5-Axis adaptive flank milling of flexible thin-walled parts based on the on-machine measurement |
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| Affiliation: | 1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, PR China;2. Manufacturing Automation Laboratory, Department of Mechanical Engineering, The University of British Columbia, Vancouver, BC, V6T 1Z4, Canada;1. Department of Mechanical Engineering, Universidad de La Frontera, Temuco, Chile;2. Department of Mechanical, Informatics and Aerospace Engineering, Universidad de Leon, Leon, Spain;3. Department of Mechanical and Manufacturing Engineering, Universidad Politecnica de Madrid, Madrid, Spain;1. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China;2. China National South Aviation Industry Co., Ltd, Zhuzhou 412002, China;1. Department of Mechanical and Aerospace Engineering, Hong Kong University of Science and Technology, Clear Water Bay, Kowloon, Hong Kong;2. International Graduate School at Shenzhen, Tsinghua University, Shenzhen 518055, China |
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| Abstract: | Deformation of the part and cutter caused by cutting forces immediately affects the dimensional accuracy of manufactured parts. This paper presents an integrated machining deviation compensation strategy based on on-machine measurement (OMM) inspection system. Previous research attempts on this topic deal with deformation compensation in machining of geometries in 3-axis machine tools only. This paper is the first time that concerned with 5-axis flank milling of flexible thin-walled parts. To capture the machined surface precision dimensions, OMM with a touch-trigger probe installed on machine?s spindle is utilized. Probe path is planned to obtain the coordinate of the sampling points on machined surface. The machined surface can then be reconstructed. Meanwhile, the cutter?s envelope surface is calculated based on nominal cutter location source file (CLSF). Subsequently, the machining error caused by part and cutter deflection is calibrated by comparing the deviation between the machined surface and the envelope surface. An iteration toolpath compensation algorithm is designed to decrease machining errors and avoid unwanted interference by modifying the toolpath. Experiment of machining the impeller blade is carried out to validate the methodology developed in this paper. The results demonstrate the effectiveness of the proposed method in machining error compensation. |
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| Keywords: | Adaptive machining Thin-walled part On-machine measurement Envelope surface |
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