Geometric error compensation for five-axis ball-end milling by considering machined surface textures

Arbitrarily adjusting tool poses during error compensation may affect the quality of surface textures. This paper presents one tool center limitation-based geometric error compensation for five-axis ball-end milling to avoid the unexpected machined textures. Firstly, the mechanism of cutter location...

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Vydané v:	International journal of advanced manufacturing technology Ročník 99; číslo 5-8; s. 1235 - 1248
Hlavní autori:	Fu, Guoqiang, Gu, Tengda, Gao, Hongli, Jin, Yu’an, Deng, Xiaolei
Médium:	Journal Article
Jazyk:	English
Vydavateľské údaje:	London Springer London 01.11.2018 Springer Nature B.V
Predmet:	Angles (geometry) Axes (reference lines) Ball-end milling CAE) and Design Compensation Computer-Aided Engineering (CAD End milling cutters Engineering Error compensation Errors Five axis Industrial and Production Engineering Machine tools Mathematical models Mechanical Engineering Media Management Milling (machining) Mutation Numerical controls Original Article Particle swarm optimization Product design Production methods Rotation Trajectory analysis Ball-end milling Five-axis machine tools Geometric error compensation Cutter contact points Tool center limitation
ISSN:	0268-3768, 1433-3015
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Abstract	Arbitrarily adjusting tool poses during error compensation may affect the quality of surface textures. This paper presents one tool center limitation-based geometric error compensation for five-axis ball-end milling to avoid the unexpected machined textures. Firstly, the mechanism of cutter location generation with cuter contact (CC) trajectory is analyzed. Due to zero bottom radius of ball-end cutter, CC points of the surface are only related to the tool center of the cutter. Realizing that, tool center limitation method of ball-end milling is established based on the generation of movements of all axes in order to ensure the machined textures. Then, geometric error compensation of ball-end milling is expressed as optimizing rotation angles of rotary axes by limiting tool centers of cutter locations. Next, particle swarm optimization (PSO) is intergraded into the geometric error compensation to obtain the compensated numerical control (NC) code. The limited region for particles of rotation angles is established, and moving criterion with a mutation operation is presented. With the help of the tool center limitation method, fitnesses of all particles are calculated with the integrated geometric error model. In this way, surface textures are considered and geometric errors of the machine tool are reduced. At last, cutting experiments on five-axis ball-end milling are carried out to testify the effectiveness of the proposed geometric error compensation.
AbstractList	Arbitrarily adjusting tool poses during error compensation may affect the quality of surface textures. This paper presents one tool center limitation-based geometric error compensation for five-axis ball-end milling to avoid the unexpected machined textures. Firstly, the mechanism of cutter location generation with cuter contact (CC) trajectory is analyzed. Due to zero bottom radius of ball-end cutter, CC points of the surface are only related to the tool center of the cutter. Realizing that, tool center limitation method of ball-end milling is established based on the generation of movements of all axes in order to ensure the machined textures. Then, geometric error compensation of ball-end milling is expressed as optimizing rotation angles of rotary axes by limiting tool centers of cutter locations. Next, particle swarm optimization (PSO) is intergraded into the geometric error compensation to obtain the compensated numerical control (NC) code. The limited region for particles of rotation angles is established, and moving criterion with a mutation operation is presented. With the help of the tool center limitation method, fitnesses of all particles are calculated with the integrated geometric error model. In this way, surface textures are considered and geometric errors of the machine tool are reduced. At last, cutting experiments on five-axis ball-end milling are carried out to testify the effectiveness of the proposed geometric error compensation.
Author	Jin, Yu’an Deng, Xiaolei Fu, Guoqiang Gu, Tengda Gao, Hongli
Author_xml	– sequence: 1 givenname: Guoqiang surname: Fu fullname: Fu, Guoqiang email: fuguoqiang@swjtu.edu.cn organization: Department of Electromechanical Measuring and Controlling, School of Mechanical Engineering, Southwest Jiaotong University, State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Key Laboratory of Advanced Manufacturing Technology of Zhejiang Province, College of Mechanical Engineering, Zhejiang University – sequence: 2 givenname: Tengda surname: Gu fullname: Gu, Tengda organization: Department of Electromechanical Measuring and Controlling, School of Mechanical Engineering, Southwest Jiaotong University – sequence: 3 givenname: Hongli surname: Gao fullname: Gao, Hongli organization: Department of Electromechanical Measuring and Controlling, School of Mechanical Engineering, Southwest Jiaotong University – sequence: 4 givenname: Yu’an surname: Jin fullname: Jin, Yu’an organization: School of Mechanical Engineering and Mechanics, Ningbo University – sequence: 5 givenname: Xiaolei surname: Deng fullname: Deng, Xiaolei organization: College of Mechanical Engineering, Quzhou University
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Snippet	Arbitrarily adjusting tool poses during error compensation may affect the quality of surface textures. This paper presents one tool center limitation-based...
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SubjectTerms	Angles (geometry) Axes (reference lines) Ball-end milling CAE) and Design Compensation Computer-Aided Engineering (CAD End milling cutters Engineering Error compensation Errors Five axis Industrial and Production Engineering Machine tools Mathematical models Mechanical Engineering Media Management Milling (machining) Mutation Numerical controls Original Article Particle swarm optimization Product design Production methods Rotation Trajectory analysis
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Title	Geometric error compensation for five-axis ball-end milling by considering machined surface textures
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