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Research Papers

Energy Consumption of Feed Drive Systems Based on Workpiece Setting Position in Five-Axis Machining Center

[+] Author and Article Information
Ryuta Sato

Department of Mechanical Engineering,
Kobe University,
1-1 Rokko-dai, Nada,
Kobe 657-8501, Japan
e-mail: sato@mech.kobe-u.ac.jp

Keiichi Shirase

Mem. ASME
Department of Mechanical Engineering,
Kobe University,
1-1 Rokko-dai, Nada,
Kobe 657-8501, Japan
e-mail: shirase@mech.kobe-u.ac.jp

Akio Hayashi

Department of Mechanical Engineering,
Kanazawa Institute of Technology,
7-1 Ohgigaoka,
Nonoichi 921-8501, Ishikawa, Japan
e-mail: a-hayashi@neptune.kanazawa-it.ac.jp

1Corresponding author.

Manuscript received April 1, 2017; final manuscript received July 18, 2017; published online December 18, 2017. Assoc. Editor: Christopher Tyler.

J. Manuf. Sci. Eng 140(2), 021008 (Dec 18, 2017) (7 pages) Paper No: MANU-17-1211; doi: 10.1115/1.4037427 History: Received April 01, 2017; Revised July 18, 2017

Energy consumption of numerical control (NC) machine tools is one of the key issues in modern industrial field. This study focuses on reducing the energy consumed by a five-axis machining center by changing only the workpiece setting position. Previous studies show that the movements along each axis in five-axis machining centers depend on the workpiece setting position, regardless of whether the same operation is performed. In addition, the energy consumptions required for the movements are different along each axis. From these considerations, an optimum workpiece setting position that can minimize the energy consumed during these motions is assumed to exist. To verify this assumption, in this study, the energy consumed by the feed drive systems of an actual five-axis machining center is first measured and then estimated using the proposed model in this study. The model for estimating the energy consumption comprises the friction, motor, and amplifier losses along each axis. The total energy consumption can be estimated by adding the energy consumptions along each axis. The effect of the workpiece setting position on the energy consumption is investigated by employing the cone-frustum cutting motion with simultaneous five-axis motions. The energy consumption that depends on the workpiece setting position is first measured and then estimated. The results confirm that the proposed model can estimate the energy consumption accurately. Moreover, the energy consumption is confirmed to depend on the workpiece setting position; the minimum energy consumption is found to be 20% lower than the maximum one.

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Figures

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Fig. 1

Power breakdown as a function of load from material removal [12]

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Fig. 2

Structural configuration of a five-axis machining center

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Fig. 3

Measurement point of power consumption

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Fig. 4

Influence of gravity on motor torque of B-axis: (a) schematic drawing and (b) relationship between tilting angle and motor torque (500 deg/min)

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Fig. 5

Relationship between angular velocity and torque of X-axis motor

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Fig. 6

Comparison of velocity, torque, and electric power of X-axis (3000 mm/min): (a) velocity, (b) torque, and (c) electric power

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Fig. 7

Relationship between angular velocity and power consumption and each loss of X-axis: (a) friction loss PLF and motor loss PLM and (b) amplifier loss PLA

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Fig. 8

Schematic illustration of cone-frustum cutting: (a) Z–X plane view and (b) Y–Z plane view

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Fig. 9

Velocity changing of each axis during cone-frustum cutting motion (dz = 0 mm, dy = 60 mm, dz = 70 mm): (a) translational axes and (b) rotary axes

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Fig. 10

Workpiece setting points for comparison

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Fig. 11

Comparison of power consumption of feed drive systems depending on the workpiece setting position

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Fig. 12

Comparison of energy consumption of feed drive systems depending on the workpiece setting position: (a) measured energy consumption and (b) estimated energy consumption

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