Identification of geometric errors of rotary axis on multi-axis machine tool based on kinematic analysis method using double ball bar

Abstract Accuracy identification of geometric errors of rotary axis is important for error compensation of the multi-axis machine tool. However, it is not easy because of the influence of setup error of measurement instrument, and there exists angular errors and displacement errors need to be identified simultaneously. In this paper, a decoupled method based on double ball bar is proposed to identify the geometric errors of rotary axis including both position independent geometric error (PIGE) and position dependent geometric error (PDGE). A formulation for ball bar measurement is derived from kinematic analysis to reveal the relationship between sensitivity direction and setup position of ball bar. The angular errors and displacement errors can be identified separately when choosing the appropriate setup position and direction of ball bar. It can effectively reduce the interaction influence between them and improve the accuracy. To identify the 4 PIGEs, a method by averaging the measured results of ball bar to compute the eccentricity and slant of rotary axis is proposed. And, the PDGEs are leaved to mainly describe the oscillation of geometric errors of rotary axis. It is useful to correct the deviation error resulting from setup error of ball bar. For the identification of 6 PDGEs, by means of adjusting setup position and direction of ball bar, they can be identified one by one along the sensitivity direction of ball bar. Furthermore, in order to reduce the influence of setup error of ball bar, the sensitivity analysis is performed to obtain the sensitivity of measured results of ball bar with respect to setup error. According to the sensitivity characteristics of setup error, a method is presented to correct the PDGEs. Finally, several numerical simulations and experiments are conducted to verify the theoretical model and the proposed identification method. The results from the simulations and experiments demonstrate that the method can identify the geometric errors of rotary axis effectively and accurately.

[1]  Jian-xiong Chen,et al.  Geometric error measurement and identification for rotary table of multi-axis machine tool using double ballbar , 2014 .

[2]  Jianzhong Fu,et al.  Accuracy enhancement of five-axis machine tool based on differential motion matrix: Geometric error modeling, identification and compensation , 2015 .

[3]  Seung-Han Yang,et al.  Robust measurement method and uncertainty analysis for position-independent geometric errors of a rotary axis using a double ball-bar , 2013 .

[4]  Soichi Ibaraki,et al.  Construction of an error map of rotary axes on a five-axis machining center by static R-test , 2011 .

[5]  Nuodi Huang,et al.  Identification of two different geometric error definitions for the rotary axis of the 5-axis machine tools , 2015 .

[6]  Seung-Han Yang,et al.  Measurement and verification of position-independent geometric errors of a five-axis machine tool using a double ball-bar , 2013 .

[7]  Masaomi Tsutsumi,et al.  Identification and compensation of systematic deviations particular to 5-axis machining centers , 2003 .

[8]  Soichi Ibaraki,et al.  Non-contact R-test with laser displacement sensors for error calibration of five-axis machine tools , 2013 .

[9]  Soichi Ibaraki,et al.  Calibration of location errors of rotary axes on five-axis machine tools by on-the-machine measurement using a touch-trigger probe , 2012 .

[10]  Jianguo Yang,et al.  Using a double ball bar to measure 10 position-dependent geometric errors for rotary axes on five-axis machine tools , 2014 .

[11]  Aun-Neow Poo,et al.  Error compensation in machine tools — a review: Part I: geometric, cutting-force induced and fixture-dependent errors , 2000 .

[12]  Yusuf Altintas,et al.  Modeling and compensation of volumetric errors for five-axis machine tools , 2016 .

[13]  Seung-Han Yang,et al.  Compensation of position-independent and position-dependent geometric errors in the rotary axes of five-axis machine tools with a tilting rotary table , 2016 .

[14]  Robert J. Cripps,et al.  A method of testing position independent geometric errors in rotary axes of a five-axis machine tool using a double ball bar , 2015 .

[15]  Shuang Ding,et al.  Identification of different geometric error models and definitions for the rotary axis of five-axis machine tools , 2016 .

[16]  Chi Fai Cheung,et al.  A kinematics and experimental analysis of form error compensation in ultra-precision machining , 2008 .

[17]  Nuodi Huang,et al.  Identification and compensation of geometric errors of rotary axes on five-axis machine by on-machine measurement , 2015 .

[18]  Jian-xiong Chen,et al.  A ballbar test for measurement and identification the comprehensive error of tilt table , 2016 .

[19]  Robert Schmitt,et al.  Geometric error measurement and compensation of machines : an update , 2008 .

[20]  Soichi Ibaraki,et al.  Indirect Measurement of Volumetric Accuracy for Three-Axis and Five-Axis Machine Tools: A Review , 2012 .