Abstract
A quantitative analysis to identify the key geometric error elements and their coupling is the prerequisite and foundation for improving the precision of machine tools. The purpose of this paper is to identify key geometric error elements and compensate for geometric errors accordingly. The geometric error model of three-axis machine tool is built on the basis of multibody system theory; and the quantitative global sensitivity analysis (GSA) model of geometric error elements is constructed by using extended Fourier amplitude sensitivity test method. The crucial geometric errors are identified; and stochastic characteristics of geometric errors are taken into consideration in the formulation of building up the compensation strategy. The validity of geometric error compensation based on sensitivity analysis is verified on a high-precision three-axis machine tool with open CNC system. The experimental results show that the average compensation rates along theX,Y, andZdirections are 59.8%, 65.5%, and 73.5%, respectively. The methods of sensitivity analysis and geometric errors compensation presented in this paper are suitable for identifying the key geometric errors and improving the precision of CNC machine tools effectively.
Highlights
With the rapid development of modern manufacturing technology, higher precision of CNC machine tools is required
The factors affecting the precision of CNC machine tools include geometric errors, thermally induced errors, cutting force deformation errors, kinematic errors, and fixture-dependent errors [1]
This paper focuses on the identification of critical geometric error elements and error compensation based on extend Fourier amplitude sensitivity test (EFAST) method for three-axis machine tools
Summary
With the rapid development of modern manufacturing technology, higher precision of CNC machine tools is required. An observer-based adaptive fuzzy controller was developed for nonlinear discrete-time systems; a fine stability in control systems has been obtained and the tracking error fluctuated within a narrow range [16] Among these methods, the modeling approach-based Multibody System (MBS) theory [17, 18] can express the motion relationship among the components of multiaxis machine tools. Chen et al [29] adopted LSA method to study the sensitivity of 37 geometric error elements of a five-axis ultraprecision machine tool; and the analysis results were used in machine tool design and manufacturing.
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