Development of Virtual Simulation System for Remote Collaborative Surface Machining

1 Introduction Many parts of aerospace ,automobile and mold industries are high precision and complex-shaped. There-fore ,it needs multi-axis machining. Multi-axis machining has advantages of i mproving efficiency and surfaceprecision,reducing production expense and shortening ti me to market . Although there are many advantages inmulti-axis machining,there are many steps on process planningfor complexsurface .And every step needs engi-neers to make appropriate decisions by their professional…     

Smoothness-oriented path optimization for robotic milling processes

Industrial robots are increasingly used for five-axis machining operations, where the rotation of the end effector along the toolaxis direction is functionally redundant. This functional redundancy should be carefully resolved when planning the robot path according to the tool path generated by a computer-aided manufacturing(CAM) system. Improper planning of the redundancy may cause drastic variations of the joint motions, which could significantly decrease the machining efficiency as well as the machining accuracy. To tackle this problem, this paper presents a new optimization-based methodology to globally resolve the functional redundancy for the robotic milling process. Firstly, a global performance index concerning the smoothness of the robot path at the joint acceleration level is proposed. By minimizing the smoothness performance index while considering the avoidance of joint limits and the singularity and the constraint of the stiffness performance, the resolution of the redundancy is formulated as a constrained optimization problem. To efficiently solve the problem, the sequential linearization programming method is employed to improve the initial solution provided by the conventional graph-based method. Then, simulations for a given tool path are presented. Compared with the graph-based method, the proposed method can generate a smoother robot path in which a significant reduction of the magnitude of the maximum joint acceleration is obtained, resulting in a smoother tool-tip feedrate profile. Finally, the experiment on the robotic milling system is also presented. The results show that the optimized robot path of the proposed method obtains better surface quality and higher machining efficiency, which verifies the effectiveness of the proposed method.     

自由曲面五轴数控加工刀具定位研究

本文为五轴数控机床曲面数控加工刀具位置和方向的确定提出了一种新方法。此方法利用局部曲面曲率和刀具几何形状进行分析。基于这些局部属性的匹配来选择最佳刀具轴向以清除加工过切误差或控制误差在指定公差范围内。     

基于S试件的AC双转台五轴数控机床加工 精度检测联合仿真

为了深入研究高档数控机床的加工精度检测机理,利用Adams和Matlab/Simulink软件平台对AC双转台五轴联动数控机床加工S试件的运动过程进行联合仿真。首先搭建了机床的机械系统和控制系统模型,然后将整机机械模型的6个输入变量和12个输出变量通过Adams/Control模块分别与Simulink建立的控制模型进行对接,完成系统输入、输出的设置,从而实现整机机电耦合的联合仿真。仿真结果表明五轴机床在加工S试件过程中各个轴的运动都呈非线性变化,与工程实际经验相符。     

基于蒙特卡洛模拟的机床关键几何误差溯源方法

为了溯源对加工误差影响最大的机床几何误差,提出了一种基于蒙特卡洛模拟的灵敏度分析方法.运用多体系统理论建立五坐标龙门加工中心加工误差生成模型,并建立了S形样件的直纹面数学模型.推导刀具轨迹到切削点的映射关系,建立了切削曲面模型.根据蒙特卡洛模拟采样机理,对机床加工误差模型进行全局灵敏度分析,获得影响机床加工误差的关键几何误差参数.按照灵敏度分析结果排序,获得影响z向加工误差最大的5项几何误差参数为δ_z(x)、δ_z(y)、δ_z(z)、δ_z(c)、δ_z(b).实验结果表明:5项关键误差参数共同作用对分析区域平均z向加工误差的影响度达88.2%,5项误差参数对机床z向加工误差影响最大,可以为提高五坐标机床的加工精度和设计精度提供指导.     

基于狮群算法的数字孪生车间调度问题优化

针对柔性作业车间调度问题,提出一种基于狮群算法的数字孪生柔性作业车间调度方法。基于实际生产过程的需求,使用狮群算法生成柔性作业车间调度初始方案,建立物理车间与虚拟车间实时交互的数字孪生柔性作业车间调度模型,在搭建的虚拟车间中对初始调度方案根据设备利用率进行方案优化。采用数字孪生模型解决设备故障等车间突发事件对生产进程的影响问题。通过使用真实车间数据对机加工车间生产调度过程试验,结果表明,采用狮群算法求解柔性作业车间调度问题,搜寻能力强,搜索速度快,可以在不同规模的问题中找到更优的解决方案;狮群算法结合数字孪生的柔性作业车间调度方案能够整体优化系统性能,有效处理扰动带来的延长生产时间问题。     

连续加工路径的进给速度规划算法研究

为了实现数控系统连续轨迹的速度规划,本文提出了混合进给速度的规划方法.此方法通过建立转弯处加工路径和加工误差的数学模型,实现了转弯处进给速度的控制.实验结果表明,这种方法不仅可以极大的提高机床的加工效率,减小由于路径转弯剧烈引起的机床震动,从而大大提高工件的加工质量.混合进给速度的规划方法保证了加工精度和加减速的稳定性.     

Continuity control method of cutter posture vector for efficient five-axis machining

During five-axis machining of impeller, the excessive local interference avoidance leads to inconsistency of cutter posture, low quality of machined surface and increase of processing time. Therefore, in order to improve the efficiency of five-axis machining of impellers, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. By using an MC-space algorithm for interference avoidance, an MB-spline algorithm for continuous control was intended to create a five-axis machining tool path with excellent surface quality and economic feasibility. A five-axis cutting experiment was performed to verify the effectiveness of the continuity control. The result shows that the surface shape with continuous method is greatly improved, and the surface roughness is generally favorable. Consequently, the effectiveness of the suggested method is verified by identifying the improvement of efficiency of five-axis machining of an impeller in aspects of surface quality and machining time.     

基于多体理论的五坐标数控机床的热误差建模

基于多体系统理论,针对数控机床加工系统中主轴部分的热误差,首次提出了五轴联动数控机床的热误差模型,并在MAKINO四轴加工中心几何误差参数辨识结果和主轴热误差参数辨识结果的基础上对该模型进行了仿真验证;仿真实验显示该建模方法具有良好的工程应用前景。     

Interpolation-based contour error estimation and component-based contouring control for five-axis CNC machine tools

High accuracy contour error estimation and direct contour error control are two major approaches to reduce the contour error. However, two key factors make them complex for five-axis machine tools: the nonlinear kinematics and the coupling between the tool position and orientation. In this study, by finding the reference point nearest to the current actual position, and interpolating the point with two neighboring reference points and using the distance ratio, a new contour error estimation method for five-axis machine tools is proposed, which guarantees high accuracy while depending on only the reference points. By adding a weighted contour error on the tracking error in the workpiece coordinate system, and specifying a desired second-order error dynamics based on the error variable, an effective contouring control method is proposed, which can alleviate the problem: when the contour error components are introduced into the controller, the contour errors increase instead in some regions of the tracking trajectory. A series of experiments are performed on a tilting-rotary-table (TRT) type five-axis machine tool. The results reveal that the proposed estimation method has high accuracy, and compared with the case without contour error control, the proposed control approach can reduce the contour error along the whole trajectory.     

基于极坐标投影法的五轴加工刀具路径生成法

针对五轴加工中刀具矢量变化较大且易产生干涉的问题,提出了基于极坐标投影法的五轴加工刀具路径生成法。利用微分几何理论计算得自由曲面的法矢、主曲率及其极值,利用极坐标投影法获得刀轴矢量,并求得可能的干涉区域;应用等距偏移曲面法计算出曲面数控精加工刀位数据,并通过控制切削残留高度的方法求得切削行距。结果表明,极坐标投影法可以得到无干涉的五轴加工刀位数据,并可以获得均匀变化的刀轴矢量。     

基于多体理论的双摆头五轴数控机床RTCP误差研究

为了提高五轴数控机床的加工精度,对双摆头五轴数控机床RTCP(rotation tool center point)模块的误差进行了分析.以多体系统运动学理论为基础,结合刚体六自由度假设理论,建立了误差分析模型.对旋转运动引起的RTCP刀具中心点误差和刀具矢量误差进行了深入分析,推导出了刀具中心点误差和刀具矢量误差公式,并利用实验室开发的刀具轨迹仿真软件,对理想轨迹和实际轨迹进行了对比分析,验证了理论和方法的正确性.     

Development of an oscillating grinding machine tool based on error analysis

Oscillating grinding machine tool is the core equipment when machining crankshaft pin journal, which directly determines the final quality. This paper describes the development of an oscillating grinding machine tool based on error analysis. First, the error analysis of oscillating grinding for crankshaft pin journal is carried out, including the effect on machining accuracy caused by each error and corresponding error sensitivity. The results show that the tracking error of X-axis has the greatest influence on the grinding accuracy of pin journal, thus, the grinding carriage feed system is the critical component of an oscillating grinding machine tool, which should be given priority during the development process. Next, the development of an oscillating grinding machine tool is described. The whole structure is given, and the grinding carriage feed system is emphatically presented involving drive mode and assembly method. Other components of the oscillating grinding machine tool are also introduced.Finally, some grinding experiments are performed on the prototype, and the results show that all workpieces are qualified under different conditions, which verify the performance of the developed oscillating grinding machine tool.     

Parallel Machine Scheduling Models with Fuzzy Parameters and Precedence Constraints： A Credibility Approach

A method for modeling the parallel machine scheduling problems with fuzzy parameters and precedence constraints based on credibility measure is provided. For the given n jobs to be processed on m machines, it is assumed that the processing times and the due dates are nonnegative fuzzy numbers and all the weights are positive, crisp numbers. Based on credibility measure, three parallel machine scheduling problems and a goal-programming model are formulated. Feasible schedules are evaluated not only by their objective values but also by the credibility degree of satisfaction with their precedence constraints. The genetic algorithm is utilized to find the best solutions in a short period of time. An illustrative numerical example is also given. Simulation results show that the proposed models are effective, which can deal with the parallel machine scheduling problems with fuzzy parameters and precedence constraints based on credibility measure.     

平面二次包络环面蜗杆数控加工误差分析研究

以多体系统建模理论和空间啮合原理为基础,研究数控机床各轴运动误差、刀具误差、工装误差等多项原始误差对平面二次包络环面蜗杆数控加工廓面精度的影响,推导出包含以上各误差的平面二次包络环面蜗杆误差廓面方程,利用牛顿迭代法计算并对误差计算结果进行对比分析,从理论上阐述各误差对加工蜗杆廓面精度的影响规律,为平面二次包络环面蜗杆高精度数控加工提供参考。       

求解调度问题的粒子群算法编码方法研究

利用粒子群算法求解调度问题的关键是建立有效的粒子编码结构。介绍了作业车间、流水车间和并行机调度等3类典型调度问题的特点,阐述了求解调度问题的粒子群算法结构,指出设计粒子群算法编码方法需要考虑的3个关键问题。提出3种求解不同调度问题的粒子群算法编码方法,并从生成调度解的可行性和有效性、粒子群计算模型的适用性和解码过程的复杂性等几个方面对粒子编码方法进行分析。以作业车间调度问题为例,验证了所提粒子编码方法的有效性。     

Optimization based scheduling for a class of production systems with integral constraints

Operation scheduling for a class of production systems with “instantly consumed” products is very important. It is challenging to satisfy the real time system demand and to consider the realizability of the production schedules. This paper formulates a new model for optimization based production scheduling problems with integral constraints. Based on the detailed analysis of the production rate constraints, it is proved that this type of optimization problems is equivalent to a smooth nonlinear programming problem. The reachable upper and lower bounds of the production amount in every period can be expressed as functions of two variables, i.e., the production rate at the start and end of that period. It is also proved that the gradients of these functions are monotonic, and their convexity or concavity is guaranteed. When the production cost function is convex, this type of optimization problems is equivalent to a convex programming problem. With the above analysis, a two-stage solution method is developed to solve the production scheduling problems with integral constraints, and in many applications the global optimal solution can be obtained efficiently. With the new model and solution method, the difficulties caused by the constraints on production rate can be overcome and the optimal schedule can be obtained with the real time system demand satisfied. Numerical testing for scheduling of electric power production systems is performed and the testing results are discussed. It is demonstrated that the new model and solution method are effective.     

Study of Quintic Spline Interpolation and Generated Velocity Profile for High Speed Machining

Modern high speed machining (HSM) machine tools often operates at high speed and high feedrate with high ac- celerations,in order to deliver the rapid feed motion.This paper presents an interpolation algorithm to generate continuous quintic spline toolpaths,with a constant travel increment at each step,while the smoother accelerations and jerks of two-order curve are obtained.Then an approach for reducing the feedrate fluctuation in high speed spline interpolation is presented.The presented ap- proach has been validated to quickly,reliably and effective with the simulation.     

基于深度强化学习的数控铣削加工参数优化方法

为了提高数控加工中的机床效能和加工效率,探究深度强化学习在加工参数优化问题中的适用性,提出一种基于深度强化学习的数控铣削加工参数优化方法. 选取切削力合力和材料除去率作为效能和效率的优化目标,利用遗传算法优化反向传播神经网络（GA-BPNN）构建切削力合力和铣削参数的优化函数,并采用经验公式建立材料除去率的优化函数. 应用竞争网络架构（Dueling DQN）算法获得切削力合力和材料除去率多目标优化的Pareto前沿,并结合优劣解距离法和熵值法从Pareto前沿中选择决策解. 基于45钢的铣削试验,验证了Dueling DQN算法用于加工参数优化的有效性,相比经验选取加工参数,通过Dueling DQN优化得到的加工方案使切削力合力降低了8.29%,加工效率提高了4.95%,为加工参数的多目标优化方法和加工参数的选择提供了指导.     

Circular Interpolation Algorithms of 5-Axis Simultaneous CNC System

Spatial circular arc can be machined conveniently by a 5-axis NC machine tool.Based on the data sampling method,circular interpolation in two-dimensional plane is discussed briefly.The key is to solve the problem of circular center ex- pressed in the workpiece coordinate system by means of the transformation matrix.Circular interpolation in three-dimensional space is analyzed in detail.The method of undetermined coefficient is used to solve the center of the spatial circle and the method of coor- dinate transformation is used to transform the spatial circle into the XY-plane.Circular arc in three-dimensional space can be ma- chined by the positional 5-axis machining and the conical surface can be machined by the continuous 5-axis machining.The velocity control is presented to avoid the feedrate fluctuation.The interpolation algorithms are tested by a simulation example and the inter- polation algorithms are proved feasible.The algorithms are applied to the 5-axis CNC system software.