Improving a real milling machine accuracy through an indirect measurement of its geometric errors

Abstract Traditional verification techniques, based on direct measurement of machine tool errors to improve accuracy, will gradually be replaced by technology based on indirect measurement techniques, reducing significantly the maintenance and verification time required. Within these techniques, the laser tracker is highlighted as a measurement system. This paper presents all the verification processes on a real milling machine, studying the principal steps and influence factors, such as the kinematic model of the machine tool, the influence of the verification points distribution, convergence criteria, the defined identification strategy and the compensation procedure. The adequacy of the mathematical compensation provided by this method is validated using traditional verification methods based on a laser interferometer and new ones based on a laser tracker.

[1]  Zbigniew Lechniak,et al.  Methodology of off-line software compensation for errors in the machining process on the CNC machine tool , 1998 .

[2]  Zhenjiu Zhang,et al.  Three-point method for measuring the geometric error components of linear and rotary axes based on sequential multilateration , 2013 .

[3]  A. Slocum,et al.  Precision Machine Design , 1992 .

[4]  Dong Gao,et al.  Geometric error compensation software system for CNC machine tools based on NC program reconstructing , 2012 .

[5]  Neil A. Duffie,et al.  Generation of Parametric Kinematic Error-Correction Functions from Volumetric Error Measurements , 1985 .

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

[7]  Jorge Santolaria,et al.  Volumetric Verification of Multiaxis Machine Tool Using Laser Tracker , 2014, TheScientificWorldJournal.

[8]  Dong Gao,et al.  A novel error compensation implementing strategy and realizing on Siemens 840D CNC systems , 2012 .

[9]  Allan D. Spence,et al.  Kinematic and geometric error compensation of a coordinate measuring machine , 2000 .

[10]  M. A. Donmez,et al.  A general methodology for machine tool accuracy enhancement by error compensation , 1986 .

[11]  Byung-Kwon Min,et al.  Reduction of machining errors of a three-axis machine tool by on-machine measurement and error compensation system , 2004 .

[12]  Anthony Chukwujekwu Okafor,et al.  Vertical machining center accuracy characterization using laser interferometer: Part 1. Linear positional errors , 2000 .

[13]  Jorge Santolaria,et al.  Identification strategy of error parameter in volumetric error compensation of machine tool based on laser tracker measurements , 2012 .

[14]  J.R.R. Mayer,et al.  Validation of volumetric error compensation for a five-axis machine using surface mismatch producing tests and on-machine touch probing , 2014 .

[15]  A. Geddam,et al.  Accuracy improvement of three-axis CNC machining centers by quasi-static error compensation , 1997 .

[16]  Jorge Santolaria,et al.  Towards an effective identification strategy in volumetric error compensation of machine tools , 2012 .

[17]  Wuyi Chen,et al.  A methodology for systematic geometric error compensation in five-axis machine tools , 2011 .

[18]  Behrooz Arezoo,et al.  Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines , 2014 .

[19]  Andrew P. Longstaff,et al.  Impact of measurement procedure when error mapping and compensating a small CNC machine using a multilateration laser interferometer , 2014 .

[20]  P. Maropoulos,et al.  Modelling and optimization of novel laser multilateration schemes for high-precision applications , 2005 .

[21]  Tian Huang,et al.  A general approach for error modeling of machine tools , 2014 .

[22]  Jun Ni,et al.  Accuracy enhancement of a horizontal machining center by real-time error compensation , 1996 .

[23]  Jindong Wang,et al.  The detection of rotary axis of NC machine tool based on multi-station and time-sharing measurement , 2012 .

[24]  P. Lin,et al.  Direct volumetric error evaluation for multi-axis machines , 1993 .

[25]  Mizanur Rahman,et al.  Five axis machine tool volumetric error prediction through an indirect estimation of intra- and inter-axis error parameters by probing facets on a scale enriched uncalibrated indigenous artefact , 2015 .

[26]  S. Sartori,et al.  Geometric Error Measurement and Compensation of Machines , 1995 .

[27]  Jenq-Shyong Chen,et al.  Geometric error calibration of multi-axis machines using an auto-alignment laser interferometer , 1999 .

[28]  J. J. Aguilar,et al.  Empirical analysis of the efficient use of geometric error identification in a machine tool by tracking measurement techniques , 2016 .

[29]  Hai Wang,et al.  Design analysis and applications of a 3D laser ball bar for accuracy calibration of multiaxis machines , 2004 .

[30]  A.C.H. van der Wolf,et al.  A General Method for Error Description of CMMs Using Polynomial Fitting Procedures , 1989 .

[31]  Jorge Santolaria,et al.  Protocol for machine tool volumetric verification using commercial laser tracker , 2014 .