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This paper presents a method to identify the position independent geometric errors of rotary axis and tool setting simultaneously using on-machine measurement. Reducing geometric errors of an ultra-precision five-axis machine tool is a key to improve machining accuracy. Five-axis machines are more complicated and less rigid than three axis machine tools, which leads to inevitable geometric errors of the rotary axis. Position deviation in the process of installing a tool on the rotary axis magnifies the machining error. Moreover, an ultra-precision machine tool, which is capable of machining part within sub-micrometer accuracy, is relatively more sensitive to the errors than a conventional machine tool. To improve machining performance, the error components must be identified and compensated. While previous approaches have only measured and identified the geometric errors on the rotary axis without considering errors induced in tool setting, this study identifies the geometric errors of the rotary axis and tool setting. The error components are calculated from a geometric error model. The model presents the error components in a function of tool position and angle of the rotary axis. An approach using on-machine measurement is proposed to measure the tool position in the range of 10 s nm. Simulation is conducted to check the sensitivity of the method to noise. The model is validated through experiments. Uncertainty analysis is also presented to validate the confidence of the error identification. 相似文献
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简述了普通刨床加工长键槽产生加工误差的多种因素,并对加工过程中产生的主要误差、定位误差、对称度误差和刀具误差进行了综合分析。 相似文献
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Evaluating machine tool performance under machining conditions is generally used as the final test in machine tool industry. The seventh part of ISO-10791 describes a machining test using the accuracy of a finished work piece to determine the accuracy of three-axis machine tools. However the kinematic errors cannot be distinguished from each other by means of these test pieces. In this paper a new method to identify the kinematic errors of three-axis machine tool is proposed. A set of test pieces are designed where the kinematic errors of a machine tool can be measured separately along X, Y and Z directions. A volumetric error model is also presented based on the measured errors. This method is initially evaluated in virtual environment and then with some test pieces designed for this purpose. The results are compared with the laser interferometry measurements. It is shown that the measured positioning and straightness errors are consistent with the laser interferometry results. Angular errors measured by the test pieces are also complied with the laser interferometry results as long as the angular error magnitudes are large enough. 相似文献
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Shih-Ming Wang Han-Jen Yu Hung-Wei Liao 《The International Journal of Advanced Manufacturing Technology》2006,28(5-6):518-526
To enhance the accuracy of CNC machines for the request of modern industry, an effective static/quasi-static error compensation
system composed of an element-free interpolation algorithm based on the Galerkin method for error prediction, a recursive
software compensation procedure, and an NC-code converting software, is developed. Through automatically analyzing the machining
path, the new error prediction method takes into consideration the fact that the machine structure is non-rigid, and can efficiently
determine the position errors of the cutter for compensation without computing a complex error model on-line. The predicted
errors are then compensated based on a recursive compensation algorithm. Finally, a compensated NC program will be automatically
generated by the NC-code converting software for the precision machining process. Because of the advantage of the element-free
theory, the error prediction method can flexibly and irregularly distribute nodal points for accurate error prediction for
a machine with complex error distribution characteristics throughout the workspace. To verify the algorithm and the developed
system, cutting experiments were conducted in this study, and the results have shown the success of the proposed error compensation
system. 相似文献
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复杂曲面零件在线检测与误差补偿方法 总被引:7,自引:0,他引:7
复杂曲面零件的高精度加工与精密检测一直是数字化制造领域的研究热点。为提高复杂曲面零件的加工精度、检测精度,提出一种集数控机床在线检测、加工误差分解与补偿加工为一体的集成化方法。介绍集成化在线检测方法及补偿系统的基本原理,分析数控加工后曲面零件测点数据的误差组成,提出一种基于空间统计分析的加工误差分解方法,在建立基于B样条曲面的确定性曲面回归模型的基础上,对回归模型残差进行空间独立性分析,分解出系统误差和随机误差,进而通过数控代码的修改,实现零件加工过程的系统误差补偿。列举一个曲面零件的加工与检测实例,进行方法有效性验证。通过加工工件的在线检测、误差分解、代码修改及补偿加工等环节,实例零件的加工精度有了大幅提高,而该系统的检测精度也通过与三坐标测量机(Coordinate measuring machine, CMM)检验结果的对比,得到了有效验证。 相似文献
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Influence of position-dependent geometric errors of rotary axes on a machining test of cone frustum by five-axis machine tools 总被引:3,自引:0,他引:3
A machining test of cone frustum, described in NAS (National Aerospace Standard) 979, is widely accepted by machine tool builders to evaluate the machining performance of five-axis machine tools. This paper discusses the influence of various error motions of rotary axes on a five-axis machine tool on the machining geometric accuracy of cone frustum machined by this test. Position-independent geometric errors, or location errors, associated with rotary axes, such as the squareness error of a rotary axis and a linear axis, can be seen as the most fundamental errors in five-axis kinematics. More complex errors, such as the deformation caused by the gravity, the pure radial error motion of a rotary axis, the angular positioning error of a rotary axis, can be modeled as position-dependent geometric errors of a rotary axis. This paper first describes a kinematic model of a five-axis machine tool under position-independent and position-dependent geometric errors associated with rotary axes. The influence of each error on machining geometric accuracy of a cone frustum is simulated by using this model. From these simulations, we show that some critical errors associated with a rotary axis impose no or negligibly small effect on the machining error. An experimental case study is presented to demonstrate the application of R-test to measure the enlargement of a periodic radial error motion of C-axis with B-axis rotation, which is shown by present numerical simulations to be among potentially critical error factors for cone frustum machining test. 相似文献
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John Allen Dragos Axinte Paul Roberts Ralph Anderson 《The International Journal of Advanced Manufacturing Technology》2010,50(9-12):843-857
With the ever increasing diversity of manufacturing and maintenance needs for modern products, the realm of machine tool design has expanded considerably in recent years. While machine tools for producing singular parts are widely documented, there is much less information available about machine tools for specialist tasks such as repair and maintenance. The paper aims to give an overview of the developments in the field of specialist machine tools and machining systems with a particular emphasis on maintenance operations and in situ machining. The difficulties of performing maintenance on large-scale systems are outlined along with the potential benefits of in situ machining in these applications. A number of examples of specialist machines for applications in various fields are described. The developing area of micro machine tools and micro factories is introduced along with examples of systems which have been developed or proposed. The possible advantages and draw-backs of the various technologies described are discussed. The paper goes on to comment on the potential for a new approach which combines these technologies to produce small in situ machine tools for performing macro-scale machining operations on large workpieces. These machining systems could offer increased versatility of in situ maintenance machining, compared to machines designed for a single repair operation, while reducing costs and environmental impacts. 相似文献
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Yuxia Lu M. N. Islam 《The International Journal of Advanced Manufacturing Technology》2012,62(9-12):1071-1085
A traditional model for thermally induced volumetric error of a three-axis machine tool requires measurement of 21 geometric error components and their variation data at different temperatures. Collecting these data is difficult and time consuming. This paper describes the development of a new model for calculating thermally induced volumetric error based on the variation of three error components only. The considered error components are the three axial positioning errors of a machine tool. They are modelled as functions of ball-screw nut temperature and travel distance to predict positioning errors when the thermal condition of the machine tool has changed due to continuous usage. It is assumed that the other 18 error components remain identical to the pre-calibrated cold start values. This assumption is justified by the fact that the machine tool’s thermal status significantly affects three axial positioning errors that dominate machining errors for a machine tool after its continuous use. To demonstrate the effectiveness of the proposed model two types of machining jobs, milling and drilling, on a three-axis horizontal CNC machining centre are simulated and the machined part profiles are predicted. The results show that the thermally induced volumetric error was reduced from 115.40 to 45.37?μm for the milled surface, and the maximum distance error between drilled holes for the drilling operation was reduced from 38.69 to ?0.14?μm after compensation. 相似文献
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Ziling Zhang Zhifeng Liu Ligang Cai Qiang Cheng Yin Qi 《The International Journal of Advanced Manufacturing Technology》2017,91(5-8):1547-1566
Accuracy design constitutes an important role in machine tool designing. It is used to determine the permissible level of each error parameter of a machine tool, so that any criterion can be optimized. Geometric, thermal-induced, and cutting force-induced errors are responsible for a large number of comprehensive errors of a machine tool. These errors not only influence the machining accuracy but are also of great importance for accuracy design to be performed. The aim of this paper is the proposal of a general approach that simultaneously considered geometric, thermal-induced, and cutting force-induced errors, in order for machine tool errors to be allocated. By homogeneous transformation matrix (HTM) application, a comprehensive error model was developed for the machining accuracy of a machine tool to be acquired. In addition, a generalized radial basis function (RBF) neural network modeling method was used in order for a thermal and cutting force-induced error model to be established. Based on the comprehensive error model, the importance sampling method was applied for the reliability and sensitivity analysis of the machine tool to be conducted, and two mathematical models were presented. The first model predicted the reliability of the machine tool, whereas the second was used to identify and optimize the error parameters with larger effect on the reliability. The permissible level of each geometric error parameter can therefore be determined, whereas the reliability met the design requirement and the cost of this machining was optimized. An experiment was conducted on a five-axis machine tool, and the results confirmed the proposed approach being able to display the accuracy design of the machine tool. 相似文献
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为研究影响大规格滚齿机加工精度的关键几何误差,提出了一种基于齿面位姿-几何误差模型结合Sobol法的机床关键几何误差识别方法。首先,基于齐次坐标变换理论,建立了刀具位姿-几何误差模型,通过求解滚齿双参数包络方程,获得了加工齿面接触迹点坐标值,建立了机床齿面位姿-几何误差模型;然后,考虑几何误差的随机性和互耦性,利用Sobol法对该模型进行敏感性分析,计算了几何误差的敏感度系数以识别出关键几何误差;最后,进行了关键几何误差虚拟仿真修正和对比验证。研究结果表明,所提方法能有效识别大规格滚齿机的关键误差项。 相似文献
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基于敏感度分析的机床关键性几何误差源识别方法 总被引:10,自引:1,他引:10
零部件几何误差耦合而成的机床空间误差是影响其加工精度的主要原因,如何确定各零部件几何误差对加工精度的影响程度从而经济合理地分配机床零部件的几何精度是目前机床设计所面临的一个难题。基于多体系统理论,在敏感度分析的基础上提出一种识别关键性几何误差源参数的新方法。以一台四轴精密卧式加工中心为例,基于多体系统理论构建加工中心的精度模型,并利用矩阵微分法建立四轴数控机床误差敏感度分析的数学模型,通过计算与分析误差敏感度系数,最终识别出影响机床加工精度的关键性几何误差。计算和试验分析表明,该方法可以有效地识别出对机床综合空间误差影响较大的主要零部件几何误差因素,从而为合理经济地提高机床的精度提供重要的理论依据。 相似文献
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A method for thermal characterization and modeling of large gantry-type machine tools 总被引:1,自引:1,他引:0
E. Gomez-Acedo A. Olarra L. N. Lopez de la Calle 《The International Journal of Advanced Manufacturing Technology》2012,62(9-12):875-886
In this paper, a method specially designed for the assessment of repeatability and accuracy of large machine tools is proposed, along with results for a large gantry-type milling machine, recorded in a medium-term period. For this purpose, temperatures were recorded and a metrological frame was used along with inductive sensors in the tool tip, performing repetitive measurements. As initial results, origin, weight and influence of every heat source on this kind of machines were found. Afterwards, high precision measurements of thermal deformations were obtained. Mechanism of errors was found, discerning between main thermal error in the vertical Z-axis and secondary error in longitudinal X-axis towards out of the plane of the gantry bridge. Finally, a finite element model was developed which showed main thermal behavior identified experimentally. This will permit to make simulations of the thermal response of the machine and to choose machining strategies for future parts. Proposed methodology was therefore proved satisfactory for thermal characterization of this kind of big machine tools. This knowledge will make possible to improve thermal design of machines and to develop error compensation procedures. This method can also be applied on workshop conditions for recalibration purposes. 相似文献
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热误差建模和补偿是提高机床加工精度的重要手段。 将得到的热误差模型应用到类似或相近任务中,对减少模型构建
和数据收集的成本具有重要意义。 本文提出了一种简易迁移学习(EasyTL)融合域内对齐的主轴热误差建模方法,以实现不同
工况下误差模型的迁移复用。 建立基于域内对齐和距离矩阵全组合择优的热误差迁移模型参数选取方法,获得最优组合。 进
一步分析不同类型的域内对齐和距离矩阵各自对模型迁移性能的影响。 最后,将迁移模型与 kNN 典型机器学习模型和卷积神
经网络深度模型进行比较验证,分别预测不同工况下主轴 Z 向和 Y 向的热误差。 此外,根据预测的主轴热误差进行工件补偿
加工实验。 该方法为热误差建模及补偿提供了一种新思路。 相似文献