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Establishing a robust thermal error model is crucial for thermal error compensation of machine tools. In this paper, an improved exponential model for thermal error modeling was proposed. First, the improved exponential model is established by combining the exponential model and the temperature-dependent model. Second, the improved fruit fly optimization algorithm is used to determine the parameters. Finally, two strategies are used to select the optimal sensor location from six potential ambient temperature sensors. The ambient temperature data is proved to be effective in improving the robustness of the model. The average root mean square error of the proposed model, the exponential model without ambient temperature, and the linear model are 1.18 μm, 1.79 μm, and 2.70 μm, respectively. The modeling results show that the proposed model has high accuracy and strong robustness, which is suitable for workshop environment and variable conditions in thermal error modeling of machine tools.

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