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

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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.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Bath, Bath, BA2 7AY, UK

    Joseph M Flynn, Alborz Shokrani, Parag Vichare, Vimal Dhokia & Stephen T Newman

Authors
  1. Joseph M Flynn
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  2. Alborz Shokrani
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  3. Parag Vichare
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  4. Vimal Dhokia
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  5. Stephen T Newman
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Corresponding author

Correspondence to Joseph M Flynn.

Additional information

The authors are pleased to thank the Engineering and Physical Science Research Council (EPSRC No. EP/K504245/1) and our industrial partner for their support during this research.

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Flynn, J.M., Shokrani, A., Vichare, P. et al. A new methodology for identifying location errors in 5-axis machine tools using a single ballbar set-up. Int J Adv Manuf Technol 99, 53–71 (2018). https://doi.org/10.1007/s00170-016-9090-6

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  • DOI: https://doi.org/10.1007/s00170-016-9090-6

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