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Journal Article

High Performance Spindle Systems for Heavy Duty Milling of Difficult-To-Cut Aerospace Materials

In order to machine a wide variety of materials with a single spindle and setup, a multi-purpose spindle for machine tools has been developed. The spindle achieves both high power/ torque for heavy duty milling operations and higher rotational speed. The developed spindle is equipped with an additional motor at the back of a conventional induction motor driven spindle to assist the induction motor when high milling torque is needed. For high speed operation, the additional motor can be mechanically disengaged and the spindle can be used as a conventional spindle. A Permanent Magnet Synchronous Motor (PMSM) is adopted for the additional motor, because a highly stable milling operation can be realized by utilizing the advantage of the PMSM. As expected, cutting experiments have shown that the material removal rate has been greatly improved with the developed spindle.
Technical Paper

A Study on Autonomous Hole Machining Process Analysis by Reverse Engineering of NC Programs

The machining know-how or knowledge exists in the NC programs if they are generated through experienced workers. To realize autonomous CNC machining, accumulation and representation of such know-how in a reusable way is needed. In this paper, an autonomous machining process analyzer for hole machining is studied. With the method, the machining process can be analyzed and the know-how can be extracted from existing successful NC programs. Specifically, machining feature, operation sequence, and cutting parameters including used tools, feedrate and spindle/cutting speed can be extracted. Based on the proposed method, a prototype system has been developed to verify the feasibility of the know-how extraction.
Technical Paper

High-Speed Machining of Titanium by New PCD Tools

The paper deals with the end-milling machinability of α-β titanium alloy (Ti-6AI-4V alloy) by new PCD (Polycrystal-line Diamond) cutting tools at high cutting speeds in order to develop a new technology for a high productivity titanium finishing. The main focus of this paper is on investigating the relationships among cutting conditions, PCD tool materials, and tool wear. It was found that the edge engagement time of cutting tools with titanium workpiece has a great effect on PCD tool wear. Compared to cemented carbide tools, PCD tools have a longer tool life, especially at higher cutting speeds. The geometric shape of cutting edges and tool material greatly influences the performance of PCD tools in cutting titanium alloy.
Technical Paper

Intelligent Multi-Axis Motion Control for Machine Tool Systems

This paper deals with a new multi-axis motion control method for high performance machine tool systems. The intelligent multi-axis motion control system proposed is mainly composed of a multi-axis motion trajectory monitoring system and an intelligent compensator with dynamic gain control. The multi-axis motion trajectory monitoring system calculates the motion trajectory error of all axes. The intelligent compensator with the dynamic gain control dynamically changes the servo gain to prevent a motion error from happening. A feasibility verification of the system is conducted on an actual CNC machining center. It is found that the new control method could improve the motion trajectory accuracy of the axes greatly. The control concept, system design, system implementation as well as the feasibility study of this new control system are described.
Technical Paper

In-Process Tool Utilization Analysis Based Machining Simulation

The study aims at analyzing the tool utilization by using a real-time machining simulation and investigating the behavior of the parameters which affect the tool wear based on the results of the analysis. In this study, the method of calculation of parameters which are necessary to predict the tool wear by using Z-map based machining simulation is developed. Furthermore, the possibility of estimating the tool wear from the results of the simulation was also examined by performing the real cutting experiments.