Abstract
For machining parts with complex shapes, consisting of computer numerical control (CNC) machine tools, different CNC machine tools will be used according to the machining method. If the workpiece is removed for off-machine measurement after machining, when the size is incorrect, it will need to be returned to the CNC machine tool for secondary machining. In this case, the workpiece surface quality and machining accuracy will be affected, which is very time-consuming. On-machine measurement and complex machine center is a key to solve this problem. In the recent researches that the touch probe was integrated on three or five axis machine for error compensation and shape construction based on on-machine measurement, but turning-milling machine was rare. In addition, the most types of parts were thin-walled parts or thin web parts. In this study, a contact measurement system is integrated into a CNC combined turning-milling machine for on-machine measuring. Macro-programming is used to design the machining path of A6061-T6 aluminum alloy hexagonal punch, and the action of probe measurement is added to the machining path. As the measured data exceed the tolerance range, the calculated data are fed back to the controller for machining improvement by compensation. The finished hexagonal punch is measured in a 3D coordinate measuring machine and the error is compared. The experimental results show that the contact probe needs to be corrected before machining, and the size of the corrected workpiece can reach the tolerance range of ±0.01 mm. The size error of rough machining is larger than that of fined machining, and the size error of rough machining will increase with the length of the workpiece.
Highlights
In relation to the progress of science and technology, the industry requires the performance and service life of industrial products and pursues machining methods of high efficiency, high precision, and high quality
If defects can be detected in each process of machining, where the size is obtained, calculated, and fed back to the machining path, errors can be corrected in real time, thereby, avoiding cumulative error of all machining programs and improving the yield rate in the final quality management [1,2,3,4]
In the shape construction and error compensation field: Zhao. etc, the authors were aiming to reduce the rejection rate of billets and save the production cost. They develop a approach for process shape construction with iterative closest point (ICP) algorithm between the design shape and the on-machine measurement points, and used for adaptive machining of curved thin-wall part [11]
Summary
In relation to the progress of science and technology, the industry requires the performance and service life of industrial products and pursues machining methods of high efficiency, high precision, and high quality. Etc, the authors were aiming to reduce the rejection rate of billets and save the production cost They develop a approach for process shape construction with iterative closest point (ICP) algorithm between the design shape and the on-machine measurement points, and used for adaptive machining of curved thin-wall part [11]. Ge et al aimed to reduce time-consumption for thin webs mechanism analysis They used on on-machine measurement to reconstruct the machined surface error, and a machining learning (multiple additive regression tree, MART) algorithm used to the compensation model [13]. Du et al aimed to solve the multiple error sources in the machining process They develop a comprehensive error compensation method that includes geometric error, thermal error, and force-induced error for thin-wall parts machining based on-machine measurement [15]. SScchheemmaatitcicdidaigargarmamofowf owrkoprkiepcieecmeemaseuarseumreemntetnetchtencohlongoylo(gay) w(ao)rkwpoierkcep;i(ebce) ;pr(eb-)pprorcee-pssromceesassumreemaseunrte; m(ce)nint;(cp)rionc-epsrsomceesassmureeamsuernetm; (edn)tp; (ods)t-pporostc-epsrsomceesassmureeamsuernetm. ent
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