Hybrid Optimization Method for Correcting Synchronization Errors in Tapping Center Machines

A hybrid method is proposed for optimizing rigid tapping parameters and reducing synchronization errors in Computer Numerical Control (CNC) machines. The proposed method integrates uniform design (UD), regression analysis, Taguchi method, and fractional-order particle swarm optimizer (FPSO) to optimize rigid tapping parameters. Rigid tapping parameters were laid out in a 28-level uniform layout for the experiments in this study. Since the UD method provided a layout with uniform dispersion in the experimental space, the UD method’s uniform layout provided iconic experimental points. Next, the 28-level uniform layout results and regression analysis results were used to obtain significant parameters and a regression function. To obtain the parameter values from the regression function, FPSO was selected because its diversity and algorithmic effectiveness are enhanced compared with PSO. The experimental results indicated that the proposed method could obtain suitable parameter values. The best parameter combination in FPSO yielded the best results in comparisons of the non-systematic method. Next, the best parameter combination was used to optimize actual CNC machining tools during the factory commissioning process. From the commissioning process perspective, the proposed method rapidly and accurately minimizes synchronization error from 23 pulses to 18 pulses and processing time from 20.8 s to 20 s. In conclusion, the proposed method reduced the time needed to tune factory parameters for CNC machining tools and increased machining precision and decreased synchronization errors.