Energy Consumption of Feed Drive Systems Based on Workpiece Setting Position in Five-Axis Machining Center
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Abstract:
Energy consumption of numerical control (NC) machine tools is one of the key issues in modern industrial field. This study focuses on reducing the energy consumed by a five-axis machining center by changing only the workpiece setting position. Previous studies show that the movements along each axis in five-axis machining centers depend on the workpiece setting position, regardless of whether the same operation is performed. In addition, the energy consumptions required for the movements are different along each axis. From these considerations, an optimum workpiece setting position that can minimize the energy consumed during these motions is assumed to exist. To verify this assumption, in this study, the energy consumed by the feed drive systems of an actual five-axis machining center is first measured and then estimated using the proposed model in this study. The model for estimating the energy consumption comprises the friction, motor, and amplifier losses along each axis. The total energy consumption can be estimated by adding the energy consumptions along each axis. The effect of the workpiece setting position on the energy consumption is investigated by employing the cone-frustum cutting motion with simultaneous five-axis motions. The energy consumption that depends on the workpiece setting position is first measured and then estimated. The results confirm that the proposed model can estimate the energy consumption accurately. Moreover, the energy consumption is confirmed to depend on the workpiece setting position; the minimum energy consumption is found to be 20% lower than the maximum one.Keywords:
Position (finance)
Frustum
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A hybrid micro machine tool is developed. This tabletop size machine tool can be applied for EDM, ECM, mechanical machining, laser processing, and complex machining which is combined each machining method. To study the basic performance of hybrid micro machine tool, a complex machining experiment is carried out with the developed machine tool. The complex machining has 3 steps : machining electrode by milling, hole shaping by EDM, and hole finishing by ECM. These steps are performed in sequence on the same machine tool. In order to evaluate a hybrid micro machine tool from the environmental point of view, machining energy, the volume of machining liquid, and installation space of hybrid micro machine tool are measured. The measured values are compared with estimated values when same complex machining is carried out with conventional machine tools. Machining energy, the volume of machining liquid, and installation space of hybrid micro machine tool areone-hundredth times smaller than that of conventional machine tool.
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In this paper, main mechanism and measurement method of energy consumption for machine tools are investigated by experiment and simulation. To evaluate total energy consumption of the machine tools, standard test workpiece and measuring method and test procedures are suggested. And, improvement of energy consumption evaluation by the motion kinematics theory is used. In addition, to estimate energy consumption of machine tools in design process, mass distribution of the structure and 5 axis motions are investigated and simulated by numerical analysis.
Machine tool
Consumption
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Frustum
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Position (finance)
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Abstract Machine tools usually cut two or more surfaces after the work piece clamped on work table. In order to improve the machining accuracy and optimize accuracy design, it is hoped that the geometric errors that influence the accuracy of machined surface prominently can be known beforehand, so the adjustment will be carried out with a definite objective rather than without any clue. Because the machining accuracy of each direction in 3-D space is different value, in this paper, machining accuracy failure mode was defined as the various combination of the machining accuracy of each direction according to whether it is up to the reserved objective value or not. A three-axis machine tool was selected as an example and there were 7 machining accuracy failure modes for it. Based on the generalized correlation analysis, the correlation relationships between 7 machining accuracy failure modes were analyzed, and the main failure modes that affect the machining accuracy of work piece to be machined were identified. For each machining accuracy failure mode, key geometric error that had major influence on it was identified based on sensitivity analysis. Finally, four stepped work pieces were milled by a 3-axis machine tool to illustrate the analytical method proposed in this study.
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In recent years, reducing the energy consumption of machine tools has been greatly required. Thus, the purpose of this study is to develop the system to generate the tool path so that it effectively reduces the energy consumption of the machine tool. In order to achieve this purpose, the simulation model of the energy consumption is proposed in this study. As the results, it is verified that the proposed model can simulate the energy consumption which varies with difference in the tool path. Therefore, the developed simulation model will be used for generating the tool path that can reduce the energy consumption of the machine tool in the machining process.
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In this study, the energy charging mechanism is mathematically modeled to determine the impact of design modifications on the thermofluidic behavior of a phase change material (PCM) filled in a triplex tube containment geometry. The surface area of the middle tube, where the PCM is placed, is supported by single or multi‐internal frustum tubes in vertical triplex tubes to increase the performance of the heating and cooling of the system. In addition to the ordinary straight triplex tubes, three more scenarios are considered: (1) changing the middle tube to the frustum tube, (2) changing the inner tube to the frustum tube, and (3) changing both the internal and central tubes to the frustum tubes. The impact of adopting the tube designs and gap width were studied. The outcomes reveal that the heat storage rates are increased for all frustum tube systems compared to the straight tube system. According to the results, the case of a gap width of 5 mm is the optimal one among the studied cases in terms of the melting time and the heat storage rate. Employing the frustum tube configuration with a 5‐mm gap width would save the melting time by 25.6% and increase the rate of heat storage by 32.8% compared to the base case of straight tubes.
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The machining error of a variableaxis NC machine tool is analyzed by studying the deformation of Stewart platform, the kinetic part of the machine tool. Vector expression of machining error is derived on the condition of static loads. Moreover, the machining error is preadjusted by establishing a relevant preadjusted model. The method is universal and provides a theoretical foundation to improve the machining accuracy of the machine tool in static stiffness. A simulation example is finally given, demonstrating that the machining error arisen from the static stiffness does exist and the error has to be corrected.
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