High Speed and Precision Machinery: Kinematics, Dynamics, Vibration and Control

In order to explore the failure mechanism of a reciprocating compressor system with clearance fault, we implemented a computational framework whereby a simulation model of the mechanism is established using ADAMS software in this paper, and a typical reciprocating compressor model is introduced to validate the design model. In this work, the joint clearance faults between the crankshaft and linkage, between the linkage and crosshead, and in both locations are taken into account computationally. These faults are one of the major causes of vibration. Through dynamic calculation and analysis of a system with clearance fault, the simulated results show that these clearance faults directly influence the vibration. The larger the gap size, the more severe the vibration and the higher the amplitude of the vibration. Furthermore, the clearance number also affects the vibration greatly. Full article

The angular positioning error of the rotary stage causes low quality in milling various angles of a workpiece. This study proposes a solution that could improve these issues by using our Laser R-test for angular positioning calibration and compensation of the five-axis machine tools in compliance with the simultaneous measurement path of ISO regulations: ISO 10791-6 and ISO 230-2. System uncertainty analysis and calibration were implemented for system prediction. The measurement method proposed in this paper could solve concentricity problems between measurement devices and the rotary table by applying the Cosine theorem with a Cartesian coordinate system. Further, we used the commercial instrument XR20-W (Renishaw, UK) rotary axis calibrator to verify and compare the measured results on a CNC machine tool. The applied system achieves an angular error of 0.0121 degrees for actual workpieces and is smaller than the referring commercial system, which achieves an error of about 0.0022 degrees. The system in this research is useful for five-axis machine tool full calibrations. Full article

When the CNC machining of continuous small line segments is performed, the direction of the machine tool movement will change abruptly at the corner of adjacent line segments. Therefore, a reasonable constraint on the feedrate at the corner is the prerequisite for achieving high-speed and high-precision machining. To achieve this goal, a feedrate-constraint method based on the nominal acceleration was proposed. The proposed method obtains the predicted value of acceleration during the machining process by the machining trajectory prediction and acceleration filtering. Then, the feedrate at the corner is constrained, according to the predicted acceleration. Specifically, for any corner of adjacent line segments, the proposed method assumes that the CNC machining of a short path centered on the corner is carried out at a constant feedrate. First, the actual machining trajectory is predicted according to the transfer function of the servo system. Then, the nominal acceleration, when the CNC machining is carried out to the corner, is calculated and processed by a low-pass FIR filter. Last, the feedrate-constraint value at the corner is obtained according to the nominal acceleration and the preset normal acceleration. The advantage of the proposed method is that it can be used for different machining paths consisting of long segments or continuous small segments and it has no special requirement for the accuracy of the machining path. As a result, the feedrate-constraint value obtained is reasonable and the smooth machining process can be ensured. The simulation results in both 2D and 3D machining paths show that the proposed method is insensitive to the length of the line segment and the angle of the corner, and the calculated feedrate-constraint value is close to the theoretical value, which has good stability and versatility. In contrast, the feedrate-constraint values obtained by conventional methods change abruptly along the machining path, especially in the 3D simulation, which will damage the machining quality. The experiment was performed on a three-axis CNC machine tool controlled by a self-developed controller, and a free-form surface workpiece was machined by a conventional feedrate-constraint method and the proposed method, respectively. The experimental results showed that the proposed method can make the feedrate of the machining process higher and more stable. Then, machining defects such as overcutting and undercutting can be avoided and the machining quality can be improved. Therefore, the article proposes a new method to constrain the feedrate at the corner of continuous small line segments, which can improve the machining efficiency and quality of the CNC machining. Full article

The curvature of the NURBS curve varies along its trajectory, therefore, the commonly used feedrate-planning method, which based on the acceleration/deceleration (Acc/Dec) model, is difficult to be directly applied in CNC machining of a NURBS curve. To address this problem, a feedrate-planning method based on the critical constraint curve of the feedrate (CCC) is proposed. Firstly, the problems of existing feedrate-planning methods and their causes are analyzed. Secondly, by considering both the curvature constraint and the kinematic constraint during the Acc/Dec process, the concept of CCC which represents the relationship between the critical feedrate-constraint value and the arc length is proposed. Then the CCC of a NURBS curve is constructed, and it has a concise expression conforming to the Acc/Dec model. Finally, a feedrate-planning method of a NURBS curve based on CCC and the Acc/Dec model is established. In the simulation, a comparison between the proposed method and the conventional feedrate-planning method is performed, and the results show that, the proposed method can reduce the Acc/Dec time by over 40%, while little computational burden being added. The machining experimental results validate the real-time performance and stability of the proposed method, and also the machining quality is verified. The proposed method offers an effective feedrate-planning strategy for a NURBS curve in CNC machining. Full article