机床沿曲线高速加工时的运动学与动力学特性分析

详细分析了刀具沿曲线加工时，刀具路径几何特性（位置、切向矢量、曲率）与机床的运动学特性（进给速度、加速度）以及动力学特性（伺服电动机驱动力、切削负载、摩擦力）之间的关系。并采用解析的方法，计算了在各轴加速度和伺服电动机驱动力约束条件下，机床沿曲线加工时的最大安全进给速度。分析结果表明刀具路径几何特性对机床的运动学和动力学特性有很大的影响。     

Precision NURBS interpolator based on recursive characteristics of NURBS

In NURBS interpolation, real-time parameter update is an indispensable step which affects not only feedrate fluctuation but also contour error. Using Taylor approximation interpolation method to find the next interpolation point causes a large feedrate fluctuation due to the accumulation and truncation errors. This paper presents a new, simple, and precise NURBS interpolator for CNC systems. The proposed interpolation algorithm does not use Taylor’s expansion, but the recursive equation of the NURBS formula. A simulation study is conducted to demonstrate the advantages of this proposed interpolator compared with those using Taylor’s equation. It is readily seen that this interpolator using the new concept of interpolation for modern CNC systems is simple and precise. The proposed method can be used for interpolating a continuous NURBS curve.     

An adaptive feedrate scheduling method of dual NURBS curve interpolator for precision five-axis CNC machining

Non-uniform rational b-spline (NURBS) tool path is becoming more and more important due to the increasing requirement for machining geometrically complex parts. However, NURBS interpolators, particularly related to five-axis machining, are quite limited and still keep challenging. In this paper, an adaptive feedrate scheduling method of dual NURBS curve interpolator with geometric and kinematic constraints is proposed for precision five-axis machining. A surface expressed by dual NURBS curves, which can continuously and accurately describe cutter tip position and cutter axis orientation, is first used to define five-axis tool path. For the given machine configuration, the calculation formulas of angular feedrate and geometric error aroused by interpolation are given, and then, the adaptive feedrate along the tool path is scheduled with confined nonlinear geometric error and angular feedrate. Combined with the analytical relations of feed acceleration with respect to the arc length parameter and feedrate, the feed profiles of linear and angular feed acceleration sensitive regions are readjusted with corresponding formulas and bi-directional scan algorithm, respectively. Simulations are performed to validate the feasibility of the proposed feed scheduling method of dual NURBS curve interpolator. It shows that the proposed method is able to ensure the geometric accuracy and good machining performances in five-axis machining especially in flank machining.     

A Cross-Coupled Path Precompensation Algorithm for Rapid Prototyping and Manufacturing

A cross-coupled path precompensation (CCPP) algorithm for a rapid prototyping and manufacturing (RPM) system is proposed in this paper in order to reduce the contour error resulting from the dynamic track error in the position control of the RPM system. The input of the CCPP plant is generated by a software interpolator, and the output is the compensated feedrate of the biaxial system. The precompensation amount is computed according to track errors that are estimated by mathematical models of each servo mechanism and the tangent angle at the desired point along the prespecified path. The new point acquired by the precompensation method is located in the normal direction of the original point. Simulation and experiments on the algorithm along a circular path of 200 mm in diameter are implemented. The experimental results demonstrate the advantage of the algorithm for RPM systems.     

基于进给速度引导曲线的参数曲线实时插补器

设计了一种基于进给速度引导曲线的参数曲线实时插补器,给出了进给速度引导曲线的B-样条曲线生成方法。该方法在数控加工之前,通过建立进给速度引导曲线,来取代参数曲线实时插补进给速度规划的前瞻处理。实验表明,采用这种基于速度引导曲线的参数曲线实时插补器后,实时计算任务少,可以获得良好的伺服轴进给速度平滑效果和实时插补性能。     

Curve interpolation with variable feedrate for surface requirement

Finish machining of a curved surface is often carried out by an NC system with curve interpolation in the field. This function, called a NURBS interpolation, adopts a feedrate optimizing strategy based on both the geometrical information of the curved path and dynamic properties such as the curvature of the curve, the allowable acceleration and the time constant. However, in the case of a finish cut using a ball-end mill, the curve interpolator needs to take the machining process into account for improved surface roughness, while reducing the polishing time. This surface roughness on high-speed machining is theoretically defined by the feed per tooth and the pickfeed at the given radius of the tool. In this study, the effect of low machinability at the bottom of a tool on surface roughness is also considered. A curve interpolation algorithm is proposed for generating particular feedrate commands that are able to control the roughness of a curved surface. The simulation of the machined surface by the proposed algorithm was carried out, and experimental results are presented. A feedrate scheme that depends on the inclination angle has important potential application in part finishes consistent with prescribed surface roughness. The results show that the proposed algorithm is potentially useful for roughness-controlled machining of curved surface products.     

Adaptive feedrate interpolation with multiconstraints for five-axis parametric toolpath

A good adaptive feedrate will be helpful for improving machining accuracy and efficiency, as well as avoiding the excess of the machine’s physical capabilities and feed fluctuations during machining. Therefore, it is highly desirable to consider the constraints of geometric error, cutting performance, and drive constraints in the feedrate scheduling of the parametric curve interpolator for five-axis computer numerical control machining. In this paper, a novel multiconstraints feedrate scheduling method is proposed for the parametric curve interpolator in five-axis machining. In the method, the feed optimization model is first built with the constraints of geometric error, the maximum feedrate and acceleration of cutter tip, and the maximum feedrate and acceleration of five-drive axes. Then, the relations between each constraint and the cutter tip feedrate are derived by means of near arc length parameterization. After that, a linear programming algorithm is applied to obtain the optimal feed profile on the sampling positions of the given tool path. Finally, illustrated examples are given to validate the feasibility and applicability of the proposed feedrate scheduling method. The comparison results show that the proposed method has an ability of the simultaneous guarantees of geometric accuracy, cutting performance, and drive characters of machine tools.     

An accurate adaptive parametric curve interpolator for NURBS curve interpolation

In this paper, an adaptive parametric curve interpolator with a real-time look-ahead function is developed for non-uniform rational B-spline curves (NURBS) interpolation, which considers the maximum acceleration/deceleration of the machine tool. In the proposed interpolator, both constant feedrate and high accuracy are achieved while the inconsistency of feedrate is reduced dramatically as well. In order to deal with the acceleration/deceleration around the feedrate sensitive corners, a look-ahead function is introduced to detect and adjust the feedrate adaptively. Two cases were respectively studied to evaluate the feasibility of the developed interpolator: one is for feedrate sensitive arc corner; the other is for feedrate sensitive sharp corner.     

Design of a real-time adaptive interpolator with parameter compensation

The interpolator is the key part of a CNC system, which has strong effect on machining accuracy, tool motion smoothness, and machining efficiency. In this paper, a real-time adaptive interpolator is developed for non-uniform rational B-spline curves (NURBS) interpolation while considering the maximum acceleration/deceleration of the machine tool. In this proposed interpolator, both constant feedrate and high accuracy are achieved while the inconsistency of feedrate is dramatically reduced as well. In order to deal with the acceleration/deceleration around the feedrate-sensitive sharp corners, a look-ahead function is introduced to detect and adjust the feedrate adaptively. Furthermore, a parameter compensation scheme is proposed to eliminate the parametric truncation error which has been analyzed by several researchers but still not incorporated into any real-time interpolator so far. A case study was conducted to evaluate the feasibility of the developed interpolator.     

Feedrate scheduling strategy for free-form surface machining through an integrated geometric and mechanistic model

In free-form surface machining, it is essential to optimize the feedrate in order to improve the machining efficiency. Conservative constant feedrate values have been mostly used up to now since there was a lack of physical models and optimization tools for the machining processes. The overall goal of this research is the integration of geometric and mechanistic milling models for force prediction and feedrate scheduling in five-axis CNC free-form surface machining. For each tool move, the geometric model calculates the cut geometry, and a mechanistic model is used along with a maximum allowable cutting force to determine a desired feedrate. The results are written into the part NC program with optimized feedrates. When the integrated modeling approach based feedrate scheduling strategy introduced in this paper was used, it was shown that the machining time can be decreased significantly along the tool path.     

隐曲线的线性和旋转插补

基于数控五轴刀具运动分析,提出了旋转插补的概念,给出了旋转插补的相关定义,在此基础上提出了隐曲线的线性和旋转插补原理和方法,并进一步提出了改进的插补方法。     

Real-time PH-based interpolation algorithm for high speed CNC machining

Various methods for parametric interpolation of non-uniform rational B-spline (NURBS) curves have been proposed in the past. However, the errors caused by the approximate nature of the NURBS interpolator were rarely taken into account. This paper proposes an integrated look-ahead algorithm for parametric interpolation along NURBS curves. The algorithm interpolates the sharp corners on the curve with the Pythagorean-hodograph (PH) interpolation. This will minimize the geometric and interpolator approximation errors simultaneously. The algorithm consists of four different modules: a sharp corner detection module, a PH construction module, a feedrate planning module, and a dynamics module. Simulations are performed to show correctness of the proposed algorithm. Experiments on an X?CY table confirm that the developed method improves tracking and contour accuracies significantly compared to previously proposed algorithms.     

具有限定的弦差和加减速度的插补器

作者提出了一种数控机床在插补过程中通过调整进给速度从而将弦差限定在一定的误差范围内的插补算法。提出的插补器是一种变进给速度插补器,在保证弦差位于一定误差范围内的同时,增加了数控机床的效率。本文给出了仿真结果以证明该插补器的可行性。     

Contouring accuracy improvement using a tangential contouring controller with a fuzzy logic-based feedrate regulator

In contour-following tasks, contour error reduction is an issue of much concern. Generally speaking, contour error is caused by the mismatched dynamics between each axis. To reduce the contour error, many previous studies have focused on developing proper controllers and/or more accurate contour error estimation algorithms. An alternative method for reducing contour errors is to exploit the idea of desired feedrate adjustment. This paper proposes using the approximate contour error information to develop a fuzzy logic-based feedrate regulator, which adjusts the value of the desired feedrate. Moreover, to further reduce contour error, an integrated motion control scheme is also developed. This scheme consists of a position loop controller with velocity command feedforward, a tangential contouring controller (TCC), a real-time contour error estimator, and the proposed fuzzy logic-based feedrate regulator. Several experiments on free-form contour-following tasks are conducted to evaluate the performance of the proposed approach. The experimental results clearly demonstrate the effectiveness of the proposed approach.     

High accurate interpolation of NURBS tool path for CNC machine tools

Feedrate fluctuation caused by approximation errors of interpolation methods has great effects on machining quality in NURBS interpolation, but few methods can efficiently eliminate or reduce it to a satisfying level without sacrificing the computing efficiency at present. In order to solve this problem, a high accurate interpolation method for NURBS tool path is proposed. The proposed method can efficiently reduce the feedrate fluctuation by forming a quartic equation with respect to the curve parameter increment, which can be efficiently solved by analytic methods in real-time. Theoretically, the proposed method can totally eliminate the feedrate fluctuation for any 2nd degree NURBS curves and can interpolate 3rd degree NURBS curves with minimal feedrate fluctuation. Moreover, a smooth feedrate planning algorithm is also proposed to generate smooth tool motion with considering multiple constraints and scheduling errors by an efficient planning strategy. Experiments are conducted to verify the feasibility and applicability of the proposed method. This research presents a novel NURBS interpolation method with not only high accuracy but also satisfying computing efficiency.     

Adaptive feedrate scheduling for NC machining along curvilinear paths with improved kinematic and geometric properties

In precision machining of free-form surfaces at high speed, it is very important to ensure part accuracy and machining properties. To achieve this, this paper develops a guide spline-based feedrate scheduling method for machining along curvilinear paths with simultaneous constraints of chord errors and ac/deceleration. Based on two metrics about feedrate scheduling from the view of geometric and kinematic properties, the nonlinear relationships between the arc-length parameter and path parameter are subsequently established with a parameter correction spline. Then a guide spline associated with the modified curvature radius of paths is constructed to the schedule feedrate. It is shown that determining the largest safe feedrate with constant chord error can be reduced to the issue of changing the feedrate proportionally with the square root of path curvature radii and ensuring the safe feed acceleration can be converted into the issue of presetting the largest slope of guide spline. The simulation results prove that the proposed feedrate scheme has potential applications in the field of finish machining.     

基于铣削力仿真模型的进给率优化方法

提出一种新的进给率优化方法,将铣削力仿真模型应用于进给率优化算法,由设定的峰值力确定出金属去除率目标值,根据每段刀具轨迹的实际切削体积计算出相应的进给率数值。作为实际应用,将新方法集成到G代码优化程序中。实验表明,该方法具有很好的优化效果。     

Self-adjustment computing method for time-partition interpolation in motion trajectory control of CNC machine tools

For time-partition interpolation in computer numerical control of the motion trajectory of a machine tool, the trajectory in a sampling cycle is approximated by a line segment from the current position of the tool to another on the expected trajectory; and locating the terminal of the line is the goal of the interpolation. In this paper, a self-adjustment computing method applicable to any explicit curve type is proposed. With the method, the terminal of the linear moving path in a cycle is first estimated by the motion information in the previous cycle, then adjusted according to the ratio of the desired moving distance to the computed linear path length. The result of the computation is fairly accurate, and it can be further enhanced with more adjustments performed in a sampling cycle, which is demonstrated in the simulation results. Furthermore, an adaptive feedrate adjustment algorithm is also introduced to enable the proposed method to control the trajectory contour errors.     

Development of integrated acceleration/deceleration look-ahead interpolation technique for multi-blocks NURBS curves

Modern motion control adopts acceleration/deceleration before interpolation (ADBI) motion planning to eliminate path command errors. However, the individual velocity profiles might not be continuous at the junction of the blocks. Acceleration/deceleration after interpolation (ADAI) method may provide an alternative for solving the discontinuous problems, but it causes path command errors. In this paper, an integrated acceleration/deceleration interpolation (IAD) scheme which integrates the ADBI and ADAI modules is proposed. The ADBI provides a look-ahead function which plans the feedrate profiles based on chord errors, command errors, curvatures, and acceleration limits. Within the look-ahead function, the command error equation is utilized to determine the feedrate at the junction of adjacent blocks. Then the ADBI performs non-uniform rational B-spline (NURBS) interpolation using the planned feedrate profile and outputs the position points to the ADAI module. The ADAI module processes the points by a digital convolution technique such that the continuity of the block junction velocity is ensured. Finally, the IAD is applied to the multi-block NURBS interpolation to validate its effectiveness. Simulations and experiments are conducted to demonstrate the IAD scheme. It is shown that the IAD scheme can reduce the acceleration significantly at the junctions of the blocks under the given tolerance of the command error. Furthermore, the proposed algorithm can improve tracking and contour accuracies as compared to the hybrid multi-blocks look-ahead approach.     

Optimal five-axis tool path generation algorithm based on double scalar fields for freeform surfaces

In order to generate efficient tool path with given precision requirements, scallop height should be kept under a given limit, while the tool path should be as short as possible to reduce machining time. Traditional methods generate CC curves one by one, which makes the final tool path far from being globally optimal. This paper presents an optimal tool path generation model for a ball-end tool which strives to globally optimize a tool path with various objectives and constraints. Two scalar functions are constructed over the part surface to represent the path intervals and the feedrate (with directions). Using the finite element method (FEM), the tool path length minimization model and the machining time minimization model are solved numerically. The proposed method is also suitable for tool path generation on mesh surfaces. Simulation results show that the generated tool path can be direction parallel or contour parallel with different boundary conditions. Compared to most of the conventional tool path generation methods, the proposed method is able to generate more effective tool paths due to the global optimization strategy.