Abstract
This paper presents the design of a precise “ball-column” device to efficiently and accurately measure the geometric error terms of both rotary axes of the five-axis machine tool. A geometric error measurement method of spherical contact was proposed based on the influence of the geometric error term from a five-axis machine tool rotating axis on the integrated geometric error of the machine tool. A multiple degree of freedom, step-by-step contact method based on on-machine measure for measuring the spherical center point is proposed, and the solution formula of each geometric error term of the rotating axis is established, respectively. This method can identify 12 geometric errors based on the influence of one rotating axis on another rotating axis after long term operation. The spatial error field of the five-axis machine tool was constructed by analyzing the error law of the two rotating axes of machine tools based on various positions and postures. Finally, after the comparison of the experiment, the results showed that the accuracy of the developed error measurement device reached 91.8% and the detection time was as short as 30–40 min.
Highlights
In the processes of curved surface milling of complex parts and thin-walled parts, the machining accuracy directly affects the production quality of the parts [1]
The efficient and accurate detection of the geometric error of the five-axis machine tool rotating axis is of particular importance
The influence of gravity, acceleration, inertia, and other factors existing in the operation of the A-axis on the average position error of the C-axis were considered, and 10 key average position error elements for the two rotating axes were determined
Summary
In the processes of curved surface milling of complex parts and thin-walled parts, the machining accuracy directly affects the production quality of the parts [1]. Jiang [33] proposed a location error identification method using a touch-trigger probe and a test-piece on a five-axis machine tool with a tilting head In their nature, all of these methods involve the contact detection of block standard parts. Japan’s Otsuka Machine Tool developed a “5-Axis Auto Tuning System” that uses a contact detector and standard ball to measure geometric error compensation in order to reduce the difference in the working surface of the table. This system only adjusts the geometric error of the rotating axis and does not accurately identify all 13 geometric errors. Compared with instruments such as DBB and R-test, the developed device has the advantages of low cost, simple and efficient operation, and good communication capability with numerical control systems
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