A new methodology for identifying location errors in 5-axis machine tools using a single ballbar set-up

Research output: Contribution to journalArticle

Abstract

Ballbar testing of rotary axes in 5-axis machine tools can be time-consuming and requires high levels of operator expertise; especially in the set-up process. Faster tests reduce down-time and encourage frequent updates to compensation parameters to reflect the current state of the machine. A virtual machine tool (VMT) is developed to emulate the machine tool, its geometric errors and the testing procedures. This was used to develop a new single set-up testing method to identify all rotary axis locations errors, whilst remaining robust in the presence of set-up error and linear axis squareness errors. New testing and data processing techniques remove the requirement for fine adjustment of the tool-cup and permit full automation of necessary toolpaths, including transitions. Using the VMT, error identification residuals were found to be 2.7 % or less. Experiments and statistical analysis then showed that all errors can be measured using a single set-up, and values are sufficiently close to the values measured using conventional multi-set-up procedures to be used in error compensation. This method will significantly reduce set-up durations and removes the need for any modified testing hardware.
LanguageEnglish
Pages1–19
JournalInternational Journal of Advanced Manufacturing Technology
Early online date26 Jul 2016
DOIs
StatusE-pub ahead of print - 26 Jul 2016

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Machine tools
Testing
Error compensation
Statistical methods
Automation
Hardware
Experiments

Keywords

  • Ballbar
  • Five-Axis Machine Tool
  • Error

Cite this

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title = "A new methodology for identifying location errors in 5-axis machine tools using a single ballbar set-up",
abstract = "Ballbar testing of rotary axes in 5-axis machine tools can be time-consuming and requires high levels of operator expertise; especially in the set-up process. Faster tests reduce down-time and encourage frequent updates to compensation parameters to reflect the current state of the machine. A virtual machine tool (VMT) is developed to emulate the machine tool, its geometric errors and the testing procedures. This was used to develop a new single set-up testing method to identify all rotary axis locations errors, whilst remaining robust in the presence of set-up error and linear axis squareness errors. New testing and data processing techniques remove the requirement for fine adjustment of the tool-cup and permit full automation of necessary toolpaths, including transitions. Using the VMT, error identification residuals were found to be 2.7 {\%} or less. Experiments and statistical analysis then showed that all errors can be measured using a single set-up, and values are sufficiently close to the values measured using conventional multi-set-up procedures to be used in error compensation. This method will significantly reduce set-up durations and removes the need for any modified testing hardware.",
keywords = "Ballbar, Five-Axis Machine Tool, Error",
author = "Joseph Flynn and {Shokrani Chaharsooghi}, Alborz and Parag Vichare and Vimal Dhokia and Stephen Newman",
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doi = "10.1007/s00170-016-9090-6",
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AU - Dhokia,Vimal

AU - Newman,Stephen

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AB - Ballbar testing of rotary axes in 5-axis machine tools can be time-consuming and requires high levels of operator expertise; especially in the set-up process. Faster tests reduce down-time and encourage frequent updates to compensation parameters to reflect the current state of the machine. A virtual machine tool (VMT) is developed to emulate the machine tool, its geometric errors and the testing procedures. This was used to develop a new single set-up testing method to identify all rotary axis locations errors, whilst remaining robust in the presence of set-up error and linear axis squareness errors. New testing and data processing techniques remove the requirement for fine adjustment of the tool-cup and permit full automation of necessary toolpaths, including transitions. Using the VMT, error identification residuals were found to be 2.7 % or less. Experiments and statistical analysis then showed that all errors can be measured using a single set-up, and values are sufficiently close to the values measured using conventional multi-set-up procedures to be used in error compensation. This method will significantly reduce set-up durations and removes the need for any modified testing hardware.

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