Design and control of a 5-DOF simulated cutting force loading device

Abstract

Reliability testing is essential for detecting early failures in computer numerical control (CNC) machine tools and enhancing their operational reliability. However, traditional ex-factory run-in tests require prolonged cutting of raw materials to simulate real-world conditions, leading to high costs, time consumption, and environmental impact. To address these challenges, this paper proposes a novel simulated cutting force loading device based on a parallel mechanism. The kinematics and dynamics of the device are thoroughly analyzed, and a unique force allocation method for redundant controlled variables is developed to improve the smoothness of pneumatic servo output by exploiting the characteristics of pneumatic actuation. Based on real-time kinematic and dynamic calculations, a force feedforward proportional integral derivative controller is designed. Loading experiments on a simulated spindle demonstrate the device’s ability to accurately apply static and low-to-medium-frequency dynamic loads to non-rotating spindles. Furthermore, experiments conducted on the rotating spindle of a CNC machine tool show that the proposed device can effectively simulate cutting forces, offering a cost-effective and environmentally friendly alternative to conventional cutting-based reliability tests.

Graphical abstract

Keywords

loading device / machine tool / reliability test / pneumatic actuation control strategy

References

[1] Yang Z J , Chen C H , Chen F , Li G F. . Progress in the research of reliability technology of machine tools. Journal of Mechanical Engineering, 2013, 49(20): 130–139

[2] Wang J , Wang X , Sun J , Zhao Q , Chen X , Li N , Li H , Yang X . Multi-dimensional force tracking-loading simulator development and simulation experiment for five-axis machining center. Advances in Mechanical Engineering, 2024, 16(9): 1–14

[3] Lian B , Sun T , Song Y , Jin Y , Price M . Stiffness analysis and experiment of a novel 5-DoF parallel kinematic machine considering gravitational effects. International Journal of Machine Tools and Manufacture, 2015, 95: 82–96

[4] Zhu B , Wang L , Wu J . Optimal design of loading device based on a redundantly actuated parallel manipulator. Mechanism and Machine Theory, 2022, 178: 105084

[5] Guo J , Wang D , Li T , Gao S , Chen W , Fan R . Triaxial loading device for reliability tests of three-axis machine tools. Robotics and Computer-Integrated Manufacturing, 2018, 49: 398–407

[6] Chen C , Wang C , Yang Z , Liu Z , Tian H. . Research status and development trend analysis of reliability modeling of CNC machine tools. Journal of Jilin University: Engineering and Technology Edition, 2022, 52(2): 253–266

[7] Li J , Li Y , Wen S , Zhang G . A novel method of key meta-action unit integrated identification for CNC machine tool reliability. Computers & Industrial Engineering, 2023, 177: 109073

[8] Wang X Y , Wang P , Lang H . Reliability prediction of CNC machine tool spindle based on optimized cascade feedforward neural network. IEEE Access: Practical Innovations, Open Solutions, 2021, 9: 60682–60688

[9] Yang Z , He J , Liu Z , Li G , Chen C. . Recent progress in reliability technology of CNC machine tools.. Journal of Mechanical Engineering, 2023, 59(19): 152–163

[10] Li D Y, Piao C D, Wang D C, Zhao D J. Reliability prediction of CNC machine tools based on GM(1,1)-SVM combined model. In: 2020 5th International Conference on Mechanical, Control and Computer Engineering (ICMCCE). Harbin: IEEE, 2020, 35–40

[11] Zhang X , Li Y , Zhang G , Liu S , Ran Y . An early fault elimination method of computerized numerical control machine tools. International Journal of Advanced Manufacturing Technology, 2020, 106(11–12): 5049–5059

[12] Bebbington M, Lai C D, Zitikis R. Bathtub shaped failure rate life distributions. In: Stochastic Ageing and Dependence for Reliability. New York: Springer, 2006, 71–107

[13] Wang Y Q , Jia Y Z , Jiang W W . Early failure analysis of machining centers: a case study. Reliability Engineering & System Safety, 2001, 72(1): 91–97

[14] Rantatalo M , Aidanpää J O , Göransson B , Norman P . Milling machine spindle analysis using FEM and non-contact spindle excitation and response measurement. International Journal of Machine Tools and Manufacture, 2007, 47(7–8): 1034–1045

[15] Matsubara A , Sawamura R , Asano K , Muraki T . Non-contact measurement of dynamic stiffness of rotating spindle. Procedia CIRP, 2014, 14: 484–487

[16] Yang Z , Chen F , Luo W , Xu B , Wang S . Reliability test rig of the motorized spindle and improvements on its ability for high-speed and long-term tests. Shock and Vibration, 2021, 2021: 6637335

[17] Liang J , Wang L , Wu J , Liu Z , Yu G . Elimination of end effects in LMD by Bi-LSTM regression network and applications for rolling element bearings characteristic extraction under different loading conditions. Digital Signal Processing, 2020, 107: 102881

[18] Ding Z , Yang Z , Chen C , Chen W , Chen H , Liu Z . Improved sliding mode dynamic matrix control strategy: Application on spindle loading and precision measuring device based on piezoelectric actuator. Mechanical Systems and Signal Processing, 2022, 167: 108543

[19] Matsubara A , Asano K , Muraki T . Contactless dynamic tests for analyzing effects of speed and temperature on the natural frequency of a machine tool spindle. High-Speed Machining, 2015, 1(1): 18–26

[20] Takasugi K , Sakai H , Ooshima M , Noda D , Asakawa N . Development of contactless dynamic spindle testing using an eddy current brake. Precision Engineering, 2022, 74: 396–402

[21] Guo J , Wang D , Chen W , Fan R . Multiaxis loading device for reliability tests of machine tools. IEEE/ASME Transactions on Mechatronics, 2018, 23(4): 1930–1940

[22] Zhao J , Wang Z , Yang T , Xu J , Ma Z , Wang C . Design of a novel modal space sliding mode controller for electro-hydraulic driven multi-dimensional force loading parallel mechanism. ISA Transactions, 2020, 99: 374–386

[23] Wang L , Zhu B , Wu J , Zhang Y . Dynamic performance evaluation of parallel manipulators and its application in a 5-axis loading device. Multibody System Dynamics, 2022, 56(1): 49–67

[24] Yang C , Zheng S , Jin J , Zhu S , Han J . Forward kinematics analysis of parallel manipulator using modified global Newton-Raphson method. Journal of Central South University of Technology, 2010, 17(6): 1264–1270

[25] Zhu B , Wang L P , Wu J , Li Q . Optimization design and performance comparison of two 5-DOF parallel manipulators used for loading device. International Journal of Robotics and Automation, 2022, 37: 310–320

[26] Su Y X , Zheng C H , Sun D , Duan B Y . A simple nonlinear velocity estimator for high-performance motion control. IEEE Transactions on Industrial Electronics, 2005, 52(4): 1161–1169

[27] Wen D Y , Wan M , Linghu S C , Zhang W H. . A slip-line field model for independently characterizing shearing and ploughing effects in metal cutting processes.. Wear, 2024, 556–557: 205504

[28] Wan M , Wen D Y , Zhang W H , Yang Y . Prediction of cutting forces in flexible micro milling processes by considering the change of instantaneous cutting direction. Journal of Manufacturing Processes, 2023, 90: 180–195

[29] Chen D W , Wu J , Zhang B B , Wang L P , Liang J H. . Load spectrum compilation for machining center spindles based on S-shaped specimens. Journal of Tsinghua University (Science and Technology), 2018, 58(12): 1107–1114

[30] Zhang J , Cui C , Gu S , Wang T , Zhao L . Trajectory tracking control of pneumatic servo system: A variable gain ADRC approach. IEEE Transactions on Cybernetics, 2023, 53(11): 6977–6986

RIGHTS & PERMISSIONS

Higher Education Press