Volumetric error modeling and compensation considering thermal effect on five-axis machine tools

Zhang, Yi; Yang, Jing; Xiang, Sitong; Xiao, Huixiao

doi:10.1177/0954406212456475

Cited by 33 publications

(18 citation statements)

References 21 publications

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“…However, most of the existing comprehensive error models [8,[39][40][41][44][45][46] do not consider the inter-layer interference in the study of machining surface accuracy for multi-layer flank milling, and there has no work on calculation and analysis for the possible machining inter-layer interference.…”

Section: Comparison and Summary Of Prediction Results With Existing Rmentioning

confidence: 99%

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

Jiang

Wang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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In five-axis multi-layer flank milling process, the geometric error of tool rotation profile caused by radial dimension error and setup error has great influence on the machining accuracy. In this work, a new comprehensive error prediction model considering the inter-layer interference caused by tool rotation profile error is established, 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. First, a series of tool contact points on the tool swept surface in each single layer without overlapping with others are calculated. Second, the position of the tool contact points on the overlapped layers is updated based on the detection and calculation of inter-layer interferences. Third, all evaluated tool contact points on the final machined surface are available for completing the accuracy prediction of the machined surface. A machining experiment has been carried out to validate this prediction model and the results show the model is effective.

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Section: Comparison and Summary Of Prediction Results With Existing Rmentioning

confidence: 99%

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

Jiang

Wang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

show abstract

“…This is particularly true for machine tools where thermal effects can affect the accuracy of manufacture. [15][16][17] Photogrammetry is an increasingly common measurement technique in large-volume metrology. Targets are adhered to the surface of the measurand, many photographs are taken, and software can measure these targets as coordinates when referenced to scale bars.…”

Section: Introductionmentioning

confidence: 99%

“…This is particularly true for machine tools where thermal effects can affect the accuracy of manufacture. 15–17…”

Section: Introductionmentioning

confidence: 99%

Thermal compensation using the hybrid metrology approach compared to traditional scaling

Ross-Pinnock

Mullineux

2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Control of temperature in large-scale manufacturing environments is not always practical or economical, introducing thermal effects including variation in ambient refractive index and thermal expansion. Thermal expansion is one of the largest contributors to measurement uncertainty; however, temperature distributions are not widely measured. Uncertainties can also be introduced in scaling to standard temperature. For more complex temperature distributions with non-linear temperature gradients, uniform scaling is unrealistic. Deformations have been measured photogrammetrically in two thermally challenging scenarios with localised heating. Extended temperature measurement has been tested with finite element analysis to assess a compensation methodology for coordinate measurement. This has been compared to commonly used uniform scaling and has outperformed this with a highly simplified finite element analysis simulation in scaling a number of coordinates at once. This work highlighted the need for focus on reproducible temperature measurement for dimensional measurement in non-standard environments.

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“…In the previously presented studies, 10–14 volumetric errors are commonly compensated for by generating new G-codes with the post-processor. Zhang et al 15 introduced the external machine zero point shift (EMZPS) method for real-time error compensation in machine tools with Fanuc computer numerical control (CNC) systems. Cui et al 16 proposed a novel error compensation technique for a Siemens 840D CNC system using a differential resolve function method.…”

Section: Introductionmentioning

confidence: 99%

Multi-machine tools volumetric error generalized modeling and Ethernet-based compensation technique

Xiang

Yang

Fan

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article proposes a volumetric error generalized model and a distributed error compensation technique for multi-machine tools. A detailed generalized kinematic model for three- and five-axis machine tools is built. It can be applied to 4 types of three-axis machine tools and 12 types of five-axis machine tools. By simply inputting the translational and rotary type numbers of the specific machine tool, the final kinematic model can be obtained without further human interventions. A new compensation technique based on an Ethernet distributed numerical control system is proposed. Ethernet distributed numerical control software integrated with the generalized kinematic model is developed for machine tools with Fanuc and Siemens systems. Based on the Ethernet distributed numerical control system, the real-time volumetric errors of multi-machine tools are simultaneously compensated for. The proposed generalized kinematic model and Ethernet distributed numerical control systems are experimentally verified on three machine tools, whose volumetric errors are significantly reduced after compensation.

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Volumetric error modeling and compensation considering thermal effect on five-axis machine tools

Cited by 33 publications

References 21 publications

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

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

Thermal compensation using the hybrid metrology approach compared to traditional scaling

Multi-machine tools volumetric error generalized modeling and Ethernet-based compensation technique

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