No abstract

No abstract

The accuracy of machine tools is significantly affected by the geometric defect and thermal deformation of the mechanical components. This paper intends to provide a comprehensive compensation method for the integrated geometric and thermal errors of machine tools. Firstly, a synthesized volumetric model is established with homogeneous transformation matrix method, considering both the geometric and thermal effects. Then, in order to improve the modeling accuracy and efficiency of the geometric error components, an automatic modeling algorithm is proposed with the Chebyshev polynomial-based orthogonal least squares regression. Also, to improve the robustness of the thermal error models for the feed axes and the spindle system, the thermal effects caused by external ambient variation and internal heat sources are identified and modeled separately. Finally, an intelligent virtual compensation system is developed for machine tools based on the function of external machine original coordinate shift and fast Ethernet data interaction technique, and compensation tests on a vertical machining center showed that the position accuracy of the machine tool could be significantly improved after compensation.

This article intends to provide an efficient modeling and compensation method for the synthetic geometric errors of large machine tools. Analytical and experimental examinations were carried out on a large gantry-type machine tool to study the spatial geometric error distribution within the machine workspace. The result shows that the position accuracy of the tool-tip is affected by all the translational axes synchronously, and the position error curve shape is non-linear and irregular. Moreover, the angular error combined with Abbe's offset during the motion of a translational axis would cause Abbe's error and generate significant influence on the spatial positioning accuracy. In order to identify the combined effect of the individual error component on the tool-tip position accuracy, a synthetic geometric error model is established for the gantry-type machine tool. Also, an automatic modeling algorithm is proposed to approximate the geometric error parameters based on moving least squares in combination with Chebyshev polynomials, and it could approximate the irregular geometric error curves with high-order continuity and consistency with a low-order basis function. Then, to implement real-time error compensation on large machine tools, an intelligent compensation system is developed based on the fast Ethernet data interaction technique and external machine origin shift, and experiment validations on the gantry-type machine tool showed that the position accuracy could be improved by 90% and the machining precision could be improved by 85% after error compensation.