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<p>Reliability testing is essential for detecting early failures in computer numerical control (CNC) machine tools and enhancing their operational reliability. However, traditional ex-factory run-in tests require prolonged cutting of raw materials to simulate real-world conditions, leading to high costs, time consumption, and environmental impact. To address these challenges, this paper proposes a novel simulated cutting force loading device based on a parallel mechanism. The kinematics and dynamics of the device are thoroughly analyzed, and a unique force allocation method for redundant controlled variables is developed to improve the smoothness of pneumatic servo output by exploiting the characteristics of pneumatic actuation. Based on real-time kinematic and dynamic calculations, a force feedforward proportional integral derivative controller is designed. Loading experiments on a simulated spindle demonstrate the device’s ability to accurately apply static and low-to-medium-frequency dynamic loads to non-rotating spindles. Furthermore, experiments conducted on the rotating spindle of a CNC machine tool show that the proposed device can effectively simulate cutting forces, offering a cost-effective and environmentally friendly alternative to conventional cutting-based reliability tests.</p>

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Design and control of a 5-DOF simulated cutting force loading device

  • 期刊论文

  • 发表日期：

    2026年7月17日

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  • Bin Zhu,
  • Runtong Sun,
  • Liping Wang,
  • Jun Wu,
  • Yanling Tian

摘要

Reliability testing is essential for detecting early failures in computer numerical control (CNC) machine tools and enhancing their operational reliability. However, traditional ex-factory run-in tests require prolonged cutting of raw materials to simulate real-world conditions, leading to high costs, time consumption, and environmental impact. To address these challenges, this paper proposes a novel simulated cutting force loading device based on a parallel mechanism. The kinematics and dynamics of the device are thoroughly analyzed, and a unique force allocation method for redundant controlled variables is developed to improve the smoothness of pneumatic servo output by exploiting the characteristics of pneumatic actuation. Based on real-time kinematic and dynamic calculations, a force feedforward proportional integral derivative controller is designed. Loading experiments on a simulated spindle demonstrate the device’s ability to accurately apply static and low-to-medium-frequency dynamic loads to non-rotating spindles. Furthermore, experiments conducted on the rotating spindle of a CNC machine tool show that the proposed device can effectively simulate cutting forces, offering a cost-effective and environmentally friendly alternative to conventional cutting-based reliability tests.