Research On Numerical Control System For Five-axis Compound Machining With Ultrasonic Aid

With the development of modern industry, hard and brittle materials have expansive application potential in the aerospace, automotive industry, precision molds, medical, optical and semiconductor fields. In order to meet the progressive needs for hard and brittle materials and their products, the composite machining technology and equipment research has become an important task for manufacturing industry and it is also an important safeguard for the sustainable development of our manufacturing technology.To solve the hard and brittle material machining problem, we launched a research on the numerical control system of a conventional milling compounded with rotating ultrasonic device.The system used a dual CPU structure composed by industrial computer and PMAC. The IPC is the foundation of the numerical control system and the PMAC-PCI is the core for motion control. The Visual C++ 6.0 language is used as the developing tool in the Windows XP environment. A typical open numerical control system is established. The PMAC-PCI is used to control the real-time motion and PLC programs and the IPC is used to carry out the non-real-time tasks such as initialization, code editor, parameter setup etc. The control program in IPC is designed. The PEWIN32PRO is used to initialize the corresponding variable of PMAC, to adjust the PID parameters which could make the system have a good motion performance. The handwheel function is realized based on PMAC's position following function. The PMC and PLC program is designed to control the I/O signals. And the state of the PMAC can be displayed dynamically.The preliminary experiments for hard and brittle materials are carried out on the ultrasonic aided five-axis mill and the machining results are compared with the ordinary machine tools.