A systematic approach to enhance machine tool accuracy for precision manufacturing

As competitive pressures demand higher levels of productivity and automation, accuracy and reliability of products become increasingly important. Innovations in manufacturing technology also are driven by demands to shorten production cycle time and to maintain a consistently high level of product quality in an advanced manufacturing environment. Innovative and cost-effective methods must be developed to advance precision manufacturing technologies to compete in the global economy. In this paper, a systematic approach is presented to advance the accuracy and functionality of multi-axis machines for precision manufacturing. Four major steps are introduced. First, a method is presented for rapid characterizing of the accuracy of multi-axis machines. Detailed derivation of a generalized error model is given. Second, a method is discussed on the feasible applications of on-machine sensing and analysis. The information obtained from on-machine sensing process is used with the information collected from post-process inspection to improve the machine performance. Third, a method is presented for utilizing post-process inspection and innovative data analysis techniques to decouple the effects of process- and machine-related errors. Finally, an adaptive error correction system is outlined for iterative identification of the residual error and the fine-tuning of the error model for more accurate error modeling and compensation.