There is an important interest in compensating thermally induced errors of modular tool systems to improve the manufacturing accuracy. In this paper, we test the hypothesis whether we can predict such thermal displacements by using a nonlinear regression analysis, namely the alternating conditional expectation algorithm (ACE [Breiman & Friedman, 1985]), reliably. The data analyzed were generated by two different finite element spindle models of modular tool systems. As the main result, we find that the ACE-algorithm is a powerful tool to model the relation between temperatures and displacements. The maximal correlation is larger than 0.999 in both cases, which demonstrates the suitability of the ACE algorithm. Furthermore, preconditions for the applicability of this approach, such as the length and the support of measured data sets, are studied. Hence, this approach seems to be promising for the application to real modular tool systems.

In the last decade, there has been an increasing interest in compensating thermally induced errors to improve the manufacturing accuracy of modular tool systems. These modular tool systems are interfaces between spindle and workpiece and consist of several complicatedly formed parts. Their thermal behavior is dominated by nonlinearities, delay and hysteresis effects even in tools with simpler geometry and it is difficult to describe it theoretically. Due to the dominant nonlinear nature of this behavior the so far used linear regression between the temperatures and the displacements is insufficient. Therefore, in this study we test the hypothesis whether we can reliably predict such thermal displacements via nonlinear temperature-displacement regression functions. These functions are estimated first from learning measurements using the alternating conditional expectation (ACE) algorithm and then tested on independent data sets. First, we analyze data that were generated by a finite element spindle model. We find that our approach is a powerful tool to describe the relation between temperatures and displacements for simulated data. Next, we analyze the temperature-displacement relationship in a silent real experimental setup, where the tool system is thermally forced. Again, the ACE algorithm is powerful to estimate the deformation with high precision. The corresponding errors obtained by using the nonlinear regression approach are 10-fold lower in comparison to multiple linear regression analysis. Finally, we investigate the thermal behavior of a modular tool system in a working milling machine and again get promising results. The thermally induced errors can be estimated with 1-2 microm accuracy using this nonlinear regression analysis. Therefore, this approach seems to be very useful for the development of new modular tool systems.

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