Abstract
This article proposes a tracing method to identify key geometric errors for a computer numerical control machine tool by cutting an S-shaped test piece. Adjacent part relationships and machine tool errors transform relationships are described by topology of the machining center. Global sensitivity analysis method based on quasi-Monte Carlo was used to analyze machining errors. Using this method, key geometric errors with significant influence on machining errors were obtained. Compensation of the key errors was used to experimentally improve machining errors for the S-shaped test piece. This method fundamentally determines the inherent connection and influence between geometric errors and machining errors. Key geometric errors that have great influence on machining errors can be determined quickly with this method. Thus, the proposed tracing method could provide effective guidance for the design and use of machine tools.
Highlights
High machining precision is critically important and has increased demand in recent years in aerospace, military, ships, cars, and other industries
Geometric errors eyðxÞ, eyðyÞ, exðxÞ, and eyðzÞ were found to be the most influential factors. Assuming that these four geometric errors are zero, absolute value of Ze reduces from 0.1985 to 0.0093 mm, that is, reducing by 95%. These results demonstrate that sensitivity errors largely affect machining error model (MEM)
In a trial cut test, mean absolute machining error was reduced by 56% after compensating for key geometric errors
Summary
High machining precision is critically important and has increased demand in recent years in aerospace, military, ships, cars, and other industries. A variety of error sources related to the machine tool are responsible for machining errors To alleviate this problem, it is important to establish a mapping relationship between machine tool errors and machining errors. This would allow tracing machining errors caused by machine tool errors. Knapp and Matthias[3] proposed a circular test for identifying machine errors by measuring circular contour along different flat of machining space. This allowed identification of the main source of errors due to uncertainty of machine in threedimensional space. Kakino et al.[4] carried out an in-depth study using the circular test with the aid of magnetic ball bars to obtain a relationship between
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