Surface error analysis and online compensation method for increasing the large-sized cylindrical part’s quality

The manufacturing quality of a large-sized cylindrical part’s surface is usually rough because of poorly positioning and improperly clamping when cutting it. This paper focuses on the surface error analysis to find the cause of the rough surface and, therefore, to improve the surface quality by online compensation. The values of online compensation are determined based on a surface error measurement and error component analysis model. This model is built upon the surface error generating mechanism and the machining system. The online error compensation is implemented by a servo controlling system. Finally, the compensation operation is simulated to check the effectiveness of this method. In simulation, more than 80 % of roundness improvements have been achieved from this compensation method over those without compensation. The great improvement reveals that the online compensation technique proposed in this paper is very practical for the large-sized cylindrical part’s manufacturing.

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