Enhancing Milling Surface Finish: The Role of Servo Parameters and Machining Stability
Received: 14 June 2024 | Revised: 11 July 2024 | Accepted: 13 July 2024 | Online: 9 October 2024
Corresponding author: Jui-Pin Hung
Abstract
Abnormal machining vibrations and inconsistent machining quality are commonly observed in high-speed machining operations and are often attributed to the inappropriate characteristics of servo dynamics and structural resonance caused by feeding motions with higher jerk. An understanding of the manner in which distinct servo system parameters impact machining, can facilitate the refinement of machine tool tuning, thereby enabling the achievement of desired machining outcomes. In practical terms, the servo parameters, including feeding acceleration and jerk, control gains, and feed-forward compensation, can be appropriately determined based on the characteristics of the machine in question, such as the presence of dynamic errors in positioning and contouring paths. This study aims to evaluate the interactive effects between servo parameters and machining parameters to gain insight into their influence on machining quality. In order to achieve this objective, different servo parameters were tuned to meet various machining requirements, and cutting experiments were conducted with consideration of the cutter stability. The results are expected to provide guidance on the control of servo systems and the optimization of machining parameters, ensuring that servo tuning effectively enhances machine tool cutting performance.
Keywords:
cutting conditions, machining stability, servo parameters, surface qualityDownloads
References
M. R. Bayoumi and A. K. Abdellatif, "Effect of surface finish on fatigue strength," Engineering Fracture Mechanics, vol. 51, no. 5, pp. 861–870, Jul. 1995.
T. H. Le, V. B. Pham, and T. D. Hoang, "Surface Finish Comparison of Dry and Coolant Fluid High-Speed Milling of JIS SDK61 Mould Steel," Engineering, Technology & Applied Science Research, vol. 12, no. 1, pp. 8023–8028, Feb. 2022.
V. C. Nguyen, T. D. Nguyen, and D. H. Tien, "Cutting Parameter Optimization in Finishing Milling of Ti-6Al-4V Titanium Alloy under MQL Condition using TOPSIS and ANOVA Analysis," Engineering, Technology & Applied Science Research, vol. 11, no. 1, pp. 6775–6780, Feb. 2021.
C. Sukkam and S. Chaijit, "Investigation of Influencing Factors on Surface Quality during Low-Speed Cutting of Steels with a Hardness exceeding 50 HRC for forging Dies," Engineering, Technology & Applied Science Research, vol. 14, no. 3, pp. 14056–14061, Jun. 2024.
M. Arizmendi et al., "Model for surface topography prediction in peripheral milling considering tool vibration,"CIRP Annals, vol. 58, no. 1, pp. 93–96, Jan. 2009.
C. David, D. Sagris, E. Stergianni, C. Tsiafis, and I. Tsiafis, "Experimental Analysis of the Effect of Vibration Phenomena on Workpiece Topomorphy Due to Cutter Runout in End-Milling Process †," Machines, vol. 6, no. 3, Sep. 2018, Art. no. 27.
S. Zahoor, N. A. Mufti, M. Q. Saleem, M. P. Mughal, and M. A. M. Qureshi, "Effect of machine tool’s spindle forced vibrations on surface roughness, dimensional accuracy, and tool wear in vertical milling of AISI P20," The International Journal of Advanced Manufacturing Technology, vol. 89, no. 9, pp. 3671–3679, Apr. 2017.
Y.-S. Lai, W.-Z. Lin, Y.-C. Lin, and J.-P. Hung, "Development of Surface Roughness Prediction and Monitoring System in Milling Process," Engineering, Technology & Applied Science Research, vol. 14, no. 1, pp. 12797–12805, Feb. 2024.
R. Neugebauer, B. Denkena, and K. Wegener, "Mechatronic Systems for Machine Tools," CIRP Annals, vol. 56, no. 2, pp. 657–686, Jan. 2007.
Y. Altintas, C. Brecher, M. Weck, and S. Witt, "Virtual Machine Tool," CIRP Annals, vol. 54, no. 2, pp. 115–138, Jan. 2005.
K. Nishio, R. Sato, and K. Shirase, "Influence of Motion Errors of Feed Drive Systems on Machined Surface," Journal of Advanced Mechanical Design, Systems, and Manufacturing, vol. 6, pp. 781–791, Jan. 2012.
B. Li, B. Luo, X. Mao, H. Cai, F. Peng, and H. Liu, "A new approach to identifying the dynamic behavior of CNC machine tools with respect to different worktable feed speeds," International Journal of Machine Tools and Manufacture, vol. 72, pp. 73–84, Sep. 2013.
R. Sato, Y. Sato, K. Shirase, G. Campatelli, and A. Scippa, "Finished Surface Simulation Method to Predicting the Effects of Machine Tool Motion Errors," International Journal of Automation Technology, vol. 8, no. 6, pp. 801–810, 2014.
R. Sato, G. Tashiro, and K. Shirase, "Analysis of the Coupled Vibration Between Feed Drive Systems and Machine Tool Structure," International Journal of Automation Technology, vol. 9, no. 6, pp. 689–697, 2015.
J. Grau, P. Souček, and M. Sulitka, "The Influence of Servo Drive Control on the NC Vertical Milling Machine Dynamic Compliance," Journal of Manufacturing and Materials Processing, vol. 4, no. 4, Dec. 2020, Art. no. 111.
X. Beudaert, O. Franco, K. Erkorkmaz, and M. Zatarain, "Feed drive control tuning considering machine dynamics and chatter stability," CIRP Annals, vol. 69, no. 1, pp. 345–348, Jan. 2020.
Y. Kakino, A. Matsubara, D. Ueda, H. Nakagawa, T. Takeshita, and H. Maruyama, "A Study on the Total Tuning of Feed Drive Systems in NC Machine Tools (3rd Report)," Journal of the Japan Society for Precision Engineering, vol. 62, no. 3, pp. 423–427, 1996.
R. Neugebauer, S. Ihlenfeldt, U. Frieß, M. Wabner, and S. Rauh, "New High-Speed Machine Tool Structure by Holistic Mechatronic Systems Design," Procedia CIRP, vol. 1, pp. 307–312, Jan. 2012.
A. Fortunato and A. Ascari, "The virtual design of machining centers for HSM: Towards new integrated tools," Mechatronics, vol. 23, no. 3, pp. 264–278, Apr. 2013.
T. Zhang, D. Zhang, Z. Zhang, and M. Muhammad, "Investigation on the load-inertia ratio of machine tools working in high speed and high acceleration processes," Mechanism and Machine Theory, vol. 155, Jan. 2021, Art. no. 104093.
H. Zhou, J. Yang, Y. Guo, K. Zhang, and H. Xiang, "An optimization method of acceleration and deceleration time of feed system based on load inertia," Measurement Science and Technology, vol. 35, no. 5, Feb. 2024, Art. no. 056207.
Heidenhain. Technical Manual iTNC530 HSCI. Traunreut, Germany: Heidenhain.
SINUMERIK 840D sl Basic Functions–Function Manual. Germany: Siemens, 2013.
Fanuc AC Servo Motor Parameter Manual, 9th ed. Oshino-mura, Yamanashi Prefecture, Japan: Fanuc Co.
K. Lee et al., "A Servo Parameter Tuning Method For Highspeed Nc Machine Tools Based On Contouring Error Measurement," Transactions on Engineering Sciences, vol. 44, pp. 181–192, 2003.
B.-F. Yu and J.-S. Chen, "Development of an Analyzing and Tuning Methodology for the CNC Parameters Based on Machining Performance," Applied Sciences, vol. 10, no. 8, Jan. 2020, Art. no. 2702.
S.-F. Wu, C.-H. Lee, and B.-R. Tseng, "Intelligent Servo Tuning of High-Speed Machine Tools Using Circular Test," IEEE Sensors Journal, vol. 23, no. 11, pp. 12084–12092, Jun. 2023.
C. K. Chen and C. Y, Kai, "Introduction of Auto Tuning Technology of Servo System in Machine Tool", Journal of the Mechatronic Industry, vol. 416,pp. 14-22, 2017.
Y.-C. Lin, K.-D. Wu, W.-C. Shih, P.-K. Hsu, and J.-P. Hung, "Prediction of Surface Roughness Based on Cutting Parameters and Machining Vibration in End Milling Using Regression Method and Artificial Neural Network," Applied Sciences, vol. 10, no. 11, Jan. 2020, Atrt no. 3941.
Y. Altintaş and E. Budak, "Analytical Prediction of Stability Lobes in Milling," CIRP Annals, vol. 44, no. 1, pp. 357–362, Jan. 1995.
Downloads
How to Cite
License
Copyright (c) 2024 Zheng-Mou Su, Wei-Zhu Lin, Yung-Chih Lin, Jui-Pin Hung
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.