Circular tests for HSM machine tools: Bore machining application

TL;DR

This paper introduces a new protocol for analyzing high-speed machining (HSM) machine tools during circular interpolation, focusing on kinematic behavior and its impact on part quality and machining time.

Contribution

A novel testing protocol and kinematic model for HSM machine tools during circular interpolation, enhancing understanding of machine behavior and part accuracy.

Findings

Axis capacities significantly affect feed rate during interpolation

Kinematic model accurately predicts bore machining outcomes

Protocol improves assessment of HSM machine tool performance

Abstract

Today's High-Speed Machining (HSM) machine tool combines productivity and part quality. The difficulty inherent in HSM operations lies in understanding the impact of machine tool behaviour on machining time and part quality. Analysis of some of the relevant ISO standards (230-1998, 10791-1998) and a complementary protocol for better understanding HSM technology are presented in the first part of this paper. These ISO standards are devoted to the procedures implemented in order to study the behavior of machine tool. As these procedures do not integrate HSM technology, the need for HSM machine tool tests becomes critical to improving the trade-off between machining time and part quality. A new protocol for analysing the HSM technology impact during circular interpolation is presented in the second part of the paper. This protocol which allows evaluating kinematic machine tool behaviour during circular interpolation was designed from tests without machining. These tests are discussed and their results analysed in the paper. During the circular interpolation, axis capacities (such as acceleration or Jerk) related to certain setting parameters of the numerical control unit have a significant impact on the value of the feed rate. Consequently, a kinematic model for a circular-interpolated trajectory was developed on the basis of these parameters. Moreover, the link between part accuracy and kinematic machine tool behaviour was established. The kinematic model was ultimately validated on a bore machining simulation.