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    CNC Manufacturing

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    © All Rights Reserved
    Download as PDF or read online from Scribd
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    46 views7 pages

    Improving CNC Machine Tool Geometric Precision Using Manufacturing Process Analysis Techniques - 1-s2.0-S2212827114002546-Main

    Uploaded by

    Angel
    CNC Manufacturing

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 7
    ase ‘Available onine at www.sciencedirect.com fo 3 ScienceDirect ELSEVIER ‘Procedia CIRP 14 (2014) 263 - 268 wen ese confocatrnoreda ‘6th CIRP International Conference on High Performance Cutting, HPC2014 Improving CNC Machine Tool Geometric Precision Using Manufacturing Process Analysis Techniques Adam Hansel", Kazuo Yamazaki, Kyle Konishi? * University of California, Davis, USA *DMG Mori Seiki, Davis, CA, USA * Comespending ator, Fl: $1530-746-7400;B mall adress ahansel@merisethcom Abstract ‘With the ever increasing demands for higher and higher accuracy on moder CNC equipment, the manufaeturing processes for machining and assembling the structural components are an increasingly important factor in ‘establishing a geometrically correct machine tool. Specifically, flatsess, perpendicularity, parallelism, an straightaess of interfacing surfaces determine whether the machine tool's basic accuracy. Exhibiting less geometric error allows other errors such as thermal growth, ballserew pitch error, and control etror to be isolated and more easily corrected, ‘The geometric errors are predominately a factor of the machine tool machining and assembly process, Multiple orientations during fixturing in both assembly and machining result in significant distortions to the final assembled product, These are a result of euting forces, fixturing deformations, gravity deformations, and bolt force deformation, By analyzing each process in detail using virtual simulation techniques, a high-fidelity model of the corresponding error at each manufacturing step can be achieved that is not physically measurable due to constraints ‘of measurement equipment. Using simulated data as offset data in the machining process as well as inthe jig and fixture design ensures a geometrically accurate final product, (© 2014 Published hy Elsevier B.V. Open asses under CC BY.NCND license Selection and peer-review under responsibility of the International Scien Committee ofthe 6th CIRP International Conference ‘op High Performance Cuting Keywords: Simulation; machining accuracy; machine tool manufacturing; FEM. Lincs and sampeiie ate of th machin olny dite ta iment improve to mahi ol tsorcy ae Rt sficen Moreover, te pict Tit of Son fstne machin rte pas gh pecon Set schived and atte machinery feo aves ml Pysca imt n he vel of pron nt cn be sod precision, the components that make up the next generation of sishter tolerances than conventional machining and grinding ‘machines also improve. This, together with value added by send tq be gost prohibitive and are not able to be widely skilled ‘creflsman results in ever increasing accuracy of adopted into the process chain, It therefore becomes ‘machine tools.(1] However, decreasing product fife cycle mmportamt to find a way to improve the process using 1. Introduction Precision manufacturing of machine tools is very evolutionary in nature. Incremental experience based improvements at 2212-8271 © 2014 Published by BseverB.V. Open access under CC BY-NC-ND lcs, Selstion and peer-evew der responsiblity of the International Scent Commitee of the 6 CIRP Intrational oo Mich Poevivonence Cattine 268 Adam Hansel ta. /Procedia CIRP 14 (2014) 263-268 ‘equipment that is currently available. The machine checked is the NHX4000, 2 400 mm pallet horizontal CNC machining center produced by DMG Mori Seiki in Davis, CA 141 Virtual modeling uses in machine tools ‘A very promising method tat could be used to analyse the ‘manufacturing process is Finite Flement Modelling and other forme of virtual simblation. In the last five yeers, computing power has become mature enough to handle ful complex todcls of machine tool systems in a very short amount of time, As an example, DMG Mori Seiki's Digital Technology Laboratory (DTL) purchased a 32 node Linux eluster for running simulation’s that took a desktop PC 30 days to solve. That cluster computer shortened the time to one day! Today. a desktop is able to beat that performance so virally any level of computer simulation is now possible for machine tol systems, Significant research has been done on how to use virtual modelling to test machine tool designs performance and is well summarized in a CIRP keynote paper by Altins, etal, jn 2005,2) Research successfully accomplished has modelled machine tools ftom component level to full virtual prototype 10 prove thatthe traditional design eyele eould be realistically. shortened by climinating physical. prototype iterations. Analyses completed range from simple static rigidity models fo complex dynamic models and thermal models, While there is sll improvement to be made, this ‘method of machine tol vital simulation bas rapidly become Another ara that as been well sted is the ute of FEM for the micro performance of individual components that have complex intemal behaviour “such contact models for ballcrews and damping behaviour of motion components. Robust component models are useful for improved produet quality and also for developing higher bandwidth control algorithms. [3] Detailed contact models have been used to assist empirical testing of component find demping values ‘which are recycled for use in overall machine éynamic models] Another considerable research area simulation is applied ‘owart is simulation ofthe eutting process tse These types of physical phenomena are often very difficult to add instrumentation and thus simulating the interaction is highly esirable. It is used to model cuting processes for surface ish determination, burr formation, chip formation, temperature dispersion, tool wear, and so oa. [5] [6] Use in the prediction of chatter and cutting stability ean also not go ‘unmentioned, (7] It's clear that computer modelling techniques are widely used for the benefit of machine tools and machining. However, this technology has not been deployed to study the ‘manvfacturing process of the machine tool itself, This is perhaps duc to the proprietary nature of precision machine tools. Regardless, there is ample opportunity to apply simuiation technology in order to improve the accuracy of ‘machine tools. To achieve greater accuracy, the analysis will show areas of improvement to be made This includes integration of cutting forces, fixture design, assombly onder, and so on. The fixttes and jigs to put the machine together for high accuracy and repeatable accuracy are also. very important and are examined, This wil Be @ natural rselt of the anelysis cared out shove, 1.2, Geometric measurable error sources Carrying out 2 machine too! analysis using virtual modelling applies itself to only certain erors. Specifically, the errors that an be corrected for are geometric in nature and measurably repeatable. Many papers aniculate geometric cervrs clearly. They are generally position dependent. Tn the case of rotating axes, the linear geometric errors may be ‘assumed tobe negligibly small compared to rotary axes eror. [8] However, the methods of improving the aecuraey of the ‘machine fool production process are applicable to machines tools of any configuration. Furthermore, linear motion errors compound the uncertainty of rolary axis error compensation [9] and are advisable to minimize as much as possible. This research will focus on errom that arc a result of the ‘manufacturing process and ean be corrected once identified 2. Manufacturing process chain statistical analysis In manufacturing precision CNC equipment, itis extremely ificull to significantly reduce cost while maintaining product quality. Therefore, analysing the variables in the production cycle systematically end identifying key focus areas for improvement has potential to provide maximum improvement, both in cost and accuraey’quality, whi ‘maintaining minimal disruption to production. Attempting €o analyse and optimize every measurement and tolerance would lly itis not feasible. Tt is also highly desirable to establish « statistical link to key areas in the smanvfacturing process tothe final accuracy of the machine tool To do so, a statistical analysis of the XY plane was carried ‘out. A machine to! is a complex machine with hundreds of ‘measurements and inspection poiats, only the most relevant for common cutting operations need be analysed. Most csttng is 2D contouring in the XY plane so the measurements that directly affect the XY accuracy in the kinematic chain were used fo investigate a statstial relationship, In order to Adam Hansel eta. /Procedia CIRP 14 (2014) 263 ~268 268 tel a reasonable sample size, 30 machines were sampled out ‘of a population of approximately 150 machines produced In onder to conduct statistical analysis, the form of the data had to be established. Tha is, to make assumptions relying ‘the normal distribution of dat, the data had to be checked for normaley. A normal plot'using the Z score isan acceplable way 10 establish a normal distribution [10] The ‘normal plot of the double ball bar ercularity measurement has 4 linear regression line with an R’ value of 0.96 which is highly linear, Other data sets had similar behavioue so it was assumed thatthe data sample of 30 machines had a normal istibution and basic assumptions regarding a normal

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