Equivalent geometric errors of rotary axes and novel algorithm for geometric errors compensation in a nonorthogonal five-axis machine tool

Kvrgić, V.; Ribić, Aleksandar I.; Dimić, Z.; Živanović, Saša; Dodevska, Zorica A.

doi:10.1016/j.cirpj.2022.03.001

Cited by 16 publications

(4 citation statements)

References 30 publications

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“…Based on previous studies and literature, it has been observed that for the precision of a five-axis machine tool, 70% of its error originates from the rotational axis PIGEs and PDGEs [18]. Currently, certain controller parameters within PIGEs and PDGEs are available, allowing users to make adjustments and compensations, mainly focusing on angular positioning errors like ECC, EAA, and EBB, and wobble errors such as XOC, YOC, AOC, BOC, and so forth.…”

Section: Research Motivation and Backgroundmentioning

confidence: 99%

Geometric error compensation method using the Laser R-test

Hsieh,

Jywe,

Zeng

et al. 2024

Int J Adv Manuf Technol

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Traditional methods for measuring geometric errors in machine tools, including interferometry and Double Ball Bar (DBB), are known to be expensive and time-intensive. Consequently, a non-contact calibration system called the “Laser R-test” has been developed. This innovative system is designed to measure both position-independent geometric errors (PIGEs) and position-dependent geometric errors (PDGEs) efficiently. Since its development in 2000, this tool has been instrumental in analyzing eccentricity errors, angular position errors, and simultaneous trajectory errors. Through extensive research, it has been determined that the total error in a five-axis machine tool can be controlled to below 40 µm after compensating for eccentricity parameters and angular position errors. However, reducing this error to below ± 10 µm is challenging, primarily due to wobble errors in the orientation of the rotary axis without compensating. In this study, a new methodology based on Laser R-test and Rodrigues’ rotation formula has been developed to establish a PIGE model of rotary axis. Based on the methodology, the 8 PIGEs can be analyzed by measuring 5 coordinate positions. The compensation of 8 PIGEs in the rotary axis is completed within 30 min using the inspection path. Compatibility with ISO-10791–6 standards for BK1, BK2, and BK4 path tests is confirmed, validating the compensation effects. A precision of below ± 10 µm is achieved, with inspection time reduced by over 50%. This system can complete multiple errors by simply using the different paths. This greatly reduces the setup time for future users, enhancing its commercial applicability.

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Section: Research Motivation and Backgroundmentioning

confidence: 99%

Geometric error compensation method using the Laser R-test

Hsieh,

Jywe,

Zeng

et al. 2024

Int J Adv Manuf Technol

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show abstract

“…At present, the post-processing research of five-axis machine tool is mainly focused on a single process mode. A number of scholars have conducted extensive research on the corresponding kinematic model according to the classification of the five-axis machine tools [7], including the configuration of orthogonal five-axis machine tools [8][9][10][11][12][13][14] and non-orthogonal five-axis machine tools [15][16][17][18][19][20][21]. Other scholars have conducted relevant studies on the post-processor with auxiliary functions based on the general kinematic model, including geometric error compensation [22,23], virtual simulation [24], rotation angle optimization [14], speed control [25,26], nonlinear error [12], etc.…”

Section: Introductionmentioning

confidence: 99%

Post-processing technology of the five-axis additive–subtractive composite manufacturing machine tool

Qiao,

Tang,

et al. 2024

Int J Adv Manuf Technol

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A post-processing technology is crucial in manufacturing complex curved surface parts as a bridge between CAD/CAM and machine manufacturing. Unlike the traditional five-axis machine tool, the five-axis additive-subtractive composite manufacturing machine tool combines additive and subtractive manufacturing. This study examines the post-processing technology to coordinate and control the contour accuracy of forming parts in the composite manufacturing. First, the basic kinematic model of the five-axis additive-subtractive composite manufacturing machine tool is constructed on the basis of the inverse kinematic principle by assuming a laser nozzle coaxial powder feeding head. Second, the reasons for the incoordination of the two process coordinates are analyzed, and the criterion of process coordinate coordination is established on the basis of the fiveaxis general kinematic model. Finally, a special five-axis additive-subtractive composite postprocessing software is developed based on a high-level language and verified by additive manufacturing, subtractive manufacturing, and process coordinate experiments. Experimental results show that the established composite post-processing model can effectively realize the contour accuracy of additive-subtractive composite manufacturing of highly complex curved parts.

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“…Another method utilizes the principles of multi-body system theory to establish topological and geometric error models, which have found wide application in equipment such as CNC machine tools. [18][19][20][21] This approach has also been applied to contact gear measuring centers. For example, for the self-developed HY 300 gear measurement center, Ye 22 applied the multi-body system topology analysis method to establish the system topology and geometric motion error model.…”

Section: Introductionmentioning

confidence: 99%

Spatial error modeling and accuracy distribution of line laser gear measuring center

Zhang,

Yang,

Liu

2023

Measurement and Control

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The Line laser gear measuring center (LLGMC) is an innovative gear measurement equipment that offers high efficiency but low accuracy. One crucial factor that influences its measurement accuracy is the presence of geometric errors. In this study, we conducted a thorough analysis of these geometric errors and proposed a method for modeling spatial errors. Instead of directly considering the geometric errors, we replaced them with the installation errors of the gear and line laser probe. This approach simplifies and improves the error transmission relationship. Subsequently, the installation errors are converted into a unified representation of the height error of the incident light from the line laser. A spatial error model that considers nine installation errors is then further established. By numerically calculating the sensitivity of different error sources, we effectively identified the errors that have a significant impact on the accuracy of LLGMC. Moreover, accuracy distribution is carried out to ensure that LLGMC can meet the measurement accuracy requirements for gears with a tolerance class of 6. This article provides a theoretical foundation for the structural design and accuracy assurance of LLGMC during the research and development phase.

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Equivalent geometric errors of rotary axes and novel algorithm for geometric errors compensation in a nonorthogonal five-axis machine tool

Cited by 16 publications

References 30 publications

Geometric error compensation method using the Laser R-test

Geometric error compensation method using the Laser R-test

Post-processing technology of the five-axis additive–subtractive composite manufacturing machine tool

Spatial error modeling and accuracy distribution of line laser gear measuring center

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