Kinematic Chain Optimization Design Based on Deformation Sensitivity Analysis of a Five-Axis Machine Tool
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International Journal of Precision Engineering and Manufacturing https://doi.org/10.1007/s12541-020-00421-w
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Kinematic Chain Optimization Design Based on Deformation Sensitivity Analysis of a Five‑Axis Machine Tool Shuyou Zhang1,2 · Ci He2 · Xiaojian Liu1,2 · Jinghua Xu2 · Yanqiang Sun2 Received: 27 April 2019 / Revised: 13 September 2020 / Accepted: 18 September 2020 © Korean Society for Precision Engineering 2020
Abstract This paper focuses on optimization of kinematic chain to reduce force-induced error in the scheme design phase of a fiveaxis machine tool. After conducting process planning on the machining target, local deformation of motion units in cutting positions is considered using a geometric way. A mathematical model is then established describing the influence of local deformation error on the general machining error through homogeneous transformation matrices. Conceptual model of the machine tool is constructed to obtain deformation distribution using static FEA. Error sensitivity coefficients are then calculated and compared among all alternative kinematic chains to select the optimized scheme. The proposed method is verified through a designing example of a five-axis vertical machining center. The optimized kinematic chain could lower the magnitude of deformation sensitivities by 9.69% and increase error equalization variance by 71.25% compared to the conventional method. Keywords Kinematic chain design · Deformation analysis · Machining error model · Machine tool design
1 Introduction Mechanical structure of a five-axis machine tool is one of the major influences of the stiffness, precision, static and dynamic performances [1, 2]. Carrying the structural configuration and motion transmission properties, configuration of the kinematic chain is one of the most fundamental stages in the scheme design phase of a five-axis machine tool [3, 4]. The number of practical kinematic chains for a five-axis machine tool is limited. Structural stiffness and machining precision should be the major considerations when choosing a preferred kinematic chain configuration [5, 6]. This paper focuses on optimization design of kinematic chain considering deformation errors in the scheme design phrase. Remarkable achievements have been presented in performance evaluation for multiple configurations of multiaxis machine tool. The target part should be analyzed first to specify manufacturing processes to help select a suited * Xiaojian Liu [email protected] 1
Ningbo Research Institute, Zhejiang University, Ningbo 315100, China
State Key Laboratory of Fluid Power & Mechatronic System, Zhejiang University, Hangzhou 310027, China
2
kinematic chain configuration in demand-driven machine tool design [7]. As a seminal and fundamental work, all possible combinations of conceptual designs are analyzed and classified in [8] through analyzing the chain feature and degrees of freedom. Design criteria, pros and cons of each category were also given. Wu et al. [9] provided an optimization method for the concep
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