Product-of-exponential formulas for precision enhancement of five-axis machine tools via geometric error modeling and compensation

2015 ◽  
Vol 81 (1-4) ◽  
pp. 289-305 ◽  
Author(s):  
Guoqiang Fu ◽  
Jianzhong Fu ◽  
Hongyao Shen ◽  
Yuetong Xu ◽  
Yu’an Jin
Keyword(s):  
Machine Tools ◽  
Geometric Error ◽  
Error Modeling ◽  
Five Axis

Geometric error modeling and compensation for five-axis CNC gear profile grinding machine tools

2017 ◽  
Vol 92 (5-8) ◽  
pp. 2639-2652 ◽  
Author(s):  
Baocang Zhou ◽  
Shilong Wang ◽  
Chenggang Fang ◽  
Shouli Sun ◽  
He Dai
Keyword(s):  
Machine Tools ◽  
Geometric Error ◽  
Error Modeling ◽  
Profile Grinding ◽  
Grinding Machine ◽  
Five Axis ◽  
Gear Profile

Geometric error compensation method based on Floyd algorithm and product of exponential screw theory

2016 ◽  
Vol 232 (7) ◽  
pp. 1156-1171 ◽  
Author(s):  
Qiang Cheng ◽  
Bingwei Sun ◽  
Zhifeng Liu ◽  
Qiunan Feng ◽  
Peihua Gu
Keyword(s):  
Error Compensation ◽  
Machine Tools ◽  
Screw Theory ◽  
Cost Effective ◽  
Geometric Error ◽  
Error Modeling ◽  
Compensation Method ◽  
Machining Accuracy ◽  
Distance Method ◽  
Five Axis

Error compensation technique is a recognized and cost-effective method to improve machining accuracy of machine tools. In this article, a new compensation method for geometric error is proposed based on Floyd algorithm and product of exponential screw theory. Based on topological structure and measured data, volumetric geometric error modeling is established by product of exponential screw theory. Then, the improved Floyd minimum-distance method was used to establish an error compensation model by adjusting weight unceasingly. In order to verify the effectiveness and generality of the method proposed in this article, two experiments were designed. A total of 5 five-axis machining centers of the same type with different use time were selected to carry out the simulation experiments. Results show that the Floyd method can provide higher compensation precision, that is, Floyd algorithm compensation method can keep positioning errors within the range [−8 µm, 9 µm]. In addition, roundness error, coaxial error, and surface roughness were reduced in the actual machining experiments of two machined conical tables. Therefore, it can be seen that the proposed compensation method is effective to improve machining accuracy of machine tools.

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

2012 ◽  
Vol 227 (5) ◽  
pp. 1102-1115 ◽  
Author(s):  
Yi Zhang ◽  
Jianguo Yang ◽  
Sitong Xiang ◽  
Huixiao Xiao
Keyword(s):  
Error Compensation ◽  
Machine Tools ◽  
Data Communication ◽  
Zero Point ◽  
Compensation System ◽  
Error Modeling ◽  
Volumetric Error ◽  
Position Errors ◽  
Homogeneous Transformation Matrix ◽  
Five Axis

This article intends to provide an error compensation system for five-axis machine tools. A volumetric error model is established with homogeneous transformation matrix method, from which compensation values of both orientation and position errors can be obtained. Thirty-seven errors on a five-axis machine tool are classified into three categories – functional, random, and negligible errors, among which the effect of the first one on volumetric accuracy is considered as great enough to be included in this model. Some typical modeling methods are discussed on positioning and straightness errors, considering both geometric and thermal effects. Then, we propose a compensation implementation technique based on the function of external machine zero point shift and Ethernet data communication protocol for machine tools. Finally, laser diagonal measurements have been conducted to validate the effectiveness of the proposed volumetric error compensation system.

Table-Based Volumetric Error Compensation of Large Five-Axis Machine Tools

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Jennifer Creamer ◽  
Patrick M. Sammons ◽  
Douglas A. Bristow ◽  
Robert G. Landers ◽  
Philip L. Freeman ◽  
...  
Keyword(s):  
Machine Tool ◽  
Error Compensation ◽  
Machine Tools ◽  
Data Gathering ◽  
Measurement Data ◽  
Geometric Error ◽  
Compensation Method ◽  
Geometric Errors ◽  
Simultaneous Generation ◽  
Five Axis

This paper presents a geometric error compensation method for large five-axis machine tools. Compared to smaller machine tools, the longer axis travels and bigger structures of a large machine tool make them more susceptible to complicated, position-dependent geometric errors. The compensation method presented in this paper uses tool tip measurements recorded throughout the axis space to construct an explicit model of a machine tool's geometric errors from which a corresponding set of compensation tables are constructed. The measurements are taken using a laser tracker, permitting rapid error data gathering at most locations in the axis space. Two position-dependent geometric error models are considered in this paper. The first model utilizes a six degree-of-freedom kinematic error description at each axis. The second model is motivated by the structure of table compensation solutions and describes geometric errors as small perturbations to the axis commands. The parameters of both models are identified from the measurement data using a maximum likelihood estimator. Compensation tables are generated by projecting the error model onto the compensation space created by the compensation tables available in the machine tool controller. The first model provides a more intuitive accounting of simple geometric errors than the second; however, it also increases the complexity of projecting the errors onto compensation tables. Experimental results on a commercial five-axis machine tool are presented and analyzed. Despite significant differences in the machine tool error descriptions, both methods produce similar results, within the repeatability of the machine tool. Reasons for this result are discussed. Analysis of the models and compensation tables reveals significant complicated, and unexpected kinematic behavior in the experimental machine tool. A particular strength of the proposed methodology is the simultaneous generation of a complete set of compensation tables that accurately captures complicated kinematic errors independent of whether they arise from expected and unexpected sources.

scholarly journals Geometric Error Modeling of Machine Tools Based on Screw Theory

2011 ◽  
Vol 24 ◽  
pp. 845-849 ◽  
Author(s):  
Zhao Yu ◽  
Li Tiemin ◽  
Tang Xiaoqiang
Keyword(s):  
Machine Tools ◽  
Screw Theory ◽  
Geometric Error ◽  
Error Modeling

A Review of Geometric Error Modeling and Error Detection for CNC Machine Tool

2013 ◽  
Vol 303-306 ◽  
pp. 627-631 ◽  
Author(s):  
Zhen Yu Han ◽  
Hong Yu Jin ◽  
Yu Long Liu ◽  
Hong Ya Fu
Keyword(s):  
Machine Tool ◽  
Error Detection ◽  
Error Compensation ◽  
Machine Tools ◽  
Performance Criterion ◽  
Geometric Error ◽  
Error Modeling ◽  
Cnc Machine Tool ◽  
Cnc Machine ◽  
Error Sources

Error compensation can improve the accuracy of machine tools effectively. Among the error sources affecting the accuracy of CNC machine tool, geometric error is always set as a key performance criterion. This paper summarizes several methods of geometric error modeling and reviews the characteristics of different methods. Furthermore, available methods for measuring geometric errors have been reviewed also based on the advanced instruments. This work aims at enhancing the efficiency of error detection and give a perspective for the application of error compensation in the future.

Dynamic and geometric error assessment of an XYC axis subset on five-axis high-speed machine tools using programmed end point constraint measurements

2010 ◽  
Vol 50 (9-12) ◽  
pp. 1063-1073 ◽  
Author(s):  
Mohamed Slamani ◽  
Rene Mayer ◽  
Marek Balazinski ◽  
Seyedhossein H. H. Zargarbashi ◽  
Serafettin Engin ◽  
...  
Keyword(s):  
Machine Tools ◽  
High Speed ◽  
Geometric Error ◽  
Error Assessment ◽  
End Point ◽  
Five Axis ◽  
High Speed Machine

R-Test Analysis Software for Error Calibration of Five-Axis Machine Tools – Application to a Five-Axis Machine Tool with Two Rotary Axes on the Tool Side –

2015 ◽  
Vol 9 (4) ◽  
pp. 387-395 ◽  
Author(s):  
Soichi Ibaraki ◽  
◽  
Yu Nagai ◽  
Hisashi Otsubo ◽  
Yasutaka Sakai ◽  
...  
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
Three Dimensional ◽  
Geometric Error ◽  
Test Analysis ◽  
Rotary Axes ◽  
Rotary Axis ◽  
Displacement Sensors ◽  
Error Calibration ◽  
Five Axis

The R-test measures the three-dimensional displacement of a precision sphere, attached to a machine spindle, by using three displacement sensors fixed to the machine’s table. Its application to error calibration for five-axis machine tools has long been studied. This paper presents software for analyzing the measured R-test trajectories for error diagnosis and numerical compensation for rotary axis location errors and error motions. The developed software first graphically presents the measured R-test trajectories to help a user intuitively understand error motions of the rotary axes. It also numerically parameterizes the rotary axis geometric error parameters, and then generates a compensation table that can be implemented in some latest-generation commercial CNC systems. An actual demonstration of its application to a five-axis machine tool with a universal head (two rotary axes on the spindle side) is presented.

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