Load spectra of CNC machine tools

Load spectra of CNC machine tools are described in this paper; 112 CNC machine tools have been traced for 3 years. Data including machining parameters and conditions, drawings and NC programs of parts, process cards and specifications of each individual CNC machine tool are gathered. A database containing this information is designed. The loads of CNC machine tools are calculated and the distribution parameters of loads are estimated. A fuzzy multicriteria comprehensive evaluation method is applied to evaluate the fitness of the distribution model. This methodology lays a foundation for the reliability designs of CNC machine tools. Copyright © 2000 John Wiley & Sons, Ltd.     

数控机床整机动态特性评价方法

动态特性是衡量机床性能的一项重要指标,但目前并没有较好的数控机床整机动态特性评价方法。利用真实的动态切削力对数控机床进行激励,能够快速获取机床在切削力作用下的动态特性。鉴于切削参数会影响各频率成分对应的切削力幅值,基于不同工件材料和切削参数下的动态切削力,建立动态激振力模型,通过分频段激励来检验数控机床在不同频段下的动态特性。通过有限元仿真分析,判断数控机床在各个频段下的动态特性;对振动信号进行快速傅里叶变换,得到机床振动时的主要频率成分,为优化机床动态特性提供指导;对比各种动态切削力激振下不同机床的动刚度,评价不同机床动态特性的优劣。最后,通过激振试验验证了仿真结果的准确性。结果表明上述方法简单实用,能快速评价数控机床的动态特性,具有一定的实用价值。     

Evaluation method of dynamic characteristics of whole NC machine tool

The dynamic characteristics is an important index to measure the performance of machine tools.However, there is no better method to evaluate the dynamic characteristics of whole NC (numerical control) machine tool. Through the excitation of real dynamic cutting force to the NC machine tool, the dynamic characteristics of the machine tool under the action of cutting force can be quickly obtained. In view of the fact that the cutting parameters would affect the amplitude of cutting force corresponding to each frequency component, a dynamic excitation force model was established based on the dynamic cutting forces under different sample materials and cutting parameters.The dynamic characteristics of the NC machine tool in different frequency bands could be tested by frequency band excitation. Through the finite element simulation analysis, the dynamic characteristics of NC machine tool in each frequency band was judged. The main frequency components in the vibration of machine tool were obtained by fast Fourier transform of vibration signal, which could provide guidance for optimizing the dynamic characteristics of machine tool. The dynamic stiffness of different machine tools under excitation of various dynamic cutting forces was compared to distinguish which machine tool had better dynamic characteristics. Finally, the simulation results were verified by the excitation test. The results indicate that the above method is simple and practical, and can quickly evaluate the dynamic characteristics of NC machine tool, which has certain practical value.     

Life Prediction Model of Machine Tool based on Deep Learning

In view of the shortage of traditional life prediction methods for machine tools, such as low accuracy of life prediction and few samples basis attributes, a life prediction model of machine tools combined with machine tool attributes is proposed. The life prediction model of machine tool adopts KL dispersion distribution theory, uses modal superposition method to carry out machine tool life analysis, calculates the theoretical life of machine tool, and then carries on the simulation, obtains the machine tool life prediction value. Compared with the traditional method of machine tool life prediction, the model is based on the application life fatigue damage model, which superimposes the service times and maintenance cycle of the machine tool, derives the influence factor of machine tool life, and obtains the linear relationship between the influence factor of machine tool life and the life of machine tool. The influence factor of machine tool life is introduced as the life prediction parameter of machine tool. The data transformation relationship of HT300 parts is constructed. The original part data is enhanced. The effective training set is obtained. The life prediction model of machine tool based on deep learning is completed. The quantitative analysis of machine tool life is carried out. The experiment of machine tool life prediction using training data set proves the validity of the model. Regression test was carried out on the training data set to reflect the robustness of the model. The prediction accuracy of the model is further verified by Weibull test.     

Reliability inference for VGA adapter from dual suppliers based on contaminated type‐I interval‐censored data

Type‐I interval‐censoring scheme only documents the number of failed units within two prespecified consecutive exam times at the larger time point after putting all units on test at the initial time schedule. It is challenging to use the collected information from type‐I interval‐censoring scheme to evaluate the reliability of unit when not all admitted units are operated or tested at the same initial time and a majority of units are randomly selected to replace the failed test units at unrecorded time points. Moreover, the lifetime distribution of all pooled units from dual resources usually follows a mixture distribution. To overcome these two problems, a two‐stage inference process that consists of a data‐cleaning step and a parameter estimation step via either Markov chain Monte Carlo (MCMC) algorithm or profile likelihood method is proposed based on the contaminated type‐I interval‐censored sample from a mixture distribution with unknown proportion. An extensive simulation study is conducted under the mixture smallest extreme value distributions to evaluate the performance of the proposed method for a case study. Finally, the proposed methods are applied to the mixture lifetime distribution modeling of video graphics array adapters for the support of reliability decision.     

Research on reliability allocation technology for NC machine tool meta‐action

The reliability of machine tool is getting more and more attention. Reasonable reliability allocation is beneficial to improve the inherent reliability of machine tool. However, the existing reliability allocation methods for machine tool have some limitations. For example, static part is selected as the reliability allocation object of machine tool, which cannot reflect the characteristics “function realized by motion”; factors affecting reliability allocation are not considered comprehensively, weights of experts are treated as the same, and the allocation results are not optimized or the impact of time on enterprise is neglected in the optimization. To solve these problems, a new multiobjective optimization reliability allocation method for machine tool is proposed in this paper. Firstly, the latest achievements about meta‐action are given, and meta‐action is set as the reliability allocation object. Secondly, more reasonable and comprehensive factors affecting reliability allocation are extracted. Thirdly, expert weight coefficient is brought to reduce the subjective impact of expert scoring. Fourthly, time factor is brought to make the optimized allocation results more reasonable and accurate. Finally, a numerical control (NC) machine tool made in China is taken as an example, with a comparison on the reliability allocation results of current methods and proposed method. The results verify the applicability, rationality, and accuracy of the proposed method, which lays a foundation for the subsequent study on the quality characteristics of machine tool based on meta‐action.     

归一化小波熵与RVM的滚动轴承运行可靠度预测

针对传统可靠度评估和预测方法难以实现对正在服役中的单台机械设备进行可靠度评估和预测的问题。设计了一种基于归一化小波包信息熵与相关向量机的滚动轴承运行可靠度预测方法;该方法主要包括确立运行可靠度指标以及构建相关向量机预测模型,通过试验测取滚动轴承运行过程中的振动信号,利用小波包分解,提取反映滚动轴承运行状态的特征频带能量,基于信息熵理论建立运行可靠度指标;构建相关向量机预测模型,准确预测正在服役中的滚动轴承运行可靠度指标及其变化趋势。试验结果表明,采用归一化小波包信息熵与相关向量机的可靠度预测模型,能有效克服传统基于概率统计数据的平均可靠度计算问题,并且相关向量机的可靠度预测精度更高。     

Reliability Analysis of the CNC System Based on Field Failure Data in Operating Environments

Reliability is a measure of how well a product will perform under a certain set of conditions for a specified amount of time especially in the field environments. In this paper, a reliability study of a computer numerical control (CNC) system is described. For this analysis, field failure data from a shop manufacturing factory collected over the course of a year on approximately 20 CNC machine tools during their operating period were analyzed. Based on the field failure data, the two‐parameter exponential distribution was found to be applicable to describe the time between failures of the CNC system from among many distributions including Weibull, gamma, two‐parameter exponential, normal, and logistic using the chi‐squared test. In this paper, we discuss the reliability estimation of the CNC system based on the collected field failure data from a manufacturing factory using the maximum likelihood estimate (MLE) and uniform minimum variance estimate (UMVUE) methods. We also discuss the confidence intervals of the mean residual lifetime and reliability function. The result shows that the UMVUE method can provide much better and more accurate results in estimating the reliability of the CNC system than the MLE. This finding, on the one hand, seems to be obvious because the UMVUE is not only an unbiased estimator but also sufficient statistic with the smallest variance; on the other hand, it is not straightforward to obtain the UMVUE of any complex function, which is the reliability function in this case. This is a very important finding and is very encouraging because it indicates that the reliability analysis of the CNC system based on the UMVUE can be more than compensated by the ability of the complexity of parameter estimation method to better evaluate and predict the reliability of the CNC system. Hence, we believe that it is worth the effort to derive those parameter functions using UMVUE method. Copyright © 2015 John Wiley & Sons, Ltd.     

机床直线轴重复定位精度三维评价方法研究

重复定位精度是机床的一个重要性能指标，会直接影响加工产品的质量一致性。现有以直线轴运动方向的位置偏差作为评价指标的一维评价方法已经不适用于精密机床重复定位精度的评价。为了更全面地评价机床直线轴重复定位精度，提出了机床直线轴重复定位精度的三维评价方法，以球概率误差半径作为评价指标，将一维定位评价扩展到三维空间评价。首先，以卧式加工机床为例，通过齐次坐标变换建立了运动件单轴和机床的重复定位精度的数学模型，对现有一维评价方法的局限性进行分析。其次，基于卡方分布的性质，对球概率误差半径的计算过程进行简化。最后，通过简化的球概率误差半径计算方法对机床直线轴重复定位精度进行评价。以精密卧式机床的工作台为研究对象，通过实验对一维评价方法和三维评价方法进行了对比，结果表明，以球概率误差半径为评价指标的三维评价结果与定位点空间分布的离散程度基本一致。采用三维评价方法可以使机床重复定位精度的评价更加全面，可为机床整体性能的提升提供更可靠的理论指导。     

A Two-stage Tuning Method of Servo Parameters for Feed Drives in Machine Tools

Based on the evaluation of dynamic performance for feed drives in machine tools, this paper presents a two-stage tuning method of servo parameters. In the first stage, the evaluation of dynamic performance, parameter tuning and optimization on a mechatronic integrated system simulation platform of feed drives are performed. As a result, a servo parameter combination is acquired. In the second stage, the servo parameter combination from the first stage is set and tuned further in a real machine tool whose dynamic performance is measured and evaluated using the cross grid encoder developed by Heidenhain GmbH. A case study shows that this method simplifies the test process effectively and results in a good dynamic performance in a real machine tool.     

宏程序在数控铣床加工中的应用

应用用户宏程序及仿真加工技术,设计了一个能够实现矩形外形(矩形、圆角形和键槽形)和矩形型腔(圆角形、键槽形和空白槽形)的粗加工,精加工,粗、精连续加工程序。建立了对应的参数变量,并在数控仿真软件里模拟加工轨迹后再在机床上进行了实际加工进行验证。     

基于多源融合理论的机床圆度误差测量不确定度评定

圆度误差是评价机床加工精度的重要指标.为实现机床圆度误差测量不确定度的评定,对基于球杆仪测量的机床圆度误差的贡献因素及不确定度评定方法进行研究.首先,采用最小二乘法(least sqaure method,LSM)对圆度误差进行评定.然后,基于黑箱理论提出了多源融合误差测量不确定度评定方法.接着,根据球杆仪测量机床圆度...     

Fatigue reliability study on T‐welded component considering load shedding

In this paper, a coupled reliability method for structural fatigue evaluation considering load shedding is first proposed based on probabilistic fracture mechanics in which the uncertainties of the structural parameters are taken into account. Then, the method is applied to predict the fatigue reliability of the T‐welded structure to the case of considering load shedding or not. The compared results show that by considering the load shedding, the structural fatigue reliability might be improved with less conservativeness. The influence rules of the load‐shedding coefficient on the fatigue failure probability of the T‐welded component are investigated, and some interesting results are obtained. That is, the influences of load‐shedding coefficient on the fatigue failure probability can be divided into three regions, namely the high, medium and low fatigue failure areas. The last area is the most intriguing when we try to design a T‐welded structure. The thickness of T‐welded structure along the crack propagation direction is found to be one of the important design variables for the design of fatigue reliability, in which the low‐fatigue failure zone is used as one of the reliability constraints. The basic design frame of T‐welded structure is established to constrain the fatigue failure probability within the low‐fatigue failure area.     

多乘员座舱人机工效满意度评价量表的信效度分析

目的为了能对多乘员座舱工效满意度进行定量分析,即座舱的工效学是否能满足机组成员的实际要求,有必要对多任务模式下多乘员座舱人机工效满意度评价技术进行研究。方法本研究通过德尔菲法进行咨询确定评价体系指标,应用序关系分析法进行指标权重系数调查,最终建立多乘员座舱人机工效满意度的评价体系。编制了人机工效满意度评价量表,通过对3种不同现役军机与各自效标即专家评价的结果进行比较来确认量表的效度;通过被试前后两次打分来验证量表的重测信度,并应用建立的评价体系对现役军机新洲一60进行了模糊综合评估。结果各型飞机普通飞行员通过量表计算得到的座舱满意度评价分数与专家给出的评价分数即“效标”间无统计学差异。对于重测信度来说,计算得到r=-O．79,属于中等水平。结论多乘员座舱人机工效满度评价量表具有较好的信效度。     

精密雕刻技术在复杂曲面模具加工中的应用

研究了精密雕刻技术在复杂曲面模具加工中的优势,采用非标准小刀具使精雕机床能够实现在加工中心、数控铣上无法完成的小尺寸加工.提出将精密雕刻技术应用于复杂曲面模具的加工,完成复杂曲面细小特征的加工,从而提高模具加工的速度,加快新产品开发的进度,降低开发成本,实现模具的快速制造,改变了传统的仅依靠数控铣床、加工中心进行模具制...     

Reliability estimation based on operational data of manufacturing systems

Maintenance management has a direct influence on equipment reliability and safety. However, a large portion of traditional maintenance models and reliability analysis methods usually assumes that only perfect maintenance is performed on the system and the system will restore to as good as new regardless of the kind of preventive maintenance work‐order that is performed. This is not practical in reality and may result in an inaccurate parametric estimation. The research objective of this paper is to develop a maximum likelihood estimation method to obtain more accurately estimated parameters based on the operational data of manufacturing systems, taking into consideration the difference between perfect and imperfect maintenance work‐orders. Weibull distribution is specifically studied for this purpose. A practical case study based on industrial operational data from an automotive assembly line is performed to illustrate the implementation and efficiency of the proposed reliability estimation method. Copyright © 2008 John Wiley & Sons, Ltd.     

材料参数对高强不锈钢管数控绕弯成形失稳起皱的影响

目的研究材料参数波动对管材数控绕弯成形失稳起皱的影响规律。方法基于ABAQUS有限元平台,建立了21-6-9高强不锈钢管数控绕弯成形过程三维弹塑性有限元模型,并验证了模型的可靠性;采用该模型模拟分析了材料参数波动对其数控绕弯成形过程失稳起皱的影响规律。结果随着厚向异性指数、屈服强度的增大或弹性模量、硬化指数的减小,弯管的起皱趋势增大,泊松比和强度系数对弯管起皱趋势的影响较小。结论材料参数对弯管起皱趋势影响的大小依次为:屈服强度、弹性模量、厚向异性指数、硬化指数、强度系数和泊松比。     

The Application of the GM(1,1) Metabolism Model to Error Data Processing of NC Machine Tools

1　IntroductionNCmachinetoolsarekeyequipmentofmoderntimesandmakesprecisionresultsingearproduction .ThecomplicatederrorsystemofarunningNCmachinetoolincludesgeometryerror,heaterrorandloaddis tortionerroretc .Thissystemisagraysystembecauseonlypartinformationisknown .Erroranalysisanddataprocessingofagraysystemistousetheknowninformationtounderstandtheerrorcharacteristic,stateanddevelopmenttogettodecision makingonitsabilitytowork .Thegraysystemtheorywasdevelopedinthe 1 980’sandiswidelyappliedinth…     

A manufacturing resource allocation method with knowledge-based fuzzy comprehensive evaluation for aircraft structural parts

Manufacturing of aircraft structural parts has the characteristics of multiple varieties, complex structures and small batches, which make the manufacturing resource allocation highly difficult. This paper proposes a manufacturing resource allocation method with knowledge-based fuzzy comprehensive evaluation, considering multiple manufacturing resources including process planners, machine tools and cutting tools, as well as manufacturing process schemes of aircraft structural parts. Knowledge in terms of experts’ experience and historical data is used for fuzzy comprehensive evaluation. A manufacturing resource allocation model is proposed based on the analysis of manufacturing processes of aircraft structural parts. The capability of planners, the complexity of structural parts, the reliability of machine tools, the reliability of cutting tools and the correlations between manufacturing resources and structural parts are evaluated using the fuzzy comprehensive evaluation method. Multiple manufacturing resources are allocated based on the fuzzy comprehensive evaluation results. A prototype system has been implemented and a case study is used to validate the proposed approach.