Tool Deflection Error of Three-Axis Computer Numerical Control Milling Machines, Monitoring and Minimizing by a Virtual Machining System
Tool Deflection Error of Three-Axis Computer Numerical Control Milling Machines, Monitoring and Minimizing by a Virtual Machining System
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DOI：
10.1115/1.4032393
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发表时间：
2016-08
影响因子：
4
通讯作者：
Mohsen Soori;B. Arezoo;Mohsen Habibi
中科院分区：
文献类型：
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作者：
Mohsen Soori;B. Arezoo;Mohsen Habibi
虚拟制造系统是在数字化环境下对制造过程进行仿真，以提高零件生产的精度和生产率。机床存在不同的误差源，如刀具偏转、动轴几何偏差、机床结构热变形等。刀具偏转误差是由切削力引起的，直接影响零件的尺寸精度、表面粗糙度以及刀具、刀架和主轴的有效寿命。本文介绍了虚拟加工系统的应用，旨在通过监测和最小化刀具偏转误差来提高零件制造的精度和生产率。对加工路径上的刀具偏转误差进行监控，以提供一种有用的方法来控制所需公差范围内的加工零件。由于具有误差监控能力，还可以选择合适的刀具和主轴。为了使误差最小，采用了基于遗传算法的优化技术来确定最优加工参数。为了验证软件的可靠性和准确性，对存在刀具偏转误差的虚拟和真实加工零件的自由曲面进行了比较。
Virtual manufacturing systems carry out the simulation of manufacturing processes in digital environment in order to increase accuracy as well as productivity in part production. There are different error sources in machine tools, such as tool deflection, geometrical deviations of moving axis, and thermal distortions of machine tool structures. The errors due to tool deflection are caused by cutting forces and have direct effects on dimensional accuracy, surface roughness of the parts, and efficient life of the cutting tool, holder, and spindle. This paper presents an application of virtual machining systems in order to improve the accuracy and productivity of part manufacturing by monitoring and minimizing the tool deflection error. The tool deflection error along machining paths is monitored to present a useful methodology in controlling the produced parts with regard to desired tolerances. Suitable tool and spindle can also be selected due to the ability of error monitoring. In order to minimize the error, optimization technique based on genetic algorithms is used to determine optimized machining parameters. Free-form profile of virtual and real machined parts with tool deflection error is compared in order to validate reliability as well as accuracy of the software.