Kinematic modelling of a 3-axis NC machine tool in linear and circular interpolation

TL;DR

This paper presents improved models for simulating high-speed 3-axis CNC machine behaviour, accurately predicting machining times within 1% error by accounting for machine dynamics and transition tolerances.

Contribution

It introduces two novel models that enhance simulation accuracy of machine dynamics and transition paths, improving machining time predictions in high-speed machining.

Findings

Simulation error on machining time is below 1%.

Polynomial transition modeling eliminates acceleration leaps.

Enhanced dynamic simulation accounts for machine accelerations and tolerances.

Abstract

Machining time is a major performance criterion when it comes to high-speed machining. CAM software can help in estimating that time for a given strategy. But in practice, CAM-programmed feed rates are rarely achieved, especially where complex surface finishing is concerned. This means that machining time forecasts are often more than one step removed from reality. The reason behind this is that CAM routines do not take either the dynamic performances of the machines or their specific machining tolerances into account. The present article seeks to improve simulation of high-speed NC machine dynamic behaviour and machining time prediction, offering two models. The first contributes through enhanced simulation of three-axis paths in linear and circular interpolation, taking high-speed machine accelerations and jerks into account. The second model allows transition passages between blocks to be integrated in the simulation by adding in a polynomial transition path that caters for the true machining environment tolerances. Models are based on respect for path monitoring. Experimental validation shows the contribution of polynomial modelling of the transition passage due to the absence of a leap in acceleration. Simulation error on the machining time prediction remains below 1%.