A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal Acceleration
When the CNC machining of continuous small line segments is performed, the direction of the machine tool movement will change abruptly at the corner of adjacent line segments. Therefore, a reasonable constraint on the feedrate at the corner is the prerequisite for achieving high-speed and high-preci...
| Main Authors: | , , , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-09-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/11/19/8837 |
| _version_ | 1797516857002950656 |
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| author | Peng Guo Ronghua Wang Zhebin Shen Haorong Zhang Peng Zhang Fei Lou Hengbo Li Yijie Wu |
| author_facet | Peng Guo Ronghua Wang Zhebin Shen Haorong Zhang Peng Zhang Fei Lou Hengbo Li Yijie Wu |
| author_sort | Peng Guo |
| collection | DOAJ |
| description | When the CNC machining of continuous small line segments is performed, the direction of the machine tool movement will change abruptly at the corner of adjacent line segments. Therefore, a reasonable constraint on the feedrate at the corner is the prerequisite for achieving high-speed and high-precision machining. To achieve this goal, a feedrate-constraint method based on the nominal acceleration was proposed. The proposed method obtains the predicted value of acceleration during the machining process by the machining trajectory prediction and acceleration filtering. Then, the feedrate at the corner is constrained, according to the predicted acceleration. Specifically, for any corner of adjacent line segments, the proposed method assumes that the CNC machining of a short path centered on the corner is carried out at a constant feedrate. First, the actual machining trajectory is predicted according to the transfer function of the servo system. Then, the nominal acceleration, when the CNC machining is carried out to the corner, is calculated and processed by a low-pass FIR filter. Last, the feedrate-constraint value at the corner is obtained according to the nominal acceleration and the preset normal acceleration. The advantage of the proposed method is that it can be used for different machining paths consisting of long segments or continuous small segments and it has no special requirement for the accuracy of the machining path. As a result, the feedrate-constraint value obtained is reasonable and the smooth machining process can be ensured. The simulation results in both 2D and 3D machining paths show that the proposed method is insensitive to the length of the line segment and the angle of the corner, and the calculated feedrate-constraint value is close to the theoretical value, which has good stability and versatility. In contrast, the feedrate-constraint values obtained by conventional methods change abruptly along the machining path, especially in the 3D simulation, which will damage the machining quality. The experiment was performed on a three-axis CNC machine tool controlled by a self-developed controller, and a free-form surface workpiece was machined by a conventional feedrate-constraint method and the proposed method, respectively. The experimental results showed that the proposed method can make the feedrate of the machining process higher and more stable. Then, machining defects such as overcutting and undercutting can be avoided and the machining quality can be improved. Therefore, the article proposes a new method to constrain the feedrate at the corner of continuous small line segments, which can improve the machining efficiency and quality of the CNC machining. |
| first_indexed | 2024-03-10T07:06:45Z |
| format | Article |
| id | doaj.art-6d6d51d5367141c58b065b00af245597 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T07:06:45Z |
| publishDate | 2021-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-6d6d51d5367141c58b065b00af2455972023-11-22T15:43:45ZengMDPI AGApplied Sciences2076-34172021-09-011119883710.3390/app11198837A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal AccelerationPeng Guo0Ronghua Wang1Zhebin Shen2Haorong Zhang3Peng Zhang4Fei Lou5Hengbo Li6Yijie Wu7State Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaDepartment of Electrical and Mechanical Engineering, Inner Mongolia Technical College of Mechanics and Electrics, Hohhot 010070, ChinaState Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaState Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaState Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaState Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaState Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaState Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaWhen the CNC machining of continuous small line segments is performed, the direction of the machine tool movement will change abruptly at the corner of adjacent line segments. Therefore, a reasonable constraint on the feedrate at the corner is the prerequisite for achieving high-speed and high-precision machining. To achieve this goal, a feedrate-constraint method based on the nominal acceleration was proposed. The proposed method obtains the predicted value of acceleration during the machining process by the machining trajectory prediction and acceleration filtering. Then, the feedrate at the corner is constrained, according to the predicted acceleration. Specifically, for any corner of adjacent line segments, the proposed method assumes that the CNC machining of a short path centered on the corner is carried out at a constant feedrate. First, the actual machining trajectory is predicted according to the transfer function of the servo system. Then, the nominal acceleration, when the CNC machining is carried out to the corner, is calculated and processed by a low-pass FIR filter. Last, the feedrate-constraint value at the corner is obtained according to the nominal acceleration and the preset normal acceleration. The advantage of the proposed method is that it can be used for different machining paths consisting of long segments or continuous small segments and it has no special requirement for the accuracy of the machining path. As a result, the feedrate-constraint value obtained is reasonable and the smooth machining process can be ensured. The simulation results in both 2D and 3D machining paths show that the proposed method is insensitive to the length of the line segment and the angle of the corner, and the calculated feedrate-constraint value is close to the theoretical value, which has good stability and versatility. In contrast, the feedrate-constraint values obtained by conventional methods change abruptly along the machining path, especially in the 3D simulation, which will damage the machining quality. The experiment was performed on a three-axis CNC machine tool controlled by a self-developed controller, and a free-form surface workpiece was machined by a conventional feedrate-constraint method and the proposed method, respectively. The experimental results showed that the proposed method can make the feedrate of the machining process higher and more stable. Then, machining defects such as overcutting and undercutting can be avoided and the machining quality can be improved. Therefore, the article proposes a new method to constrain the feedrate at the corner of continuous small line segments, which can improve the machining efficiency and quality of the CNC machining.https://www.mdpi.com/2076-3417/11/19/8837continuous small line segmentsCNC machiningcornerfeedrateacceleration |
| spellingShingle | Peng Guo Ronghua Wang Zhebin Shen Haorong Zhang Peng Zhang Fei Lou Hengbo Li Yijie Wu A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal Acceleration Applied Sciences continuous small line segments CNC machining corner feedrate acceleration |
| title | A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal Acceleration |
| title_full | A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal Acceleration |
| title_fullStr | A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal Acceleration |
| title_full_unstemmed | A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal Acceleration |
| title_short | A Feedrate-Constraint Method for Continuous Small Line Segments in CNC Machining Based on Nominal Acceleration |
| title_sort | feedrate constraint method for continuous small line segments in cnc machining based on nominal acceleration |
| topic | continuous small line segments CNC machining corner feedrate acceleration |
| url | https://www.mdpi.com/2076-3417/11/19/8837 |
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