Virtual verification of 5-axis machine tools based on workpiece accuracy analysis: Software tool instead of expensive machining tests

Abstract

An approach to predict the workpiece accuracy in 5-axis machining based on the standard acceptance conditions for machining centers (ISO 230-1) is introduced. The end-user should be able to verify the machine tool accuracy performances in advanced to the purchasing stage and prevent false buying decisions as well as non-relevant expensive machining tests. The preparatory testing of the machine may be not sufficient for the machine tool end-user to define the machining accuracy boundaries of complex parts. To set the machining process providing the required part accuracy, software interface “machine accuracy–machined part accuracy” is developed. The software combines data bases of machines and typical parts connected by virtual machining processes. As a mathematical tool, the modified form-shaping function is applied. The modification enables simulation of multi-tasking machining accuracy. Experimental testing is carried out to validate the effectiveness of the proposed approach.