Design of a new fast tool positioning system and systematic study on its positioning stability

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

The challenge of maintaining good surface quality under high operational frequencies in freeform machining invokes the need for a deterministic error analysis approach and a quantitative understanding on how structural design affects the positioning errors. This paper proposes a novel stiff-support positioning system with a systematic error analysis approach which reveals the contributions of disturbances on the tool positioning errors. The new design reduces the structural complexity and enables the detailed modelling of the closed loop system. Stochastic disturbances are analysed in the frequency domain while the non-stochastic disturbances are simulated in the time domain. The predicted following error spectrum agrees with the measured spectrum across the frequency range and this approach is justified. The real tool positioning error, which is free from sensor noise, is revealed for the first time. The influences of moving mass under various bandwidth settings have been studied both theoretically and experimentally. It is found that a larger moving mass helps combating disturbances except the sensor noises. The influences of cutting force are modelled and experimentally verified in the micro lens array cutting experiments. The origins of the form errors of the lenslet are discussed based on the error analysis model.

Original languageEnglish
Pages (from-to)54-65
Number of pages12
JournalInternational Journal of Machine Tools and Manufacture
Volume142
Early online date30 Apr 2019
DOIs
Publication statusPublished - 31 Jul 2019

Fingerprint

Error analysis
Systematic errors
Sensors
Structural design
Closed loop systems
Surface properties
Lenses
Machining
Bandwidth
Experiments

Keywords

  • freeform machining
  • positioning stability
  • following error
  • error analysis
  • fast tool servo

Cite this

@article{be82bb69bd874cb4b0d0281dfc118a2f,
title = "Design of a new fast tool positioning system and systematic study on its positioning stability",
abstract = "The challenge of maintaining good surface quality under high operational frequencies in freeform machining invokes the need for a deterministic error analysis approach and a quantitative understanding on how structural design affects the positioning errors. This paper proposes a novel stiff-support positioning system with a systematic error analysis approach which reveals the contributions of disturbances on the tool positioning errors. The new design reduces the structural complexity and enables the detailed modelling of the closed loop system. Stochastic disturbances are analysed in the frequency domain while the non-stochastic disturbances are simulated in the time domain. The predicted following error spectrum agrees with the measured spectrum across the frequency range and this approach is justified. The real tool positioning error, which is free from sensor noise, is revealed for the first time. The influences of moving mass under various bandwidth settings have been studied both theoretically and experimentally. It is found that a larger moving mass helps combating disturbances except the sensor noises. The influences of cutting force are modelled and experimentally verified in the micro lens array cutting experiments. The origins of the form errors of the lenslet are discussed based on the error analysis model.",
keywords = "freeform machining, positioning stability, following error, error analysis, fast tool servo",
author = "Fei Ding and Xichun Luo and Wenbin Zhong and Wenlong Chang",
year = "2019",
month = "7",
day = "31",
doi = "10.1016/j.ijmachtools.2019.04.008",
language = "English",
volume = "142",
pages = "54--65",
journal = "International Journal of Machine Tools and Manufacture",
issn = "0890-6955",

}

TY - JOUR

T1 - Design of a new fast tool positioning system and systematic study on its positioning stability

AU - Ding, Fei

AU - Luo, Xichun

AU - Zhong, Wenbin

AU - Chang, Wenlong

PY - 2019/7/31

Y1 - 2019/7/31

N2 - The challenge of maintaining good surface quality under high operational frequencies in freeform machining invokes the need for a deterministic error analysis approach and a quantitative understanding on how structural design affects the positioning errors. This paper proposes a novel stiff-support positioning system with a systematic error analysis approach which reveals the contributions of disturbances on the tool positioning errors. The new design reduces the structural complexity and enables the detailed modelling of the closed loop system. Stochastic disturbances are analysed in the frequency domain while the non-stochastic disturbances are simulated in the time domain. The predicted following error spectrum agrees with the measured spectrum across the frequency range and this approach is justified. The real tool positioning error, which is free from sensor noise, is revealed for the first time. The influences of moving mass under various bandwidth settings have been studied both theoretically and experimentally. It is found that a larger moving mass helps combating disturbances except the sensor noises. The influences of cutting force are modelled and experimentally verified in the micro lens array cutting experiments. The origins of the form errors of the lenslet are discussed based on the error analysis model.

AB - The challenge of maintaining good surface quality under high operational frequencies in freeform machining invokes the need for a deterministic error analysis approach and a quantitative understanding on how structural design affects the positioning errors. This paper proposes a novel stiff-support positioning system with a systematic error analysis approach which reveals the contributions of disturbances on the tool positioning errors. The new design reduces the structural complexity and enables the detailed modelling of the closed loop system. Stochastic disturbances are analysed in the frequency domain while the non-stochastic disturbances are simulated in the time domain. The predicted following error spectrum agrees with the measured spectrum across the frequency range and this approach is justified. The real tool positioning error, which is free from sensor noise, is revealed for the first time. The influences of moving mass under various bandwidth settings have been studied both theoretically and experimentally. It is found that a larger moving mass helps combating disturbances except the sensor noises. The influences of cutting force are modelled and experimentally verified in the micro lens array cutting experiments. The origins of the form errors of the lenslet are discussed based on the error analysis model.

KW - freeform machining

KW - positioning stability

KW - following error

KW - error analysis

KW - fast tool servo

UR - https://www.journals.elsevier.com/international-journal-of-machine-tools-and-manufacture

U2 - 10.1016/j.ijmachtools.2019.04.008

DO - 10.1016/j.ijmachtools.2019.04.008

M3 - Article

VL - 142

SP - 54

EP - 65

JO - International Journal of Machine Tools and Manufacture

JF - International Journal of Machine Tools and Manufacture

SN - 0890-6955

ER -