Accuracy Enhancement with Processing Error Prediction and Compensation of a CNC Flame Cutting Machine Used in Spatial Surface Operating Conditions

Abstract

Abstract. This study deals with the precision performance of the CNC flamecutting machine used in spatial surface operating conditions and presents an accuracy enhancement method based on processing error modeling prediction and real-time compensation. Machining coordinate systems and transformation matrix models were established for the CNC flame processing system considering both geometric errors and thermal deformation effects. Meanwhile, prediction and compensation models were constructed related to the actual cutting situation. Focusing on the thermal deformation elements, finite element analysis was used to measure the testing data of thermal errors, the grey system theory was applied to optimize the key thermal points, and related thermal dynamics models were carried out to achieve high-precision prediction values.Comparison experiments between the proposed method and the teaching method were conducted on the processing system after performing calibration. The results showed that the proposed method is valid and the cutting quality could be improved by more than 30% relative to the teaching method. Furthermore, the proposed method can be used under any working condition by making a few adjustments to the prediction and compensation models.

Two-sided manual machining method for three-axis CNC milling machine for small and medium-sized enterprises

“…The hardness of the material, the tool strength [20], the tool design, and any other potential cutting parameters [21] can affect the accuracy of the machining results. There is a possibility that the tool might bend during the marking-point making or be deformed because of the heat generated when the tool penetrates through some hard materials like hardwoods, acrylic, resin, or steel [22].…”