Research Papers

A Multi-Tier Design Methodology for Reconfigurable Milling Machines

[+] Author and Article Information
Hay Azulay

Department of Mechanical and
Industrial Engineering,
University of Toronto,
5 King's College Road,
Toronto, ON M5S 3G8, Canada
e-mail: h.azulay@utoronto.ca

James K. Mills

Department of Mechanical and
Industrial Engineering,
University of Toronto,
5 King's College Road,
Toronto, ON M5S 3G8, Canada
e-mail: mills@mie.utoronto.ca

Beno Benhabib

Department of Mechanical and
Industrial Engineering,
University of Toronto,
5 King's College Road,
Toronto, ON M5S 3G8, Canada
e-mail: benhabib@mie.utoronto.ca

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received June 7, 2013; final manuscript received March 23, 2014; published online May 21, 2014. Assoc. Editor: Robert Landers.

J. Manuf. Sci. Eng 136(4), 041007 (May 21, 2014) (10 pages) Paper No: MANU-13-1253; doi: 10.1115/1.4027315 History: Received June 07, 2013; Revised March 23, 2014

Reconfigurable Machine Tools (RMTs) have been developed in response to agile flexible manufacturing demands. Current design methodologies for RMTs support modular reconfigurability in which a machine configuration is assembled for a given part. In this paper, on the other hand, reconfigurability relies on redundancy, namely, a desired RMT configuration is obtained through topological reconfiguration by locking/unlocking degrees-of-freedom (dof). Thus, in order to design a Redundant Reconfigurable Machine Tool (RRMT) with all of its dof already included, a new multi–tier optimization based design methodology was developed. The design is formulated for the efficient selection of the best architecture from a set of serial/parallel/hybrid solutions, while considering the redundant reconfigurability effect on performance. The viability of the methodology is demonstrated herein via a design test case of a Parallel Kinematic Mechanism (PKM)-based Redundant Reconfigurable meso-Milling Machine Tool (RRmMT) that can attain high stiffness at the high feed-rate required in meso-milling.

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Fig. 1

Pseudo-code for the five-tier optimization-based design methodology

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Fig. 2

Actuation schema of the configurations of: (a) 7-dof Eclipse based RRmMT, (b) 7-dof UofT based RRmMT

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Fig. 3

Schematics of the stiffness model of UofT PKM based RRmMT

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Fig. 5

Machining feature of Part 1: (a) isometric view and (b) side view

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Fig. 4

FEA and MSA static stiffness simulations results of postures of the Eclipse based RRmMT

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Fig. 7

Machining feature of Part 3

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Fig. 6

Machining feature of Part 2

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Fig. 11

Kyy stiffness of Configuration I of the 7-dof Eclipse based RRmMT with Part 1, for: (case (a)) x-axis workpiece-holder stage, (case (b)) y-axis workpiece-holder stage

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Fig. 10

Mean stiffness of Configuration I and II of the 7-dof Eclipse based RRmMT with Part 2

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Fig. 9

7-dof Eclipse based RRmMT: task allocation of Configuration II with Part 1

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Fig. 8

7-dof Eclipse based RRmMT—static stiffness of Configurations I and II relative to Part 1



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