An energy consumption field model considering motion position errors for energy efficient machining on CNC machines:CNC programming perspective

Abstract

Motion position errors, which are caused by factors such as machine tool assembly accuracy and thermal effects, often result in deviations in both machining energy consumption and precision, compared to what is expected. Furthermore, the degree of deviations dynamically varies with the machining schemes. These issues hinder the implementation of high-quality energy-saving machining. To address this challenge, an energy consumption field model is proposed, reflecting the impact of motion position errors on energy consumption and precision variations in different machining scenarios. Firstly, by analysing the conversion process from process plans to programming instructions, a dynamic cascading mechanism is revealed, driven by motion position errors that impact tool cutting trajectory offset, machining energy consumption and precision deviation. Subsequently, a dynamic quantification model for the cutting trajectory offset at the programming origin is established by correlating static geometric errors and dynamic spindle rotation errors with the programming origin coordinates. Finally, a transformation function is established by using the cutting trajectory offset as an intermediate variable to correlate motion position error, machining energy consumption and precision deviation. A spatial energy consumption field model is developed. Experimental results indicate that, while meeting precision constraints in the XYZ directions, a 10.96% reduction in energy consumption is achieved through the correction of programming origin coordinates.