Using a double ball bar to identify position-independent geometric errors on the rotary axes of five-axis machine tools

Xiang, Sitong; Yang, Jing; Zhang, Yi

doi:10.1007/s00170-013-5432-9

Cited by 77 publications

(18 citation statements)

References 20 publications

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“…Cartesian TMBB are still widely used due to their ability to identify both location and component errors in rotary axes [11][12][13][14], which is generally not possible (or very difficult) with cylindrically aligned tests. This is because cylindrically aligned tests identify errors by fitting functions to all measurements in a toolpath, whereas Cartesian aligned tests can consider individual measurements.…”

Section: State-of-the-art Five-axis Tmbb Testing Methodsmentioning

confidence: 99%

A new methodology for identifying location errors in 5-axis machine tools using a single ballbar set-up

Flynn

Shokrani

Vichare

et al. 2016

Int J Adv Manuf Technol

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Ballbar testing of rotary axes in 5-axis machine tools can be time-consuming and requires high levels of operator expertise; especially in the setup process. Faster tests reduce down-time and encourage frequent updates to compensation parameters to reflect the current state of the machine. A virtual machine tool (VMT) is developed to emulate the machine tool, its geometric errors and the testing procedures. This was used to develop a new single setup testing method to identify all rotary axis locations errors, whilst remaining robust in the presence of setup error and linear axis squareness errors. New testing and data processing techniques remove the requirement for fine adjustment of the tool-cup and permit full automation of necessary toolpaths, including transitions. Using the VMT, error identification residuals were found to be 2.7% or less. Experiments and statistical analysis then showed that all errors can be measured using a single setup , and values are sufficiently close to the values measured using conventional multi-setup procedures to be used in error compensation. This method will significantly reduce setup durations and removes the need for any modified testing hardware.

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Section: State-of-the-art Five-axis Tmbb Testing Methodsmentioning

confidence: 99%

A new methodology for identifying location errors in 5-axis machine tools using a single ballbar set-up

Flynn

Shokrani

Vichare

et al. 2016

Int J Adv Manuf Technol

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“…13,14 Other methods include estimation of geometric errors for rotary axes by varying the DBB location and orientation. 15,16 It has been suggested that a DBB is an ideal tool for fast machine diagnostic testing for linear axes. 17 However, there is a lack of simple and fast identification methods using a DBB to test the rotary axes.…”

Section: Error Categorization and Measuring Approachesmentioning

confidence: 99%

Accuracy evaluation of rotary axes of five-axis machine tools with a single setup of a double ball bar

Jiang

Cripps

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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A double ball bar (DBB) is used extensively to evaluate the geometric and dynamic performance of three-axis machine tools by means of the XY, YZ and XZ planar circular tests. However, research using a DBB to test the rotary axes of fiveaxis machine tools simply, quickly and effectively is scarce. In this paper, a method having two steps to identify the imprecision of the rotary axes caused by the position-independent geometric errors (PIGEs) is presented for a tilting rotary type five-axis machine tool using a DBB. The first step is designed to evaluate two rotary axes with one setup. Its advantage of fast diagnosis effectively reduces the machine down time, and thus can be employed as a quick testing approach of the machine tool. However, if some of the diagnosed errors fall outside their tolerances, a more accurate but slower check needs to be carried out due to the limitation of the first step. The second step aims to test the two rotary axes separately, each in two sub-steps. By means of varying the position of the pivot, the A-and C-axes can be tested individually. Both steps are performed with only one axis moving, thus simplifying the error analysis. Implementation of the proposed methods was carried out on a Hermle C600U five-axis machine tool. To show the validity of the method, the identified PIGEs are compensated for in each step, which suggests that the first step can be used as a fast and preliminary indication of a five-axis machine tool's performance, whilst the second can be carried out if a more thorough evaluation is needed.

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“…This can contribute significantly to improving the accuracy of the machined part cost-effectively [2,3]. There have been several studies to measure position-dependent geometric errors (also termed "error motions" [4]) and position-independent geometric errors (also termed "location and orientation errors") via direct and indirect approaches [5,6].…”

Section: Introductionmentioning

confidence: 99%

Parallelism error measurement for the spindle axis of machine tools by two circular tests with different tool lengths

Lee

Shin

Yang

2016

Int J Adv Manuf Technol

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In this study, parallelism errors between the spindle axis and the linear axis of machine tools were measured using a double ball-bar. Specifically, two circular tests were performed to measure the parallelism errors using tool balls with different tool lengths and a workpiece ball fixed to a workpiece table. Parallelism errors were calculated by analyzing, simultaneously, the measured double ball-bar (DBB) data from the circular tests. The proposed method provides accurate measurements due to a large offset between the circular tests within the working space of machine tools. Additionally, the approach only requires a DBB and adjustment/extension fixtures; thus, it simplifies measurements and is cost-effective.

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Using a double ball bar to identify position-independent geometric errors on the rotary axes of five-axis machine tools

Cited by 77 publications

References 20 publications

A new methodology for identifying location errors in 5-axis machine tools using a single ballbar set-up

A new methodology for identifying location errors in 5-axis machine tools using a single ballbar set-up

Accuracy evaluation of rotary axes of five-axis machine tools with a single setup of a double ball bar

Parallelism error measurement for the spindle axis of machine tools by two circular tests with different tool lengths

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