0
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.

FIGURES IN THIS ARTICLE
<>
Copyright © 2014 by ASME
Your Session has timed out. Please sign back in to continue.

References

Moon, Y.-M., and Kota, S., 2002, “Design of Reconfigurable Machine Tools,” ASME J. Manuf. Sci. E, 124(2), pp. 480–483. [CrossRef]
Cheng, K., and Huo, D., 2013, Micro Cutting—Fundamentals and Applications, John Wiley & Sons, Oxford, UK.
Dhanorker, A., and Özel, T., 2008, “Meso/Micro Scale Milling for Micro-Manufacturing,” Int. J. Mechatronics Manuf. Syst., 1(1), pp. 23–41. [CrossRef]
Zhang, D., Wang, L., and Lang, S. Y. T., 2005, “Parallel Kinematic Machines: Design, Analysis, and Simulation in an Integrated Virtual Environment,” ASME J. Mech. Des., 127(4), pp. 580–588. [CrossRef]
Weck, M., and Staimer, D., 2002, “Parallel Kinematic Machine Tools-Current State and Future Potentials,” CIRP Ann., 51(2), pp. 671–683. [CrossRef]
Zhang, D., 2010, Parallel Robotic Machine Tools, Springer, New York/Dordrecht, Heidelberg.
Son, S., Kim, T., Sarma, S. E., and Slocum, A., 2009, “A Hybrid 5-Axis CNC Milling Machine,” Precis. Eng., 33(4), pp. 430–446. [CrossRef]
Gogu, G., 2008, Structural Synthesis of Parallel Robots Part 1: Methodology, Springer, Dordrecht, Netherlands.
Harib, K. H., Sharif Ullah, A. M. M., and Hammami, A., 2007, “A Hexapod-Based Machine Tool With Hybrid Structure: Kinematic Analysis and Trajectory Planning,” Int. J. Mach. Tool Manuf., 47(9), pp. 1426–1432. [CrossRef]
Owen, W. S., Croft, E. A., and Benhabib, B., 2008, “A Multi-Arm Robotic System for Optimal Sculpting,” Rob. Comput.-Integr. Manf., 24(1), pp. 92–104. [CrossRef]
Bi, Z. M., Lang, S., Verner, M., and Orban, P., 2008, “Development of Reconfigurable Machines,” Int. J. Adv. Manuf. Technol., 39(11), pp. 1227–1251. [CrossRef]
Zhang, D., 2006, “On the Re-Configurability Design of Parallel Machine Tools,” Information Technology for Balanced Manufacturing Systems, W.Shen, ed., Springer, Boston, MA, pp. 309–316.
Bi, Z. M., and Kang, B., 2010, “Enhancement of Adaptability of Parallel Kinematic Machines With an Adjustable Platform,” J Manuf. Sci. E, 132(6), p. 061016. [CrossRef]
Plitea, N., Lese, D., Pisla, D., and Vaida, C., 2013, “Structural Design and Kinematics of a New Parallel Reconfigurable Robot,” Rob. Comput.-Integr. Manf., 29, pp. 219–235. [CrossRef]
Budde, C., Helm, M., Last, P., Raatz, A., and Hesselbach, J., 2011, “Configuration Switching for Workspace Enlargement,” Robotic Systems for Handling and Assembly, D.Schütz, and F.Wahl, eds., Springer, Berlin Heidelberg, pp. 175–189.
Ye, W., Fang, Y., Zhang, K., and Guo, S., 2014, “A New Family of Reconfigurable Parallel Mechanisms With Diamond Kinematotropic Chain,” Mech. Mach. Theory, 74, pp. 1–9. [CrossRef]
Honegger, A. E., Langstaff, G. Q., Phillip, A. G., VanRavenswaay, T. D., Kapoor, S. G., and DeVor, R. E., 2006, “Development of an Automated Microfactory: Part 1—Microfactory Architecture and Sub-Systems Development,” Transactions of the North American Manufacturing Research Institute of SME, 34, pp. 334–340.
Azulay, H., Hawryluck, C., Mills, J. K., and Benhabib, B., 2011, “Configuration Design of a Meso-Milling Machine,” Proceedings of the 23rd CANCAM Vancouver, Canada.
Zhao, R., Azulay, H., Mahmoodi, M., Mills, J. K., and Benhabib, B., 2013, “Analysis of 6-dof 3×PPRS Parallel Kinematic Mechanisms for Meso-Milling,” 2nd International Conference on Virtual Machining Process Technology, Hamilton, Canada.
Kannan, M., and Saha, J., 2009, “A Feature-Based Generic Setup Planning for Configuration Synthesis of Reconfigurable Machine Tools,” Int. J. Adv. Manuf. Technol., 43(9), pp. 994–1009. [CrossRef]
Chen, L., Xi, F., and Macwan, A., 2005, “Optimal Module Selection for Preliminary Design of Reconfigurable Machine Tools,” ASME J. Manuf. Sci. E, 127(1), pp. 104–115. [CrossRef]
Bi, Z. M., and Wang, L., 2009, “Optimal Design of Reconfigurable Parallel Machining Systems,” Rob. Comput.-Integr. Manf., 25(6), pp. 951–961. [CrossRef]
Liu, W., and Liang, M., 2008, “Multi-Objective Design Optimization of Reconfigurable Machine Tools: A Modified Fuzzy-Chebyshev Programming Approach,” Int. J. Prod. Res., 46(6), pp. 1587–1618. [CrossRef]
Dash, A. K., Chen, I.-M., Yeo, S. H., and Yang, G., 2005, “Task-Oriented Configuration Design for Reconfigurable Parallel Manipulator Systems,” Int. J. Comput.-Int. Manuf., 18(7), pp. 615–634. [CrossRef]
Belchior, J., Guillo, M., Courteille, E., Maurine, P., Leotoing, L., and Guines, D., 2013, “Off-Line Compensation of the Tool Path Deviations on Robotic Machining: Application to Incremental Sheet Forming,” Rob. Comput.-Integr. Manuf., 29(4), pp. 58–69. [CrossRef]
Pateloup, S., Chanal, H., and Duc, E., 2012, “Process Definition of Preformed Part Machining for Taking Benefit of Parallel Kinematic Machine Tool Kinematic Performances,” Int. J. Adv. Manuf. Technol., 58(9), pp. 869–883. [CrossRef]
Finistauri, A. D., and Xi, F., 2013, “Reconfiguration Analysis of a Fully Reconfigurable Parallel Robot,” J. Mech. Rob., pp. 295–304. [CrossRef]
Abouridouane, M., Klocke, F., Lung, D., and Adams, O., 2012, “Size Effects in Micro Drilling Ferritic-Pearlitic Carbon Steels,” CIRP Conference on Manufacturing Systems, pp. 91–96.
Phillip, A. G., Kapoor, S. G., and DeVor, R. E., 2006, “A New Acceleration-Based Methodology for Micro/Meso-Scale Machine Tool Performance Evaluation,” Int. J. Mach. Tool Manuf., 46(12–13), pp. 1435–1444. [CrossRef]
Nanomotion, 2013, “Nanomotion,” http://www.nanomotion.com/
Pérez, R., Molina, A., and Ramirez, M., 2014, “Development of an Integrated Approach to the Design of Reconfigurable Micro/Meso-Scale CNC Machine Tools,” J. Manuf. Sci. E, 136(3), p. 031003. [CrossRef]
Breitkopf, P., and Coelho, R. F., 2010, Design Optimization in Computational Mechanics, Wiley-ISTE, London/Hoboken, NJ.
Phillips, C. A., and Drake, J. C., 2000, “Trajectory Optimization for a Missile Using a Multitier Approach,” J. Spacecr. Rockets, 37(5), pp. 653–662. [CrossRef]
Chin-Yin, C., and Chi-Cheng, C., 2005, “Integrated Design for a Mechatronic Feed Drive System of Machine Tools,” Proceedings, 2005 IEEE/ASME International Conference on Advanced Intelligent Mechatronics, Monterey, CA, July 24–28, pp. 588–593. [CrossRef]
Jongwon, K., Chongwoo, P., Sun Joong, R., Jinwook, K., JaeChul, H., Changbeom, P., and Iurascu, C. C., 2001, “Design and Analysis of a Redundantly Actuated Parallel Mechanism for Rapid Machining,” IEEE J. Rob. Autom., 17(4), pp. 423–434. [CrossRef]
Azulay, H., Mahmoodi, M., Zhao, R., Mills, J. K., and Benhabib, B., 2014, “Comparative Analysis of a New 3 × PPRS Parallel Kinematic Mechanism,” Rob. Comput. Integr. Manuf, 30(4), pp. 369–378. [CrossRef]
Bibber, D., 2010, “Earning Respect, Little by Little,” Med. Manuf., pp. 53–55.
Sutherland, J. W., and DeVor, R. E., 1988, “A Dynamic Model for the Cutting Force System in the End Milling Process,” Sensors and Controls for Manufacturing, ASME-PED, 33, pp. 52–62.
Schaller, T., John, L., Mayer, J., and Schubert, K., 1999, “Microstructure Grooves With a Width of Less than 50 μm Cut With Ground Hard Metal Micro End Mills,” Precis. Eng., 23, pp. 229–235. [CrossRef]
Mishima, N., 2004, “A Study on Optimization of Miniature Machine Tool Design,” Proceedings of 4th International Workshop on Microfactories (IWMF2004), Shanghai, China, pp. 56–61.

Figures

Grahic Jump Location
Fig. 1

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

Grahic Jump Location
Fig. 2

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

Grahic Jump Location
Fig. 3

Schematics of the stiffness model of UofT PKM based RRmMT

Grahic Jump Location
Fig. 4

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

Grahic Jump Location
Fig. 5

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

Grahic Jump Location
Fig. 6

Machining feature of Part 2

Grahic Jump Location
Fig. 7

Machining feature of Part 3

Grahic Jump Location
Fig. 8

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

Grahic Jump Location
Fig. 9

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

Grahic Jump Location
Fig. 10

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

Grahic Jump Location
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

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In