Selective polishing method to increase precision in large format lightweight machine tools working with petrous material
DOI:
https://doi.org/10.17533/udea.redin.n90a08Keywords:
geometric error, removal function, embedded intelligence, accuracyAbstract
In this article two complementary methods are developed. Firstly, a method to add precision in large machine tools with modular lightweight structures (APLM), which performs the compensation of geometrics and dynamics errors using embedded intelligence, and secondly, an alternative polishing method called selective polishing (SP). This systematic process comprehends measurement tools and algorithm resources. Phenomena occurred in the machine structure, due to interaction between the cutting tools and the petrous materials in the grinding and polishing processes are modeled mathematically. Using validated flatness models, the variables and parameters were discretized to determine the errors with respect to the Z axis. To validate the method, a test machine of 3m2 workspace with a multi-body lightweight structure design was built. The geometrical errors were determined using precision instruments and those were compared with a pattern surface. A higher flatness is achieved through a combined grinding-traditional polishing and selective polishing process using the same machine. This method saves time and energy consumption.
Downloads
References
C. Raksiri and M. Parnichkun, “Geometric and force errors compensation in a 3-axis cnc milling machine,” International Journal of Machine Tools & Manufacture, vol. 44, no. 12–13, pp. 1283–1291, Oct. 2004.
M. Sortino, S. Belfio, B. Motyl, and G. Totis, “Compensation of geometrical errors of cam/cnc machined parts by means of 3d workpiece model adaptation,” Computer-Aided Design, vol. 48, pp. 28–38, Mar. 2014.
I. Arango and F. Pineda, “Design of cnc turret punch for small batches production,” Ingeniería y Desarrollo, vol. 30, pp. 79–100, Jun. 2012.
R. Ramesh, M. A. Mannan, and A. Poo, “Error compensation in machine tools — a review: Part i: geometric, cutting-force induced and fixture-dependent errors,” International Journal of Machine Tools & Manufacture, vol. 40, no. 9, pp. 1235–1256, Jul. 2000.
S. Aguado, D. Samper, J. Santolaria, and J. J. Aguilar, “Towards an effective identification strategy in volumetric error compensation of machine tools,” Measurement Science and Technology, vol. 23, pp. 1–12, May. 2012.
A. C. Okafor and Y. M. Ertekin, “Derivation of machine tool error models and error compensation procedure for three axes vertical machining center using rigid body kinematics,” International Journal of Machine Tools and Manufacture, vol. 40, no. 8, pp. 1199–1213, Jun. 2000.
H. Schwenke and et al, “Geometric error measurement and compensation of machines—an update,” CIRP Annals-Manufacturing Technology, vol. 57, no. 2, pp. 660–675, 2008.
X. Zuo, B. Li, J. Yang, and X. Jiang, “Integrated geometric error compensation of machining processes on cnc machine tool,” Procedia CIRP, vol. 8, pp. 135–140, 2013.
N. A. Barakat, M. A. Elbestawi, and A. D. Spence, “Kinematic and geometric error compensation of a coordinate measuring machine,” International Journal of Machine Tools and Manufacture, vol. 40, pp. 833–850, May. 2000.
G. Fu, F. Jianzhong, Y. Xu, Z. Chen, and J. Lai, “Accuracy enhancement of five-axis machine tool based on differential motion matrix: Geometric error modeling, identification and compensation,” International Journal of Machine Tools and Manufacture, vol. 89, pp. 170–181, Feb. 2015.
J. Yang and Y. Altintas, “Generalized kinematics of five-axis serial machines with non-singular tool path generation,” International Journal of Machine Tools and Manufacture, vol. 75, pp. 119–132, Dec. 2013.
M. Pezeshki and B. Arezoo, “Kinematic errors identification of three-axis machine tools based on machined work pieces,” Precision Engineering, vol. 43, pp. 493–504, Jan. 2016.
D. Kono, A. Matsubara, K. Nagaoka, and K. Yamazaki, “Analysis method for investigating the influence of mechanical components on dynamic mechanical error of machine tools,” Precision Engineering, vol. 36, no. 3, pp. 477–484, Jul. 2012.
W.-S. Yun and d.-w. Cho, “An improved cutting force model considering the size effect in end milling,” vol. 11, pp. 223–229, Jan. 2000.
S. C. Park and B. K. Choi, “Tool-path planning for direction-parallel area milling,” Computer-Aided Design, vol. 32, no. 1, pp. 17–25, Jan. 2000.
L. Liao, F. J. Xi, and K. Liu, “Adaptive control of pressure tracking for polishing process,” Journal of Manufacturing Science and Engineering, vol. 132, no. 1, pp. 1–12, Feb. 2010.
E. J. Terrell and C. F. Higgs, “Hydrodynamics of slurry flow in chemical mechanical polishing a review,” Journal of The Electrochemical Society, vol. 153, no. 6, pp. 15–22, 2006.
M. Schinhaerl and et al, “Mathematical modelling of influence functions in computer-controlled polishing: Part i,” Applied Mathematical Modelling, vol. 32, no. 12, pp. 2888–2906, 2008.
G. Smith and et al, “Mathematical modelling of influence functions in computer-controlled polishing: Part ii,” Applied Mathematical Modelling, vol. 32, no. 12, pp. 2907–2924, 2007.
J. Huissoon, F. Ismail, A. Jafari, and S. Bedi, “Automated polishing of die steel surfaces,” The International Journal of Advanced Manufacturing Technology, vol. 19, no. 4, pp. 285–290, 2002.
G. S. Khan, M. Gubarev, C. Speegle, and B. Ramsey “Computer-controlled cylindrical polishing process for development of grazing incidence optics for the hard x-ray region,” Proc SPIE, vol. 7802, Aug. 2010.
G. Wang, Y. Wang, and Z. Xu, “Modeling and analysis of the material removal depth for stone polishing,” Journal of Materials Processing Technology - J MATER PROCESS TECHNOL, vol. 209, pp. 2453–2463, Mar. 2009.
A. Temmler, E. Willenborg, and K. Wissenbach, “Design surfaces by laser remelting,” Physics Procedia, vol. 12, pp. 419–430, 2011.
A. W. Khan and W. Chen, “A methodology for systematic geometric error compensation in five-axis machine tools„” The International Journal of Advanced Manufacturing Technology, vol. 53, no. 5-8, pp. 615–628, Mar. 2011.
K. G. Ahn and D. W. Cho, “Proposition for a volumetric error model considering backlash in machine tools,” The International Journal of Advanced Manufacturing Technology, vol. 15, no. 8, pp. 554–561, Jul. 1999.
A. W. Khan and C. Wuyi, “Systematic geometric error modeling for workspace volumetric calibration of a 5-axis turbine blade grinding machine,” Chinese Journal of Aeronautics, vol. 23, no. 5, pp. 604–615, Oct. 2010.
H. Haitjema and J. Meijer, “Evaluation of surface plate flatness measurements,” European Journal Mech. Eng., vol. 38, no. 4, pp. 165–172, 1993.
S. Lakota and A. Görög, “Flatness measurement by multi-point methods and by scanning methods,” Journal of interdiciplinary research, vol. 01, no. 01, p. 124, 2011.
K. C. Fan and F. J. Shiou, “An optical flatness an optical flatness medium-sized surface plates,” Precision Engineering, vol. 21, no. 2, pp. 102–112, Sep. 1997.
H. J. Pahk, Y. S. Kim, and J. H. Moon, “A new technique for volumetric error assessment of cnc machine tools incorporating ball bar measurement and 3d volumetric error model,” International Journal of Machine Tools and Manufacture, vol. 37, no. 11, pp. 1583–1596, Nov. 1997.
S. Aguado, D. Samper, J. Santolaria, and J. J. Aguilar, “Volumetric verification of multiaxis machine tool using laser tracker,” The Scientific World Journal, vol. 2014, pp. 1–16, 2014.
S. Timoshenko and J. M. Gere, Theory of elastic stability. Mineola, New York: Dover Publications, 2009.
D. L. Qin, F. Wang, F. J. Xi, and Z. F. Liu, “A theoretical model of grinding force and its simulation,” vol. 690. Trans. Tech. Publications, Jul. 2013, pp. 2395–2402.
W. Lin, P. Xu, B. Li, and X. Yang, “Path planning of mechanical polishing process for freeform surface with a small polishing tool,” Robotics and Biomimetics, pp. 1–24, 2014.
F. Au, Y. Cheng, and Y. Cheung, “Vibration analysis of bridges under moving vehicles and trains,” Progress in Structural Engineering and Materials - PROG STRUCT ENG MATER, vol. 3, pp. 299–304, Jul. 2001.
B. Zhang and W. Shepard, “Dynamic responses of supported beams with intermediate supports under moving loads,” Shock and Vibration, vol. 19, pp. 1403–1413, Jan. 2012.
M. S. Kozień, “Analytical solutions of excited vibrations of a beam with application of distribution,” Acta Physica Polonica A., vol. 123, pp. 1029–1033, May. 2013.
Published
How to Cite
Issue
Section
License
Copyright (c) 2019 Revista Facultad de Ingeniería Universidad de Antioquia
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
Revista Facultad de Ingeniería, Universidad de Antioquia is licensed under the Creative Commons Attribution BY-NC-SA 4.0 license. https://creativecommons.org/licenses/by-nc-sa/4.0/deed.en
You are free to:
Share — copy and redistribute the material in any medium or format
Adapt — remix, transform, and build upon the material
Under the following terms:
Attribution — You must give appropriate credit, provide a link to the license, and indicate if changes were made. You may do so in any reasonable manner, but not in any way that suggests the licensor endorses you or your use.
NonCommercial — You may not use the material for commercial purposes.
ShareAlike — If you remix, transform, or build upon the material, you must distribute your contributions under the same license as the original.
The material published in the journal can be distributed, copied and exhibited by third parties if the respective credits are given to the journal. No commercial benefit can be obtained and derivative works must be under the same license terms as the original work.
Twitter