Highly efficient and accurate calibration method for the position-dependent geometric errors of the rotary axes of a five-axis machine tool

Guo, Siu-Siu; Tang, Shufeng; Jiang, Gedong; Mei, Xuesong

doi:10.1177/0954405420951096

Cited by 11 publications

(10 citation statements)

References 31 publications

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“…The methods proposed in this study for practically effective creation of postprocessors for 5-axis CNC machines were also successfully applied to determine the inverse kinematic equations for the 5-axis CNC machines that include the 5-axis CNC machines with the non-orthogonal rotary axes [3][4][5][6][7][8] and the 5-axis CNC machines with the orthogonal rotary axes. [9][10][11][12][13][14][15] The proposed methods were also verified with the 5-axis CNC machines with the TTTRR configurations, 3,5,6 and the 5-axis CNC machines with the RTTTR configurations.…”

Section: Discussionmentioning

confidence: 99%

A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

Lê

Hoang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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The 5-axis CNC (Computer Numerical Control) machining plays an important role in manufacturing, especially in making parts of complex shapes such as turbine or propeller blades. However, there are always challenges of generating 5-axis CNC machining programs when working with different 5-axis CNC machines of various structures; and 5-axis CNC programs must be automatically generated by CNC postprocessors which calculate the inverse kinematics and convert the Cutter Location data to the CNC programs that are used for operating 5-axis CNC machines. Since the family of 5-axis CNC machines has a wide spectrum of machine configurations, with hundreds of mechanisms of 5 degrees of freedom, it is therefore practically challenging for engineers and CNC machine operators to create CNC postprocessors for specific 5-axis CNC machines. It is more challenging to create CNC postprocessors if engineers or CNC operators do not have strong backgrounds and professional skills in mathematical modeling and kinematics of machines. This paper presents a universal and intuitive framework and practical guidance to create CNC postprocessors for all 5-axis CNC machines, with the focus on a novel mathematical formulation of inverse kinematics of three main groups of 5-axis CNC machines. The case studies of creating CNC postprocessors with the commercially available 5-axis CNC machines were successfully demonstrated, in which the simulation scenarios and experiments were implemented to verify the created CNC postprocessors. The proposed frameworks and guides for generating CNC postprocessors can be conveniently and effectively applied in industrial practices, without the required strong backgrounds and skills for engineers or CNC operators in mathematical modeling and kinematics of machines, especially mathematical modeling of multibody systems.

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Section: Discussionmentioning

confidence: 99%

A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

Lê

Hoang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…The mapping model of geometric error and error vector can characterize the error terms and spatial accuracy, and in-depth studies were performed to establish volumetric error model [11,12]. For the position-dependent geometric error, the algebraic values of error terms is corresponding with the positional of motion axis.…”

Section: Introductionmentioning

confidence: 99%

All position-independent and position-dependent geometric error measurement and identification of the precision of a horizontal boring machine tool

Guo

Tang

et al. 2022

Int J Adv Manuf Technol

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 Geometric error is the main obstacle that affects the quasi-static accuracy of horizontal boring machine tool. To improve quasi-static performance, the error terms that all PIGEs and PDGEs must be measurement and identified precisely. This study proposes a novel methodology for measuring and identifying that the above two types of geometric errors based on DBB for rotary axis. The error terms of linear axis are identified from measurement model based on exponential product method and a preset measure trajectory, and the measure coordinate system be unified together with reference coordinate to lower the uncertainty of identification accuracy, and then Elastic Net method and improved weight function IGG3-LTS method are established to identify the PIGEs and PDGEs of rotary and linear axes respectively. This method has the advantage that measurement with built in-sensors method that synchronously without interfering with the running state of the machine tool, and neither the inaccuracy of reference-frame misalignment nor installation error of the measuring instrument affects the geometric error identification results of linear axis. , the other is all PIGEs and PDGEs particular to rotary axis of horizontal boring machine tool are determinated accurately. The measurement and identify strategy is demonstrated by experimental comparison on a four-axis precision horizontal boring machine tool, the minimum compensation rate of each precision index of test specimen is 40.0%, the average compensation rate is 52.7%, and the maximum compensation rate is 62.5%. under the actual condition of machine tool.

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“…Although Liu et al 3 realized that the six geometric errors of the linear axis can be obtained in one measurement, the assembly and debugging of the mirror group were difficult. The geometric errors of the rotating axis are mainly measured and identified by Double Ball-Bar (DBB) and R-test, [5][6][7] but these methods need to decouple the measurement results to obtain the corresponding geometric errors, the measurement efficiency is not high, and it is impossible to identify all geometric errors of the machine tool simultaneously.…”

Section: Introductionmentioning

confidence: 99%

Kinematic modeling and error parameter identification of automated fiber placement machine based on measured data

Zhang

Cheng

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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This paper presents a novel kinematic modeling and error parameter identification method for a six-axis gantry automated fiber placement (AFP) machine. Multi-body system theory is used to model the kinematics of the AFP machine, and then use the homogeneous transformation matrix to represent the transfer relationship of the coordinate system. Based on 54 geometric errors of the AFP machine, a volumetric error transfer model is established. To eliminate the training bias caused by sampling randomness, 10-fold cross-validation combined with the Levenberg–Marquardt method is used to train the kinematic model of the AFP machine. Based on the coordinates of random points in space measured by a laser tracker, all the position-dependent geometric errors and position-independent geometric errors of the linear and rotary axes can be identified simultaneously. After the error parameters are identified, the average error of the random points in the X-direction is reduced from 0.72 to 0.08 mm, a drop of 88.9%. Corresponding experiments are carried out on the body diagonals and the winglet placement path. The experimental results show that the volumetric error transfer model and error parameter identification method proposed in the article can accurately predict the volumetric errors of the AFP machine, and can also meet the requirements of the AFP machine placement accuracy.

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Highly efficient and accurate calibration method for the position-dependent geometric errors of the rotary axes of a five-axis machine tool

Cited by 11 publications

References 31 publications

A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

All position-independent and position-dependent geometric error measurement and identification of the precision of a horizontal boring machine tool

Kinematic modeling and error parameter identification of automated fiber placement machine based on measured data

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