Calibration Methods of an On-Line Inspection System on a Large-Scale Turning-Milling Machining Center

2011 ◽  
Vol 189-193 ◽  
pp. 1253-1257 ◽  
Author(s):  
Ying Shu Chen ◽  
Li Bing Liu ◽  
Qing Kai Jiang ◽  
Ze Qing Yang ◽  
Kai Peng
Keyword(s):  
Error Compensation ◽  
Large Scale ◽  
Compensation Method ◽  
Inspection System ◽  
Error Sources ◽  
Machining Center ◽  
Calibration Methods ◽  
On Line ◽  
Error Calibration ◽  
Five Axis

To improve the accuracy of the on-line inspection system used by a large-scale turning-milling machining center, its error sources were analyzed and some calibration methods were researched, including error calibration in Z, Y, -X and any angular directions. The error compensation method based on embedded HMI control and CNC variables control was proposed. The EN86N touch system with TT25G probe of Marposs is calibrated on the five-axis turning-milling machining center HTM125. The experiments improved that the calibration methods and the compensation method are reasonable and effective.

Five-Axis Machining Center On-Line Inspection System Based on Workpiece

2011 ◽  
Vol 480-481 ◽  
pp. 1150-1154
Author(s):  
Hong Qiang Sang ◽  
Jian Jun Meng
Keyword(s):  
Production Efficiency ◽  
Effective Means ◽  
Inspection System ◽  
Additional Function ◽  
Manual Inspection ◽  
Machining Center ◽  
On Line ◽  
And Control ◽  
Tool Damage ◽  
Five Axis

Machining center on-line inspecting technology is an effective means that can improve precision and efficiency of machining center, which effectively integrates machining and inspection, makes machining center with partly inspecting function of coordinate measuring machines and improves the degree of inspecting automation compared with manual inspection and off-line inspection. Machining center on-line inspection system based on workpiece has been successfully developed and applied in SSK-U6035 five-axis machining center for palm inspection and control. The application result shows that machining center on-line inspection system based on workpiece can realize integration of machining and inspection more efficiently, increase precision and production efficiency, and reduce the rate of rejection and tool damage. At the same time, the on-line inspection system increases the additional function of the machining center for the manufacturer of machining center, improves the automation degree of the inspection and provides a new inspecting approach for other specific type’s workpiece.

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.

On-line first-order machining error compensation for thin-walled parts considering time-varying cutting condition

2021 ◽  
pp. 1-16
Author(s):  
Xiong Zhao ◽  
Lianyu Zheng ◽  
Yuehong Zhang
Keyword(s):  
Error Compensation ◽  
Compensation Method ◽  
Cutting Condition ◽  
Time Varying ◽  
Machining Error ◽  
Process Step ◽  
Compensation Model ◽  
First Order ◽  
On Line ◽  
Thin Walled

Abstract Mirror error compensation is usually employed to improve the machining precision of thin-walled parts. However, this zero-order method may result in inadequate error compensation, due to the time-varying cutting condition of thin-walled parts. To cope with this problem, an on-line first-order error compensation method is proposed for thin-walled parts. With this context, firstly, the time-varying cutting condition of thin-walled parts is defined with its in-process geometric and physical characteristics. Based on it, a first-order machining error compensation model is constructed. Then, during the process planning, the theory geometric and physical characteristic of thin-walled parts are respectively obtained with CAM software and structure dynamic modification method. After process performing, the real geometric characteristic of thin-walled parts is measured, and it is used to calculate the dimension error of thin-walled parts. Next, the error compensated value is evaluated based on the compensation model, from which, an error compensation plane is constructed to modify the tool center points for next process step. Finally, the machining error is compensated by performing the next process step. A milling test of thin-walled part is employed to verify the proposed method, and the experiment results shown that the proposed method can significantly improve the error compensation effect for low-stiffness structure, and thickness precision of thin-walled parts is improved by 71.4 % compared with the mirror error compensation method after machining.

Sensitivity Analysis of Error Motions and Geometric Errors in the Case of Sphere-Shaped Workpiece

2020 ◽  
Author(s):  
Zongze Li ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Sensitivity Analysis ◽  
Machine Tools ◽  
End Milling ◽  
Geometric Errors ◽  
Machined Surface ◽  
Error Sources ◽  
Motion Error ◽  
Machining Center ◽  
Machining Errors ◽  
Five Axis

Abstract Motion error of machine tool feed axes influences the machined workpiece accuracy. However, the influences of each error sources are not identical; some errors do not influence the machined surface although some error have significant influences. In addition, five-axis machine tools have more error source than conventional three-axis machine tools, and it is very tough to predict the geometric errors of the machined surface. This study proposes a method to analyze the relationships between the each error sources and the error of the machined surface. In this study, a kind of sphere-shaped workpiece is taken as a sample to explain how the sensitivity analysis makes sense in ball-end milling. The results show that the method can be applied for the axial errors, such as motion reversal errors, to make it clearer to obverse the extent of each errors. In addition, the results also show that the presented sensitivity analysis is useful to investigate that how the geometric errors influence the sphere surface accuracy. It can be proved that the presented method can help the five-axis machining center users to predict the machining errors on the designed surface of each axes error motions.

Real-time thermal error compensation method for robotic visual inspection system

2014 ◽  
Vol 75 (5-8) ◽  
pp. 933-946 ◽  
Author(s):  
Shibin Yin ◽  
Yin Guo ◽  
Yongjie Ren ◽  
Jigui Zhu ◽  
Shourui Yang ◽  
...  
Keyword(s):  
Real Time ◽  
Error Compensation ◽  
Visual Inspection ◽  
Thermal Error ◽  
Compensation Method ◽  
Inspection System ◽  
Thermal Error Compensation

Error Calibration Technique of Laser Tracker and its Application

2010 ◽  
Vol 455 ◽  
pp. 690-693
Author(s):  
Yong Gang Yan ◽  
Zhan Kui Wang ◽  
X.B. Wang ◽  
Y.Q. Li
Keyword(s):  
High Precision ◽  
Large Scale ◽  
The Body ◽  
Manufacturing Industries ◽  
Laser Tracker ◽  
Calibration Technique ◽  
Axis Direction ◽  
Calibration Methods ◽  
Error Calibration ◽  
Lathe Tool

Laser tracker has widely been used in manufacturing industries, such as the industry of the large-scale machining tool, automobile, aircraft. So a high precision laser tracker is essential to satisfy the measuring requirements. In the paper the errors of laser tracker was analyzed and their calibration methods were discussed and studied. Then a calibration for laser tracker was carried on by using CMM and the measuring accuracy was verified. Finally, we demonstrate the application of laser tracker for detecting the large-scale machining tools. The measurement shows that the feeding straightnesses of tool rest in the two orthogonal directions are 0.0564 mm and 0.0309 mm in the working scope respectively. The results show the straightness of the body guide for the lathe meets the requirement, whereas the lathe tool workbench on the X axis direction does not and needs to be adjusted.

scholarly journals A Novel Error Compensation Method of Five-axis Flank Milling of Ruled Surface by Modifying Tool Path

2021 ◽  
Author(s):  
Gaiyun He ◽  
Chenglin Yao ◽  
Yicun Sang ◽  
Yichen Yan
Keyword(s):  
Error Compensation ◽  
Tool Path ◽  
Error Distribution ◽  
Ruled Surface ◽  
Compensation Method ◽  
Distribution Model ◽  
Flank Milling ◽  
Average Error ◽  
Machining Accuracy ◽  
Five Axis

Abstract Five-axis flank milling is widely used in the aerospace and automotive industry. However, diverse sources of errors prevent the improvement of machining accuracy. This paper proposes a novel error compensation method for five-axis flank milling of ruled surface by modifying the original tool path according to the error distribution model. The method contains three steps: First, the errors at the middle of the straight generatrix on the machined surface are calculated according to error distribution, and the corresponding normal vectors are obtained by geometric calculation. Second, multi-peaks Gaussian fitting method is utilized to make connections between parameters in the original tool path and error distribution. Finally, the new tool path is generated by adjusting original tool path. Machining experiments are performed to test the effectiveness of the proposed error compensation method. The error distribution after compensation shows that the average error decreases 74%, and the maximum error (contains overcutting and undercutting) decreases 26%. Results show that the proposed error compensation method is effective to improve the accuracy for five-axis flank milling.

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