Prediction of machining accuracy based on geometric error estimation of tool rotation profile in five-axis multi-layer flank milling process

Yu, Hangzhuo; Jiang, Lei; Wang, Jindong; Qin, Shengfeng; Ding, Guofu

doi:10.1177/0954406220903760

Cited by 7 publications

(4 citation statements)

References 50 publications

(97 reference statements)

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“…For getting the connection stiffness between the nut and the screw, the axial stiffness of the screw nut, the stiffness of the screw, bearing housing stiffness, and bearing stiffness should be taken into consideration, which can be calculated by equation (10).…”

Section: Ac Servo System Modeling and Performance Analysismentioning

confidence: 99%

“…On the other hand, for the problem of geometric error prediction of CNC machine tools, Zhang et al 9 proposed an improved hybrid grey wolf optimization algorithm to optimize the geometric error modeling scheme of the support vector regression machine. Yu et al 10 established a new comprehensive error prediction model considering the inter-layer interference caused by tool rotation profile error, which incorporates a pre-existing prediction model dealing with a variety of errors such as geometric errors of machine tool, workpiece locating errors, and spindle thermal deflection errors. Ding et al 11 and Liu et al 12 predicted milling errors of part's surfaces based on geometric error modeling.…”

Section: Introductionmentioning

confidence: 99%

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An Integrated Model Based Prediction of Machining Accuracy for Milling Machine

Huang,

Wang

2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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The accuracy of machining can be predicted during the design process of CNC machine tools, while the prediction accuracy depends on the prediction model. However, when establishing the prediction model, the coupling effect among the machine tool’s different components is always ignored for modeling efficiency, so this will lead to its reliability cannot be guaranteed. To address this problem, the model reduction theory and the lumped parameter method are used in this study to set the state-space equations of the essential structural parts. Moreover, the electro-mechanical coupling parameter equation of the servo system is transformed into a state-space equation. Then the state-space equations of the components and the servo system are coupled to establish the machine tool dynamic model. Furthermore, a theoretical model of instantaneous undeformed chip thickness is found, and according to the linear relationship between the micro-cutting force and the instantaneous undeformed chip thickness, the instantaneous cutting force model of the cylindrical milling cutter is established. Based on these, the integrated model, which considers the mechanical structure, control system and cutting force, is obtained and further used in Simulink to build the machining accuracy prediction platform, as well as the accuracy of the integrated prediction model is verified. Moreover, the prediction model established by the integrated modeling method can effectively simulate the actual machining conditions of the machine tool, and the superiority of prediction is confirmed by comparing the simulated and measured results in peripheral milling applications. The results show the error in the system response efficiency is 14.8%, while the error in position accuracy and delay characteristics is less than 10%, the error between the predicted size of the prediction model and the actual size is within 28 μm, a minimum prediction error is 7 μm.

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Section: Ac Servo System Modeling and Performance Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

An Integrated Model Based Prediction of Machining Accuracy for Milling Machine

Huang,

Wang

2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…The dynamic and static error of the machine tool will restrict the motion accuracy of the machine tool: in more detail, the geometric error, the error caused by the cutting force and the thermal error have a greater impact on the accuracy, 1,2,3 therefore, to improve the machining accuracy of the machine tool, the overall error should be controlled.…”

Section: Introductionmentioning

confidence: 99%

A spatial grid point compensation method for a one-translational two-rotational power head

Lu²,

Zhou³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Positioning accuracy is an important index used to indicate the accuracy of the moving parts in a machine tool under the control of CNC system. In order to improve positioning accuracy, error compensation is needed. Existing error compensation methods include model compensation and non-model compensation. However, due to the simplification of the error mapping model, some error parameters cannot be mapped to the model, so only part of the error parameters can be modified, and the compensation result is not ideal. In the present work, based on the thinking method of finite element, a non-model compensation method is used to compensate for the geometric error of a one-translational two-rotational (1T2R) power head (which is independently developed by Tianjin University). First, the pose error prediction model will be established, and the error of any point in the workspace can be predicted. The input correction method is then proposed to compensate for the pose error. Finally, both the proposed error prediction model and error compensation method are verified by simulation and experiment, and the results show that the proposed method can reduce the error of this 1T2R power head.

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“…Microscopically, it reflects the final processing level of parts, and macroscopically, it reflects the advanced and backward processing technology [1][2]. If the precision of the grinder processing key parts is poor, the quality of the parts is difficult to ensure, and the machining accuracy, positioning accuracy and repeated positioning accuracy are three important indicators of the precision of CNC machine tools, among which, the machining accuracy is one of the important indicators to measure its machining performance, especially for the machine tools with high precision requirements [3][4].…”

Section: Introductionmentioning

confidence: 99%

Research on Geometric Error Modeling and Compensation Method of CNC Precision Cylindrical Grinder Based on Differential Motion Matrix and Jacobian Matrix

Fan¹,

Ye²

2021

Preprint

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In this paper, the geometric error modeling method of CNC cylindrical grinder based on the differential motion relationship between coordinate systems, the function fitting model method of basic geometric error terms based on cftool toolbox and the error compensation method based on Jacobian matrix are proposed. Firstly, the differential motion theory, which is widely used in the field of robot kinematics error modeling, is used to build the machine tool space machining error model of CNC cylindrical grinder. Different from the multi-body theory, this modeling method can clearly reflect the influence degree of each moving part on the grinding wheel cutter. Secondly, SJ6000 laser interferometer was used to measure and identify the geometric error terms of B2-K3032 CNC precision cylindrical grinder. MATLAB cftool toolbox was used to perform mathematical function fitting on the known error data, and the mathematical relationship between 24 geometric errors and machining instructions was found. Finally, combining with the 24 Sum of Sine function model, the known verticality error and position deviation, the differential motion matrix of each moving part in the tool coordinate system and the corresponding Jacobian matrix, the compensation quantity (dx dz db dc) of the comprehensive geometric error in the tool coordinate system by the CNC precision cylindrical grinder is obtained. In order to verify the feasibility of the above method, RA1000 series roundness meter was used to measure the radial circular runout error before and after the correction. The experimental results show that the precision of each shaft section is increased by 17.54%, 15.22%, 15.71%, 18.4%, 12.87%, respectively, and the average machining accuracy is increased by 15.948%. Therefore, the above methods are effective and reasonable for improving the precision of spindle workpieces, and can also be used for reference in the initial design stage of CNC cylindrical grinder manufacturing enterprises or improving the machining accuracy of existing machine tools.

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Prediction of machining accuracy based on geometric error estimation of tool rotation profile in five-axis multi-layer flank milling process

Cited by 7 publications

References 50 publications

An Integrated Model Based Prediction of Machining Accuracy for Milling Machine

An Integrated Model Based Prediction of Machining Accuracy for Milling Machine

A spatial grid point compensation method for a one-translational two-rotational power head

Research on Geometric Error Modeling and Compensation Method of CNC Precision Cylindrical Grinder Based on Differential Motion Matrix and Jacobian Matrix

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