Ward, R. orcid.org/0000-0002-6201-0285, Sencer, B., Jones, B. orcid.org/0000-0002-7465-1389 et al. (1 more author) (2021) Accurate prediction of machining feedrate and cycle times considering interpolator dynamics. The International Journal of Advanced Manufacturing Technology, 116 (1-2). pp. 417-438. ISSN 0268-3768
Abstract
This paper presents an accurate machining feedrate prediction technique by modelling the trajectory generation behaviour of modern CNC machine tools. Typically, CAM systems simulate machines’ motion based on the commanded feedrate and the path geometry. Such approach does not consider the feed planning and interpolation strategy of the machine’s numerical control (NC) system. In this study, trajectory generation behaviour of the NC system is modelled and accurate cycle time prediction for complex machining toolpaths is realised. NC system’s linear interpolation dynamics and commanded axis kinematic profiles are predicted by using finite impulse response (FIR)–based low-pass filters. The corner blending behaviour during non-stop interpolation of linear segments is modelled, and for the first time, the minimum cornering feedrate that satisfies both the tolerance and machining constraints has been calculated analytically for 3-axis toolpaths of any geometry. The proposed method is applied to 4 different case studies including complex machining toolpaths. Experimental validations show actual cycle times can be estimated with > 90% accuracy, greatly outperforming CAM-based predictions. It is expected that the proposed approach will help improve the accuracy of virtual machining models and support businesses’ decision-making when costing machining processes.
Metadata
Item Type: | Article |
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Authors/Creators: |
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Copyright, Publisher and Additional Information: | © 2021 The Author(s). This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article's Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article's Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/. |
Keywords: | Interpolation; Feedrate prediction; FIR filters; Cycle time estimation; Milling |
Dates: |
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Institution: | The University of Sheffield |
Academic Units: | The University of Sheffield > Faculty of Engineering (Sheffield) > Department of Automatic Control and Systems Engineering (Sheffield) |
Funding Information: | Funder Grant number Engineering and Physical Sciences Research Council EP/L016257/1 |
Depositing User: | Symplectic Sheffield |
Date Deposited: | 30 Mar 2022 08:24 |
Last Modified: | 30 Mar 2022 08:24 |
Status: | Published |
Publisher: | Springer Nature |
Refereed: | Yes |
Identification Number: | 10.1007/s00170-021-07211-2 |
Open Archives Initiative ID (OAI ID): | oai:eprints.whiterose.ac.uk:185222 |