Identification and compensation machining evaluation of position-independent geometric error of dual rotation axes

• Published in: International journal of advanced manufacturing technology 2023-11, Vol.129 (5-6), p.2783-2799
• Main Authors: Wang, Hao, Jiang, Xiaogeng, Li, Maojun
• Format: Article
• Language: English
• Subjects: Advanced manufacturing technologies; Approximation; CAE) and Design; Circular cones; Computer-Aided Engineering (CAD; Conical bodies; Coordinate measuring machines; Engineering; Error analysis; Error compensation; Five axis; Identification; Industrial and Production Engineering; Kinematics; Machine tools; Machining; Mechanical Engineering; Media Management; Original Article; Position errors; Quaternions; Rotation; Workpieces
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-12443-5

In this paper, a general error identification and compensation method is proposed for the position-independent geometric errors (PIGEs) of dual rotation axes of cradle-type five-axis machine tools with non-intersecting rotation axes. A unique hole machining specimen is designed to evaluate the compensation effect. First, the kinematic error model of the five-axis machine tool is established based on the dual quaternion, and the correlation between the PIGEs defined based on the dual quaternion and the PIGEs in ISO 230–7 is analyzed. Then, eight PIGEs of the two rotation axes are simultaneously identified by using a double-ball bar (DBB) through the synchronous motion trajectory of the A - and C -axes. Moreover, an error compensation strategy based on the principle of tool pose approximation is proposed, which preferentially compensates for the direction error. The direction and position vector errors of the tool are directly compensated by establishing the ideal and actual relative pose difference model between the tool and workpiece. Finally, a unique hole machining experiment on a circular cone surface is proposed according to the position structure of the rotation axis of the target machine tool. The machining of the hole on the conical surface is realized by controlling the tool through the motion of the rotation axis, thus effectively avoiding the influence of the translational axis. The effectiveness of the proposed compensation strategy is verified by the measurement and fitting of the points on the machining hole wall by a three-coordinate measuring machine. The average residual error after compensation is reduced by about 88.65% and 85.2% compared with that before compensation by using the established position error and direction error compensation evaluation function.