Nonlinear error compensation based on the optimization of swing cutter trajectory for five-axis machining

Chen, Liangji; Tang, Jinmeng; Wu, Wei; Wei, Zisen

doi:10.1007/s00170-022-09534-0

Cited by 5 publications

(2 citation statements)

References 25 publications

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“…Liu 8 proposed a method that uses a flat-bottom cutter to substitute the cutter envelope surface with a discrete bottom circle, iterating step errors in calculations. Chen 9 modeled the nonlinear error of the tool center point, demonstrating that, within the same interpolation cycle, the tool center point lies on the same plane, thereby converting the three-dimensional problem into a two-dimensional one for research. Wang 10 established a motion error model of five-axis machine tools using a method based on dual quaternions and analyzed its correlation with the PIGE (Position Independent Geometric Error) definition in ISO 230-7.…”

Section: Introductionmentioning

confidence: 99%

An integrated method for compensating and correcting nonlinear error in five-axis machining utilizing cutter contacting point data

Chen,

Xu,

Huang

et al. 2024

Sci Rep

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In current five-axis computer numerical control (CNC) machining, the use of minute linear path segments as an approximation for the ideal cutter contacting (CC) point trajectory is still prevalent. However, introducing rotation axes leads to a deviation of the actual CC point trajectory from the ideal, resulting in nonlinear errors. An integrated method is proposed in this paper for compensating and correcting both the contour error, associated with the approximation of the part surface by the ideal CC point trajectory and the nonlinear error of the CC point trajectory based on the information in the CC point data. By analyzing the spatial relationship between the tool posture and the CC point path during the five-axis linear interpolation process, two adjacent machining tool positions containing CC point data information are selected as the starting and ending points of the five-axis linear interpolation machining. The ideal tool center point and the actual CC point are calculated during the interpolation process, as well as the distance and the unit vector in the perpendicular direction between the actual CC point and the ideal CC point trajectory segment. In the comprehensive error compensation and correction phase, the obtained unit vectors are used as direction vectors for error compensation, and the tool center point during interpolation is first compensated and corrected. This ensures the actual CC point and the contour curve are on the same plane. The compensation direction for contour error is calculated using the start/end tool axis vectors and the ideal CC point trajectory vectors. The size of the contour error approximating the contour curve is calculated through the chord error. A second compensation and correction are applied to the tool center point for interpolation, ultimately achieving comprehensive compensation and correction of nonlinear errors. The data calculations were conducted in the MATLAB environment using actual machining data. After compensation and correction, the contour error was reduced by 76%, the nonlinear error of the CC point trajectory decreased to below 0.88 μm, and the comprehensive nonlinear error of the CC point trajectory was reduced from 19 to 1.5 μm, a reduction of 93%. This demonstrates significant practical value in enhancing the accuracy of five-axis CNC machining. Through actual machining verification, after using the method described in this paper, the average surface roughness decreased from 1.133 to 0.220 μm, and the maximum surface roughness decreased from 6.667 to 1.240 μm. This significantly demonstrates that the compensation and correction method proposed in this paper can significantly improve the surface quality of machined parts.

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Section: Introductionmentioning

confidence: 99%

An integrated method for compensating and correcting nonlinear error in five-axis machining utilizing cutter contacting point data

Chen,

Xu,

Huang

et al. 2024

Sci Rep

Self Cite

View full text Add to dashboard Cite

show abstract

“…The iso-scallop machining method was proposed to address this issue; however, the algorithms are complicated. Literature studies have also investigated errors associated with five-axis machining processes [17,18]. For example, Li et al [19] conducted an experimental study to test the motion error of the machine axis in the five-axis machining process; the systematic errors were identified and could be effectively compensated.…”

Section: Introductionmentioning

confidence: 99%

Research on Continuous Machining Strategy for Five-Axis Machine Tool: Five-Axis Linkage to Four-Axis Linkage

et al. 2023

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The article presents a novel strategy for enhancing the efficiency of machines that are used for complex structure machining. It proposes a low-cost five-axis four-linkage milling system as an alternative to the more expensive five-axis five-linkage system. Kinematic analysis of the machine tool is conducted to establish a correlation between the tool location data and the displacement of kinematic axes. An interpolation algorithm is then devised to determine a four-axis linkage milling strategy. The theoretical errors of the interpolation trajectory are observed to be reduced following the transformation. The research employs impeller processing as a case study, wherein the five-axis linkage machining path is translated into a more efficient five-axis four-linkage path using the interpolation algorithm. The practical application of this novel milling strategy confirms its effectiveness in processing the integral impeller within acceptable efficiency parameters. The results provide a theoretical foundation for the practical application of the low-cost five-axis four-linkage machining strategy in high-precision five-axis five-linkage machine tools.

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A Novel Laser Pulse Output Algorithm for Three-dimensional Complex Surfaces with Adjustable Spot Intervals

Kong,

Liu,

Tao

et al. 2024

Int. J. Precis. Eng. Manuf.

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Nonlinear error compensation based on the optimization of swing cutter trajectory for five-axis machining

Cited by 5 publications

References 25 publications

An integrated method for compensating and correcting nonlinear error in five-axis machining utilizing cutter contacting point data

An integrated method for compensating and correcting nonlinear error in five-axis machining utilizing cutter contacting point data

Research on Continuous Machining Strategy for Five-Axis Machine Tool: Five-Axis Linkage to Four-Axis Linkage

A Novel Laser Pulse Output Algorithm for Three-dimensional Complex Surfaces with Adjustable Spot Intervals

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