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Block Diagram Model of Lathe Machine
Block Diagram Model of Lathe Machine
Block Diagram Model of Lathe Machine
Abstract: This paper presents a computer aided method for the analyses and simulation of a non-linear
mathematical model of a CNC Lathe machine tool. The derived model consist of the controller, axis drive and
the spindle drive of a CNC turning machine and their connection through the cutting process. The overall
model uses a modular multi-model approach to prototype the machine tool and its process.
Keywords: Block-diagram, Lathes, modelling, simulation, dynamic
1 Introduction
The role of virtual prototyping in design, optimization and
product development is crucial giving knowledge of
cutting forces in the computer modeling and design of the
lathe machines. The computer aided analysis generating
the cutting forces has been developed by many researchers
in the past but these models are either based on
mechanistic approaches, which are highly complicated and
labour intensive or on statistical methods. There is clearly
a need for a simplistic approach, which simulates the
dynamic response of the cutting process. The output of the
model then can be used as inputs to other CAD packages
such as finite element or multi-body dynamic for the
structural analysis of the machine. The overall model then
can result in a virtual prototyping environment for design
optimization. The analysis of the cutting forces can reveal
valuable information about the machine tool structure. This
is because the cutting process is the one relationship of the
whole machine tool dynamic which closes the loop between
the axis feed subsystem and the spindle subsystem (Martin
and Ebrahimi, 1999). Also it is the cutting process that
affects the control of the servo-mechanism, generating the
disturbance torque on the feed and the spindle motors.
The turning process has been investigated by many
researchers. Mackinnon et al. (1986) developed a method
of wear estimation for carbide tools using multicomponent force measurements for the purpose of tool
condition monitoring during adaptively controlled metal
cutting on a turret lathe. Dan and Mathew (1990)
presented a review for cutting force measurements for online tool wear and breakage sensing. El Baradie (1991)
discussed a closed loop system with two main elements
representing the machine tool structure and the cutting
process to develop a generalized statistical theory of
VSM +
Workpiece
Chuck
Spindle axis
Spindle
controller
Tool
Post
Saddle
X-axis Slideway
DC motor
of spindle
drive
VE
TG
K
M
Motor torque
constant
Motor armature
Generated
torque
Axis Table
Gear
box
Nut
Ball screw
Voltage
constant
Bearing
X
Axis Drive System
DC motor of
axis drive
Back EMF
TC
K+
P
VSM
VSM
PWM
Speed regulator
V
Tachogenerator
P , P
1
TSMF
BSM 1
Spindle shaft
VC
Power control
loop
P , P
BS 2
P2
Servo ampilifier
TSF
1
SM
AC Power supply
( J )
SG
Speed
regulator
Workpiece
P2
P1
(1)
K PWM s + 1
( JS )
rS2
TSD
P1
Motor speed
Axis
Controller
G PWM =
IS
1
Ls+R
Saddle
movement Y
3 Equations of Motion
The coulomb friction of the spindle motor and gearbox
TSMF are ignored in the beginning to simplify the equations
of motion for the motor pulley, which is given below.
T SG (P1 P2 ) rS 1
B SM &1
= J &&
SM
K B (P1 - P0 ) = K B (P0 - P2 )
(P1 - P0 ) = (P0 - P2 )
(2)
P0 = (P1 + P2 ) 2
P1 P0 = P1 - (P1 + P2 ) 2
d B = (1 K B )(P1 - P2 ) 2
(3)
TSD = rS 2 (P1 - P2 )
(P1 - P2 ) = TSD
(4)
(6)
(P1 - P2 ) r S1
1
JSM s + BSM
(16)
= d B r S 2
TSG
rS 2
(14)
(15)
TSD
dB =
2 K B rS2
(5)
2 = 2
(9)
(10)
(11)
(12)
(13)
TSMF
TSD
(18)
2 K B rS 2 2
TSD
KC
(19)
K C = 2 K B rS 2 2
(20)
(17)
TC + TSD B S s 2
= J S s 2 2
(22)
(7)
where, TC is the cutting torque acting on the spindle shaft
and is related to the tangential force, Ft.
(21)
TC = rWP Ft
(23)
(24)
PWM
s+1
_
VT
Ls +R
IS
SG
JSM s + BSM
Motor torque
constant
TSMF
Voltage
constant
V SM
KI
KP +
SD
KC
Ft
Spindle shaft
(26)
rWP
(P1 - P2 ) r S1
(25)
at
JS s + BS
TSF
Coulomb friction
Coulomb friction
KV
KT
Workpiece
+ b4 x 2 2 + b5 x13 + b6 x 2 3 + b7 x1 x 2
Ff
Fr
Tool
(27)
Ft
F
6 Simulation
The model has been simulated using MATLAB software.
The input to the simulation is the spindle velocity
command, feed rate, and depth of cut. The outputs are the
motor current, the spindle speed, as shown in figures 10
and 11, respectively.
(28)
+ 0 .2944 x1 x 2
14
Coefficient
Constant
x1
x2
x12
x22
X13
x23
x1 x2
8.2858
1.34161
3.5819
-0.02923
2.2287
0.0934
0.5329
0.29442
Std.
Error
0.2944
0.07611
0.7604
0.03743
0.6040
0.1477
0.1477
0.02709
t
value
28.14
17.63
4.71
-0.78
3.69
0.63
3.61
10.87
12
P
0.000
0.000
0.000
0.443
0.001
0.533
0.001
0.000
10
Starting of cutting
0
0
Time (sec)
700
Regression
Residual
Error
Lack of Fit
D
F
5
SS
MS
3.7761
2.7552
26
0.0427
0.0016
P
500
10
0.0218
167
6
0.0022
Source
0.000
0.176
200
16
0.0210
0.0013
31 13.8188
R2
= R2adj= 99.6%
99.7%
-100
0
Time (sec)
Conclusion
100
1.66
Pure Error
Total
Model
summary
Starting of cutting
400
Depth
of cut
t
Spindle drive
system model
Cutting force
model
Spindle speed
Velocity
command signal
feed
Axis drive
model
(Not presented)
(Using multiple
regression analysis)
REFERENCES
Tangential
force
Feed rate