数控机床可靠性分配方法

针对层次分析法(AHP)处理可靠性分配问题时存在的局限性,将直觉梯形模糊数与层次分析法相结合,提出了一种新的数控机床可靠性分配方法。在确定影响机床可靠性分配的重要因素种类及分配原则后,利用层次分析法确定数控机床可靠性分配问题的层次模型和可靠性分配中影响因素的重要性权重。运用直觉梯形模糊数准确表达出模糊信息和专家意见,最终确定子系统在可靠性分配中的分配比例。以一数控机床为例,通过和层次分析法进行对比,证明了该方法的有效性。     

Exploration and design of knitted composites for architectural application: The MeiTing project

Knitted composites are textile composite materials that consist of knitted textile reinforcement and polymer matrix. Knitted composites exhibit great design flexibility by allowing the customization of shapes, textures, and material properties. These features facilitate the optimization of buildings’ material systems and the creation of buildings with light weight and high material efficiency.To achieve such a lightweight, material-efficient building structure with knitted composites, this research investigates the material properties of knitted composites and proposes a design process for building-scale knitted composite systems. In the material study, this research examines certain mechanical properties of the material and the effects of additional design elements. In the design exploration, this research explores the design workflow of the structural form, element arrangement, and knit distribution of the material system at the macro-, meso-, and microscales. The project of MeiTing serves as proof of the concept and the design workflow.     

Analysis of Frequency,Intensity, and Interference of Discomfort in Computerized Numeric Control Machine Operations

The introduction of Computerized Numeric Control (CNC) technology in manufacturing industries revolutionized the production process a few decades back. There are some health and safety problems associated with these machine operations, however. The main objectives of the present work is to study the health and safety issues associated with the CNC machines with respect to control and display, specifically to determine the frequency, intensity of discomfort, and its interference in operating different CNC machines as reported by the workers operating them. The postural discomfort associated with CNC machines was studied, and the frequency, intensity of discomfort, and interference of the level of discomfort with the participants' ability to work were recorded and analyzed. The study revealed that 20.5% of the operators reported discomfort 1 or 2 times, 25.4% experienced discomfort 3 to 4 times in a week, 37.7% had discomfort daily, and 16.4% reported discomfort several times a day. Discomfort was reported in all the body parts involved (lower back, neck, upper back, shoulder, and leg), but the highest discomfort scores were associated with the shoulder and arm region. Workers reporting discomfort several times a day also reported high mean discomfort scores. The study established that the frequency and intensity of the discomfort in all body parts is related to the position of the control panel and display. © 2012 Wiley Periodicals, Inc.     

数控加工编程及修改的注意事项

对数控加工编程中容易出现的一些问题进行具体分析,并提出了相应的对策。强调数控编程并不是单一的纯编程,还应结合实际加工的具体情况进行考虑,才能真正发挥数控加工的高效率和高精度等特点。     

数控车床进给驱动系统的设计

介绍了数控机床进给伺服系统的组成和分类,重点对合肥中宝机械制造有限公司的一台S1系列数控机床进行改造,选用了合肥工业大学的GL2000数控系统,配置了安川伺服电机和驱动器,整个系统运行可靠,达到预期的设计改造要求。