Question

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To overcome the limitations of existing machine-tool performance evaluation methods, a new machine performance evaluation methodology based on the high micromachining
acceleration demands has been developed and
tested. Specific conclusions drawn from this work are:
1. Micro-machining operations have their own set of
motion parameters, imposed by the combination of
the minimum chip thickness effect and the high spindle
speeds needed when using small diameter tools. These
motion parameters involve minimum required feedrates
of over 3000 mm/min, leading to acceleration requirements
above 5G (49 m/s2).
2. A new acceleration-based performance evaluation
methodology was proposed involving a series of singlestage,
constant acceleration, linear moves to observe thevariation of following error (command minus actual
position) with acceleration magnitude.
3. Results from testing two prototype mMTs with the new
acceleration-based methodology provide a basis to
determine allowable acceleration levels to achieve a
relative accuracy of 10_2–10_3.
4. Additional following error performance evaluations
conducted using circular contour and spline contour
moves showed the same trend and lower following error
magnitudes compared to those determined from the
proposed evaluation methodology. This demonstrated
that the proposed methodology provides a worst-case
evaluation of following error as a function of acceleration.
5. A linear model relating servo frequency, bandwidth,
acceleration and following error was proposed as a way
to determine expected mMT following error during
micro-machining operations. The model was fit to the
evaluation results and demonstrated that closed-loop
bandwidth is a driver in the relationship between
acceleration and following error.
6. The model for following error as a function of
acceleration was used to show the need for a significant
improvement in closed-loop bandwidth to deliver the
performance desired of mMTs. These improvements can
initially be obtained through the use of lower inductance,
higher voltage motors.
Acknowledgements
The authors gratefully acknowledge the support of the
US Army Aviation and Missile Command through Alion
Science and Technology (Contract DAAH23-00C-R232)
during the course of this research. The authors gratefully
acknowledge the support of Jerry Dickson of the US Army
Aviation and Missile Research and Development Command.
The authors also gratefully acknowledge the partial
funding support of the NSF NSEC: Center for Nano-
Chemical-Electrical-Mechanical Manufacturing Systems
(NanoCEMMS) (project DMI-0328162).

Answer 1

performance desired of mMTs. These improvements can
initially be obtained through the use of lower inductance,
higher voltage motors.
Acknowledgements
The authors gratefully acknowledge the support of the
US Army Aviation and Missile Command through Alion
Science and Technology (Contract DAAH23-00C-R232)
during the course of this research. The authors gratefully
acknowledge the support of Jerry Dickson of the US Army
Aviation and Missile Research and Development Command.
The authors also gratefully acknowledge the partial
funding support of the NSF NSEC: Center for Nano-
Chemical-Electrical-Mechanical Manufacturing Systems
(NanoCEMMS) (project DMI-0328162).
1. Micro-machining operations have their own set of
motion parameters, imposed by the combination of
the minimum chip thickness effect and the high spindle
speeds needed when using small diameter tools. These
motion parameters involve minimum required feedrates
of over 3000 mm/min, leading to acceleration requirements
above 5G (49 m/s2).
2. A new acceleration-based performance evaluation
methodology was proposed involving a series of singlestage,
constant acceleration, linear moves to observe thevariation of following error (command minus actual
position) with acceleration magnitude.
3. Results from testing two prototype mMTs with the new
acceleration-based methodology provide a basis to
determine allowable acceleration levels to achieve a
relative accuracy of 10_2–10_3.
4. Additional following error performance evaluations
conducted using circular contour and spline contour
moves showed the same trend and lower following error
magnitudes compared to those determined from the
demonstrated that closed-loop
bandwidth is a driver in the relationship between
acceleration and following error.
6. The model for following error as a function of
acceleration was used to show the need for a significant
improvement in closed-loop bandwidth to deliver the
performance desired of mMTs. These improvements can
initially be obtained through the use of lower inductance,
higher voltage motors.
Acknowledgements
The authors gratefully acknowledge the support of the
US Army Aviation and Missile Command through Alion
Science and Technology (Contract DAAH23-00C-R232)
during the course of this research. The authors gratefully
acknowledge the support of Jerry Dickson of the US Army
To overcome the limitations of existing machine-tool performance evaluation methods, a new machine performance evaluation methodology based on the high micromachining
acceleration demands has been developed and
tested. Specific conclusions drawn from this work are:
1. Micro-machining operations have their own set of
motion parameters, imposed by the combination of
the minimum chip thickness effect and the high spindle
speeds needed when using small diameter tools. These
motion parameters involve minimum required feedrates
of over 3000 mm/min, leading to acceleration requirements
above 5G (49 m/s2).
2. A new acceleration-based performance evaluation
methodology was proposed involving a series of singlestage,
constant acceleration, linear moves to observe thevariation of following error (command minus actual
position) with acceleration magnitude.
3. Results from testing two prototype mMTs with the new
acceleration-based methodology provide a basis to
determine allowable acceleration levels to achieve a
relative accuracy of 10_2–10_3.
4. Additional following error performance evaluations
conducted using circular contour and spline contour
moves showed the same trend and lower following error
magnitudes compared to those determined from the
proposed evaluation methodology. This demonstrated
that the proposed methodology provides a worst-case
evaluation of following error as a function of acceleration.
5. A linear model relating servo frequency, bandwidth,
acceleration and following error was proposed as a way
These improvements can
initially be obtained through the use of lower inductance,
higher voltage motors.
Acknowledgements
The authors gratefully acknowledge the support of the
US Army Aviation and Missile Command through Alion
Science and Technology (Contract DAAH23-00C-R232)
during the course of this research. The authors gratefully
acknowledge the support of Jerry Dickson of the US Army
Aviation and Missile Research and Development Command.
The authors also gratefully acknowledge the partial
funding support of the NSF NSEC: Center for Nano-
Chemical-Electrical-Mechanical Manufacturing Systems
(NanoCEMMS) (project DMI-0328162).
To overcome the limitations of existing machine-tool performance evaluation methods, a new machine performance evaluation methodology based on the high micromachining
acceleration demands has been developed and
tested. Specific conclusions drawn from this work are:
1. Micro-machining operations have their own set of
motion parameters, imposed by the combination of
the minimum chip thickness effect and the high spindle
speeds needed when using small diameter tools. These
motion parameters involve minimum required feedrates
of over 3000 mm/min, leading to acceleration requirements
above 5G (49 m/s2).
2. A new acceleration-based performance evaluation
methodology was proposed involving a series of singlestage,
constant acceleration, linear moves to observe thevariation of following error (command minus actual
position) with acceleration magnitude.
3. Results from testing two prototype mMTs with the new
acceleration-based methodology provide a basis to
determine allowable acceleration levels to achieve a
relative accuracy of 10_2–10_3.
4. Additional following error performance evaluations
conducted using circular contour and spline contour
moves showed the same trend and lower following error
magnitudes compared to those determined from the
proposed evaluation methodology. This demonstrated
that the proposed methodology provides a worst-case
evaluation of following error as a function of acceleration.
5. A linear model relating servo frequency, bandwidth,
acceleration and following error was proposed as a way
to determine expected mMT following error during
micro-machining operations. The model was fit to the
evaluation results and demonstrated that closed-loop
bandwidth is a driver in the relationship between
acceleration and following error.
6. The model for following error as a function of
acceleration was used to show the need for a significant
improvement in closed-loop bandwidth to deliver the
performance desired of mMTs. These improvements can
initially be obtained through the use of lower inductance,
higher voltage motors.
Acknowledgements
The authors gratefully acknowledge the support of the
US Army Aviation and Missile Command through Alion
Science and Technology (Contract DAAH23-00C-R232)
during the course of this research. The authors gratefully
acknowledge the support of Jerry Dickson of the US Army
Aviation and Missile Research and Development Command.
The authors also gratefully acknowledge the partial
funding support of the NSF NSEC: Center for Nano-
Chemical-Electrical-Mechanical Manufacturing Systems
(NanoCEMMS) (project DMI-0328162).
proposed involving a series of singlestage,
constant acceleration, linear moves to observe thevariation of following error (command minus actual
position) with acceleration magnitude.
3. Results from testing two prototype mMTs with the new
acceleration-based methodology provide a basis to
determine allowable acceleration levels to achieve a
relative accuracy of 10_2–10_3.
4. Additional following error performance evaluations
conducted using circular contour and spline contour
moves showed the same trend and lower following error
magnitudes compared to those determined from the
proposed evaluation methodology. This demonstrated
that the proposed methodology provides a worst-case
evaluation of following error as a function of acceleration.
5. A linear model relating servo frequency, bandwidth,
acceleration and following error was proposed as a way
to determine expected mMT following error during
micro-machining operations. The model was fit to the

Answer 2

EN