An efficient method for measuring and identifying geometric and dynamic errors in dual five-axis machine tools

Abstract

The dual five-axis machining machine is state-of-the-art equipment designed for producing thin-walled aerospace parts like skins and panels. It comprises two five-axis machine tools with mirrored synchronous motions: one bi-rotary machine for milling and the other machine for follow-up support. The high absolute accuracy of the five-axis machine tools themselves and the high synchronous motion accuracy between the two machines are both crucial to ensure machining accuracy. This paper proposes an efficient method to measure and identify geometric and dynamic errors of dual five-axis machine tools. Using the R-test combined with three measurement trajectories to measure the absolute motion error of two five-axis machine tools and the synchronous motion error between the two machines. The designed trajectories include the main rotary axis linkage conditions and can fully reflect the primary motion forms of the dual five-axis machine tool. The main position-independent geometric errors and rotational axis linkage dynamic errors are identified by converting quasi-static and dynamic measurement data from three different trajectories into a unified reference coordinate system. The entire process requires only one instrument installation, effectively avoiding time-consuming repetitive installations and calibration processes while reducing the impact of installation errors on results. The effectiveness of the proposed method for measuring and identifying the geometric and dynamic errors is analyzed combined with Monte Carlo simulation. Experiments were carried out on a dual five-axis mirror milling system (MMS) with a 5000 mm X-stroke. Both simulations and experiments confirmed that the proposed method is efficient in quickly identifying key error sources of the MMS.