We propose a large combined moving component composed of carbon fiber reinforced polymer(CFRP)laminates for making lightweight machine tools with high dynamic performance.The accurate dynamic prediction of composite m...We propose a large combined moving component composed of carbon fiber reinforced polymer(CFRP)laminates for making lightweight machine tools with high dynamic performance.The accurate dynamic prediction of composite machine tools is essential for the new generation machine tool.This paper aims to address two challenges in numerical dynamic modeling and the design of composite machine tools to enhance development efficiency.(1)Anisotropic composite laminates,which form the composite machine tool,exhibit coupling in various directions.We propose the generalized continuity condition of the boundary to tackle this dynamic modeling challenge.(2)Composite machine tools feature numerous composite-metal coupled structures.The mechanical model correction of isotropic metals is performed to address their dynamics.We take the example of a five-axis gantry machine tool with composite moving parts,establish a dynamic model for efficient prediction,and verify it through simulation and experimentation.The proposed method yields remarkable results,with an average relative error of only 3.85%in modal frequency prediction and a staggering 99.7%reduction in solution time compared to finite element analysis.We further discuss the dynamic performance of the machine tool under varied stacking angles and layer numbers of the composite machine tool.We propose general design criteria for composite machine tools to consider the modal frequency and manufacturing cost of machine tools.展开更多
A mirror milling system(MMS)comprises two face-to-face five-axis machine tools,one for the cutting spindle and the other for the support tool.Since it is essential to maintain the cutter and support coaxial during the...A mirror milling system(MMS)comprises two face-to-face five-axis machine tools,one for the cutting spindle and the other for the support tool.Since it is essential to maintain the cutter and support coaxial during the cutting process,synchronous motion accuracy is the key index of the MMS.This paper proposed a novel method for measuring and estimating the synchronous motion accuracy of the dual five-axis machine tools.The method simultaneously detects errors in the tool center point(TCP)and tool axis direction(TAD)during synchronous motion.To implement the suggested method,a measurement device,with five high-precision displacement sensors was developed.A kinematic model was then developed to estimate the synchronous motion accuracy from the displacement sensor output.The screw theory was used to obtain the analytical expression of the inverse kinematic model,and the synchronous motion error was compensated and adjusted based on the inverse kinematic model of the dual five-axis machine tools.TCP and TAD quasi-static errors,such as geometric and backlash errors,were first compensated.By adjusting the servo parameters,the dynamic TCP and TAD errors,such as gain mismatch and reversal spike,were also reduced.The proposed method and device were tested in a large MMS,and the measured quasi-static and dynamic errors were all reduced when the compensation and adjustment method was used.Monte Carlo simulations were also used to estimate the uncertainty of the proposed scheme.展开更多
基金supported by the National Natural Science Foundation of China(Grant No.U21B2081)。
文摘We propose a large combined moving component composed of carbon fiber reinforced polymer(CFRP)laminates for making lightweight machine tools with high dynamic performance.The accurate dynamic prediction of composite machine tools is essential for the new generation machine tool.This paper aims to address two challenges in numerical dynamic modeling and the design of composite machine tools to enhance development efficiency.(1)Anisotropic composite laminates,which form the composite machine tool,exhibit coupling in various directions.We propose the generalized continuity condition of the boundary to tackle this dynamic modeling challenge.(2)Composite machine tools feature numerous composite-metal coupled structures.The mechanical model correction of isotropic metals is performed to address their dynamics.We take the example of a five-axis gantry machine tool with composite moving parts,establish a dynamic model for efficient prediction,and verify it through simulation and experimentation.The proposed method yields remarkable results,with an average relative error of only 3.85%in modal frequency prediction and a staggering 99.7%reduction in solution time compared to finite element analysis.We further discuss the dynamic performance of the machine tool under varied stacking angles and layer numbers of the composite machine tool.We propose general design criteria for composite machine tools to consider the modal frequency and manufacturing cost of machine tools.
基金supported by the National Natural Science Foundation of China(Grant No.51875357)the State Key Program of National Natural Science Foundation of China(Grant No.U21B2081)the National Defense Science and Technology Excellence Youth Foundation(Grant No.2020-JCJQ-ZQ-079)。
文摘A mirror milling system(MMS)comprises two face-to-face five-axis machine tools,one for the cutting spindle and the other for the support tool.Since it is essential to maintain the cutter and support coaxial during the cutting process,synchronous motion accuracy is the key index of the MMS.This paper proposed a novel method for measuring and estimating the synchronous motion accuracy of the dual five-axis machine tools.The method simultaneously detects errors in the tool center point(TCP)and tool axis direction(TAD)during synchronous motion.To implement the suggested method,a measurement device,with five high-precision displacement sensors was developed.A kinematic model was then developed to estimate the synchronous motion accuracy from the displacement sensor output.The screw theory was used to obtain the analytical expression of the inverse kinematic model,and the synchronous motion error was compensated and adjusted based on the inverse kinematic model of the dual five-axis machine tools.TCP and TAD quasi-static errors,such as geometric and backlash errors,were first compensated.By adjusting the servo parameters,the dynamic TCP and TAD errors,such as gain mismatch and reversal spike,were also reduced.The proposed method and device were tested in a large MMS,and the measured quasi-static and dynamic errors were all reduced when the compensation and adjustment method was used.Monte Carlo simulations were also used to estimate the uncertainty of the proposed scheme.
