Abstract
This paper presents a technique for assessing the volumetric errors on a five-axis machine tool for motion involving two linear axes and one rotary axis at selected feed rates using data from two sources. The first source of data is obtained through a programmed end point constraint procedure with measurement of the 3D volumetric positioning errors between a point on the tool holder and another fixed to the machine table reference frame. The tests involve maintaining the nominal coincidence of these two points whilst exercising the three axes. The second source of data is the position feedback signal from the encoder provided by the machine controller. Tests were carried out at low and high feed rates to evaluate the effect of geometric and dynamic errors. Polynomial functions are used to represent and then predict the geometric errors. The predicted geometric errors are then added to the dynamic errors provided by the servo errors from position feedback signals and propagated to the tool centre point and are compared with the measured volumetric errors. It shows that the influence of the geometric errors are dominant at low feed, whereas the effects of the servo errors of the linear axes become dominant as the feed increases, reaching 80% of the total error at a feed of 10,000 mm/min.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Hocken RJ, the machine-tool Task Force (1980) 'Technology of machine—tools, vol 5: machine tool accuracy. UCRL-52960-5. Lawrence Livermore Laboratory, Report
Ramesh R, Mannan MA, Poo AN (2000) Error compensation in machine tools—a review. Part I: geometric, cutting-force induced and fixture-dependent errors. Int J Mach Tools Manuf 40:1235–1256
Zhang G, Veale R, Charlton T, Borchardt B, Hocken R (1985) Error compensation of coordinate measuring machines. CIRP Annals 34:445–448
Mir YA, Mayer JRR, Fortin C (2002) Tool path error prediction of a five-axis machine tool with geometric errors. Proc Inst Mech Eng, B J Eng Manuf 216:697–712
Tsutsumi M, Saito A (2003) Identification and compensation of systematic deviations particular to 5-axis machining centers. Int J Mach Tools Manuf 43:771–780
Zargarbashi SHH, Mayer JRR (2006) Assessment of machine tool trunnion axis motion error, using magnetic double ball bar. Int J Mach Tools Manuf 46:1823–1834
Lei WT, Sung MP, Liu WL, Chuang YC (2007) Double ballbar test for the rotary axes of five-axis CNC machine tools. Int J Mach Tools Manuf 47:273–285
Weikert S, Knapp W (2004) R-test, a new device for accuracy measurements on five axis machine tools. CIRP Annals–Manuf Technol 53:429–432
Bringmann B, Knapp W (2006) Model-based ‘Chase-the-Ball’ calibration of a 5-axes machining center. CIRP Annals–Manuf Technol 55:531–534
Yague JA, Velazquez J, Albajez JA, Aguilar JJ, Lope MA, Santolaria J (2009) Development and calibration of self-centring probes for assessing geometrical errors of machines. Meas Sci Technol 20:115103. doi:10.1088/0957-0233/20/11/115103
Trapet E, Aguilar Martín J-J, Yagüe J-A, Spaan H, Zelený V (2006) Self-centering probes with parallel kinematics to verify machine-tools. Precis Eng 30:165–179
Ibaraki S, Kakino Y, Lee K, Ihara Y, Braasch J, Eberherr A (2001) Diagnosis and compensation of motion errors in NC machine tools by arbitrary shape contouring error measurement. Laser Metrology and Machine Performance V, pp 59–68
Yau HT, Ting JY, Chuang CM (2004) NC simulation with dynamic errors due to high-speed motion. Int J Adv Manuf Technol 23:577–585
Zargarbashi SHH, Mayer JRR (2009) Single setup estimation of a five-axis machine tool eight link errors by programmed end point constraint and on the fly measurement with Capball sensor. Int J Mach Tools Manuf 49:759–766
Slamani M, Mayer JRR, Cloutier GM (2010) Modeling and experimental validation of machine tool motion errors using degree optimized polynomial including motion hysteresis. Exp Tech. doi:10.1111/j.1747-1567.2009.00576.x
Bennett DJ, Hollerbach JM (1988) Self-calibration of single-loop, closed kinematic chains formed by dual or redundant manipulators. Proceedings of the IEEE Conference on Decision and Control, pp 627–629
Ciarlet PG (1982) Introduction à l’analyse numérique matricielle et à l’optimisation. Masson, Paris
Berenson ML, Levine DM, Goldstein M (1983) Intermediate statistical methods and applications: a computer package approach. Prentice-Hall, Englewood Cliffs
Venugopal R (1985) Thermal effects on the accuracy of numerically controlled machine tools (numerical methods, experimental). PhD Thesis, Purdue University, United States-Indiana
Ahn KG, Cho DW (1999) Proposition for a volumetric error model considering backlash in machine tools. Int J Adv Manuf Technol 15:554–561
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Slamani, M., Mayer, R., Balazinski, M. et al. Dynamic and geometric error assessment of an XYC axis subset on five-axis high-speed machine tools using programmed end point constraint measurements. Int J Adv Manuf Technol 50, 1063–1073 (2010). https://doi.org/10.1007/s00170-010-2584-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-010-2584-8