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A tool orientation smoothing method for five-axis machining to avoid singularity problems

Cui Chuanhui, Zhu Zhengqing, Chen Shuai, Zheng Qiang, Chai Jinfeng, Li Xiancai

Journal of Theoretical and Applied Mechanics

2023

Vol. 61 nr 1

89--102

In numerically controlled grinding of aeroengine blades, a sharp change in a rotating shaft caused by a singular zone greatly reduces grinding precision and quality. This paper proposes an algorithm to optimize the tool-path that combines optimization of the C-axis rotation angle, a modification to the tool orientation and adjustments to the tool position by taking a four-array machine tool with two rotational axes (B-axis and C-axis) as an example. The algorithm was verified using VERICUT software, furthermore, in machining experiments, the rotation amplitudes of the rotary axis in singular areas was effectively reduced, which ensured grinding quality of blades.

An analytic model for tool trajectory error in 5-axis machining

So B. S., Park D. H., Cho Y., Kim T. J., Song T. S., Ko T. J.

Journal of Achievements in Materials and Manufacturing Engineering

2008

Vol. 31, nr 2

570-575

Purpose: This paper proposes an analytical method of evaluating the maximum error by modeling the exact tool path when the tool traverses singular region in five-axis machining. Design/methodology/approach: It is known that the Numerical Control (NC) data obtained from the inverse kinematic transformation can generate singular positions, which have incoherent movements on the rotary axes. Such movements cause unexpected errors and abrupt operations, resulting in scoring on the machined surface. To resolve this problem, previous methods have calculated several tool positions during a singular operation, using inverse kinematic equations to predict tool trajectory and approximate the maximum error. This type of numerical approach, configuring the tool trajectory, requires a lot of computational time to obtain a sufficient number of tool positions in the singular region. We have derived an analytical equation for the tool trajectory in the singular area by modeling the tool operation, by considering linear and nonlinear parts that are a general form of the tool trajectory in the singular area and that are suitable for all types of five-axis machine tools. In addition, evaluation of the maximum tool-path error shows high accuracy, using our analytical model. Findings: In this study, we have separated the linear components of the tool trajectory from the nonlinear ones, to propose a tool trajectory model that is applicable to any kind of 5-axis machine. We have also proposed a method to calculate the maximum deviation error based on the proposed tool trajectory model. Practical implications: The algorithms proposed in this work can be used for evaluating NC data and for linearization of NC data with singularity. Originality/value: Our algorithm can be used to modify NC data, making the operation smoother and reducing any errors within tolerance.