Thermal error measurement and modelling in machine tools.: Part I. Influence of varying operating conditions

Thermal error in machine tools has been observed to be closely linked to the temperature of critical elements of the machine. It was found, in the experiments conducted herein, that there was a significant increase in the axis positioning error on account of an increase in the temperature of the machine elements due to continuous operation. However, it was also observed that the specific operating parameters of the test cycles carried out also significantly affected the positioning error. Different sets of operating parameters generated significantly different error values even though the temperature of the machine elements generated by those operating conditions was similar. As such, this observation forms a very important consideration in the development of a generic thermal error compensation system. It appears to indicate that such a system needs to be capable of evaluating the compensation depending upon the temperature values of the machine elements as well as account for the effect that different operating parameters induce upon the positioning error under the same thermal condition of the machine. This paper attempts to analyse the thermal behaviour of a three-axis vertical machining centre under the influence of various operating parameters and, through the experimental results obtained, point out and explain the effect of these parameters on the axis positioning error. This behaviour forms the basis of an improved modelling methodology that is presented separately in Part II of this paper.