Abstract

To address the problems of the low accuracy of geometric error identification and incomplete identification results of the linear axis detection of computer numerical control (CNC) machine tools, a new 21-item geometric error identification method based on double ball-bar measurement was proposed. The model between the double ball-bar reading and the geometric error term in each plane was obtained according to the three-plane arc trajectory measurement. The mathematical model of geometric error components of CNC machine tools is established, and the error fitting coefficients are solved through the beetle antennae search particle swarm optimization (BAS–PSO) algorithm, in which 21 geometric errors, including roll angle errors, were identified. Experiments were performed to compare the optimization effect of the BAS–PSO and PSO and BAS and genetic particle swarm optimization (GA–PSO) algorithms. Experimental results show that the PSO algorithm is trapped in the local optimum, and the BAS–PSO is superior to the other three algorithms in terms of convergence speed and stability, has higher identification accuracy, has better optimization performance, and is suitable for identifying the geometric error coefficient of CNC machine tools. The accuracy and validity of the identification results are verified by the comparison with the results of the individual geometric errors detected through laser interferometer experiments. The identification accuracy of the double ball-bar is below 2.7 µm. The proposed identification method is inexpensive, has a short processing time, is easy to operate, and possesses a reference value for the identification and compensation of the linear axes of machine tools.

Highlights

  • The computer numerical control (CNC) machine-on-machine measurement system is composed of the machine tool body and trigger probe

  • The CNC machine-on-machine measurement system is composed of the machine tool body and trigger probe

  • The error separation method must be utilized to separate the geometric errors of the machine tool, and a high-precision error model1 needs to be established to compensate for the measurement error

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Summary

Introduction

The CNC machine-on-machine measurement system is composed of the machine tool body and trigger probe. Gang et al. utilized the six-step measurement method of the double ball-bar and the least squares method to eliminate the influence of the installation error of the former They identified 10 geometric errors of the multi-axis CNC machine tool turntable, including verticality and position errors. Combining the characteristics of the two algorithms, this study proposes a beetle antennae search–particle swarm optimization (BAS-PSO) algorithm, which is applied to solve the identification coefficients of the geometric errors of CNC machine tools on the basis of the double ball-bar to obtain enhanced global search capabilities and algorithm stability, and compared the results of the three-axis single geometric error detection through laser interferometer for a comparative verification. Ignoring higher-order terms, the HTM of the Y-axis geometric error can be represented by

ÀezðyÞ eyðyÞ dxðyÞ
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