Modeling and compensation of comprehensive errors for thin-walled parts machining based on on-machine measurement

Du, Zhengchun; Ge, Guangyan; Xiao, Yukun; Feng, Xiaobing; Yang, Jing

doi:10.1007/s00170-021-07397-5

Cited by 14 publications

(4 citation statements)

References 22 publications

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“…In terms of real-time compensation, Zeng et al [16] proposed a position measurement method based on a laser displacement sensor to adjust the spindle position of the machine tool in real time to achieve online compensation of the hole-position error. Du et al [17] proposed a comprehensive errorcompensation method containing three major error sources: geometric error, thermal error, and force error. Deng et al [18] proposed a new method of geometric-error identification using a tracking interferometer that considers the rigid-body motion constraint, which is more robust to random factors and not only improves the identification accuracy but also reduces the maximum angular-positioning error by 84% after compensation.…”

Section: Error-compensation Methods For Workpiece Featuresmentioning

confidence: 99%

Characterization of Dimensional Variations in Turning Process for Multistep Rotary Shaft of High-Speed Motorized Spindle

Tian

Liu

et al. 2023

Machines

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The surface accuracy of a multistep rotary shaft is very important in manufacturing and the assembly process of the high-speed motorized spindle of CNC machine tools, which is closely related to the machined dimensional variation induced by the turning process. This paper attempts to enhance a comprehensive understanding of the impact of different locating-error sources and machine toolpaths on the machined dimensional variation for multistep rotary parts of the high-speed motorized spindle in the turning process. A modeling method and a compensation strategy of dimensional variation are introduced in this paper and based on the relationship definition between the error sources and the machined surface using the differential motion vector and stream-of-variation methods. Validation experiments were conducted to verify the proposed model. Additionally, the relationship between locating errors and dimensional variation was investigated with varied case studies, providing a theoretical methodology for the prediction and characterization of the expected dimensional variations of the surface machined with the given conditions.

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Section: Error-compensation Methods For Workpiece Featuresmentioning

confidence: 99%

Characterization of Dimensional Variations in Turning Process for Multistep Rotary Shaft of High-Speed Motorized Spindle

Tian

Liu

et al. 2023

Machines

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“…Among them, ij x is the i measurement data in the j group variable. (2) Standardize the sample data and obtain normalization and correlation matrix [4] . The standardized matrix is represented as:…”

Section: Optimization Algorithm Based On Factor Extractionmentioning

confidence: 99%

Modeling of machine tool thermal error based on factor extraction

Zhang,

Peng,

Chen

2024

J. Phys.: Conf. Ser.

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In the process of modeling thermal errors in machine tools, optimizing the extraction of temperature information affects the prediction accuracy of the thermal error model. This paper proposes a thermal error modeling method based on factor extraction. Firstly, the temperature measurement points are optimized to determine the optimal number using finite element, fuzzy clustering, and correlation methods. Then, the common deformation factors in the machine tool temperature information are extracted through factor analysis, and they are used as independent variables for thermal error modeling. Finally, the method was applied to establish a model for thermal error model for a certain model of precision machine tool, and a regression model of the machine tool was obtained after factor extraction optimization, the effectiveness and feasibility of the proposed method in this paper were verified by comparing it with experimental data. The method proposed in this study provides a reference for modeling thermal errors in various types of machine tools in the future.

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“…To measure and decrease the rotary axis geometric errors on a five-axis machine tool, a machining test is proposed by Ibaraki et al (Ibaraki, Yoshida, and Asano 2019). To reduce errors during machining operations of thin-walled components, Du et al (Du et al 2021) provided modelling and compensation of comprehensive errors for thinwalled parts based on on-machine measurement methodology. To minimise thermal error and enhance the dimensional accuracy of the workpiece, Nguyen and Feng (Nguyen, Huang, and Feng 2023) proposed the modelling of thermal deformation and real-time error correction of a CNC milling machine in cutting processes.…”

Section: Introductionmentioning

confidence: 99%

Dimensional, geometrical, thermal and tool deflection errors compensation in 5-Axis CNC milling operations

Soori

Arezoo

2023

Australian Journal of Mechanical Engineering

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The dimensional, geometrical, thermal and tool deflection errors which have a big portion of the overall error of machined parts need more attention in precision of components produced by using CNC machine tools. As a result, it is essential to simulate and compensate the errors in the machined components in order to increase accuracy of machined parts. In order to simulate and analyse the real manufactured components in virtual environments, virtual machining systems are proposed. In this paper, application of virtual machining system is investigated in order to simulate and compensate dimensional, geometrical, thermal and tool deflection errors in 5-axis milling operations of free form surfaces. The volumetric error vectors regarding the dimensional, geometrical, thermal and tool deflection errors at each cutting tool location throughout the machining pathways are calculated and compensated utilising the study's created virtual machining technology. In order to validate the study, a sample workpiece free from surfaces is milled by using the 5-axis CNC machine tool. The machine part is then measured by suing the CMM machine in order to obtain the dimensional, geometrical, thermal and tool deflection errors during milling operations of free form surfaces. Thermal sensors are also installed to the different locations of CNC machine tool in order to measure the thermal error of CNC machine tool during machining operations. Finally, in order to improve accuracy in 5-axis milling operations of free form surfaces, new cutting tool paths regarding the compensated volumetric errors of dimensional, geometrical, thermal, and tool deflection errors are generated. As a result, by utilising the proposed virtual machining system in the research work, precision as well as reliability during 5-axis milling operations of free form surfaces can be enhanced.

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Modeling and compensation of comprehensive errors for thin-walled parts machining based on on-machine measurement

Cited by 14 publications

References 22 publications

Characterization of Dimensional Variations in Turning Process for Multistep Rotary Shaft of High-Speed Motorized Spindle

Characterization of Dimensional Variations in Turning Process for Multistep Rotary Shaft of High-Speed Motorized Spindle

Modeling of machine tool thermal error based on factor extraction

Dimensional, geometrical, thermal and tool deflection errors compensation in 5-Axis CNC milling operations

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