Development and evaluation of the machining performance of a CNC gantry double motion machine tool in different modes

  • Abdul Hadi Jalaludin
  • Mohd Hamdi Abd Shukor
  • Noor Azizi Mardi
  • Ahmed Aly Diaa Mohammed Sarhan
  • Mohd Sayuti Ab Karim
  • Seyed Reza Besharati
  • Wan Nur Izzati Wan Badiuzaman
  • Yusuf S. Dambatta
ORIGINAL ARTICLE
  • 87 Downloads

Abstract

Conventional methods of building CNC machine tools involve using linear motors and ball screw drives to obtain table motion. The double opposite sync motion design is an improvement over traditional CNC machines. In this work, an enhanced CNC gantry machine design is proposed, which exhibits a double motion mechanism. The new design is based on a rack and pinion system such that both the gantry tool and worktable are movable. The gantry’s natural frequency was designed at 202 Hz in the first vibration mode, enabling it to work at higher speeds of up to 11,530 rpm, which makes the gantry suitable for both rough cutting and fine finishing. A prototype of the multi-mode motion CNC gantry milling machine was developed to investigate the machining performance and efficiency of the double opposite sync system. Performance analysis was done using ball bar precision tests on the different modes of CNC gantry operation. Validation tests were carried out to determine the effects of the motion of the machine parts on the dimensional accuracy and surface finish of the machined parts. The results indicated that the straightness of the developed machine was reduced from 176.3 to 114.6 μm, which occurred due to the reduced total distance travelled by the tool and worktable. Moreover, the circularity increased from 338.7 to 667.0 μm. This increase could be attributed to the combination of errors arising from both the gantry and table.

Keywords

CNC gantry Double motion Machining Accuracy Ball bar test Backlash 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Lu H, Tang D (2015) Design and Application on the Composite Rail of Column-Beams in Gantry Machine. In: 3rd International Conference on Material, Mechanical and Manufacturing Engineering-IC3ME. pp 1968–1973Google Scholar
  2. 2.
    Suh S-H, Lee E-S (2000) Contouring performance measurement and evaluation of NC machine controller for virtual machining CAM system. Int J Adv Manuf Technol 16(4):271–276CrossRefGoogle Scholar
  3. 3.
    Lin R-S, Koren Y (1996) Efficient tool-path planning for machining free-form surfaces. Journal of engineering for industry 118(1):20–28CrossRefGoogle Scholar
  4. 4.
    Du Z, Zhang S, Hong M (2010) Development of a multi-step measuring method for motion accuracy of NC machine tools based on cross grid encoder. Int J Mach Tools Manuf 50(3):270–280CrossRefGoogle Scholar
  5. 5.
    Gomez-Acedo, E., A. Olarra, and L. Lopez de la Calle, (2012) A method for thermal characterization and modeling of large gantry-type machine tools. The International Journal of Advanced Manufacturing Technology. 62(9):875–886Google Scholar
  6. 6.
    Cheng Q, Zhang Z, Zhang G, Gu P, Cai L (2015) Geometric accuracy allocation for multi-axis CNC machine tools based on sensitivity analysis and reliability theory. Proceedings of the Institution of Mechanical Engineers, Part C. J Mech Eng Sci 229(6):1134–1149CrossRefGoogle Scholar
  7. 7.
    Hong K-S, Choi K-H, Kim J-G, Lee S (2001) A PC-based open robot control system: PC-ORC. Robot Comput Integr Manuf 17(4):355–365CrossRefGoogle Scholar
  8. 8.
    Sarhan AA, Besharaty S, Akbaria J, Hamdi M (2015) Improvement on a CNC gantry machine structure design for higher machining speed capability. World Academy of Science, Engineering and Technology. International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering 9(4):572–576Google Scholar
  9. 9.
    Lei W, Hsu Y (2003) Accuracy enhancement of five-axis CNC machines through real-time error compensation. Int J Mach Tools Manuf 43(9):871–877CrossRefGoogle Scholar
  10. 10.
    Gordon S, Hillery MT (2005) Development of a high-speed CNC cutting machine using linear motors. J Mater Process Technol 166(3):321–329CrossRefGoogle Scholar
  11. 11.
    Stenerson JS, Curran K (2005) Computer numerical control: operation and programming. Prentice-Hall, Inc., New YorkGoogle Scholar
  12. 12.
    Xu X, Newman ST (2006) Making CNC machine tools more open, interoperable and intelligent—a review of the technologies. Comput Ind 57(2):141–152CrossRefGoogle Scholar
  13. 13.
    Feng W, Yao X, Azamat A, Yang J (2015) Straightness error compensation for large CNC gantry type milling centers based on B-spline curves modeling. Int J Mach Tools Manuf 88:165–174CrossRefGoogle Scholar
  14. 14.
    Schwenke H, Knapp W, Haitjema H, Weckenmann A, Schmitt R, Delbressine F (2008) Geometric error measurement and compensation of machines—an update. CIRP Annals-Manufacturing Technology 57(2):660–675CrossRefGoogle Scholar
  15. 15.
    Kao J, Yeh Z-M, Tarng Y, Lin Y (1996) A study of backlash on the motion accuracy of CNC lathes. Int J Mach Tools Manuf 36(5):539–550CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2017

Authors and Affiliations

  • Abdul Hadi Jalaludin
    • 1
  • Mohd Hamdi Abd Shukor
    • 2
  • Noor Azizi Mardi
    • 3
  • Ahmed Aly Diaa Mohammed Sarhan
    • 2
  • Mohd Sayuti Ab Karim
    • 4
  • Seyed Reza Besharati
    • 4
  • Wan Nur Izzati Wan Badiuzaman
    • 4
  • Yusuf S. Dambatta
    • 4
  1. 1.LondonUK
  2. 2.Kyoto UniversityKyotoJapan
  3. 3.Royal Melbourne Institute of TechnologyMelbourneAustralia
  4. 4.Department of Mechanical EngineeringUniversity of MalayaKuala LumpurMalaysia

Personalised recommendations