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Identification and compensation of position-dependent geometric errors of rotary axes on five-axis machine tools by using a touch-trigger probe and three spheres

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Abstract

For the machining accuracy of five-axis machine tools, it must be emphasized that not only the PIGEs but also the PDGEs of rotary axes influence the machining accuracy. However, until now there is no any commercial measurement system available for identifying the PDGEs in the rotary axes of five-axis machine tools. As a result, this study proposes a robust, efficient, and automatic measurement method to identify and compensate the position-dependent geometric errors (PDGEs) of rotary axes on five-axis machine tools. The proposed measurement method has established an on-machine measurement for the PDGEs of rotary axes by using a touch-trigger probe and three spheres installed on the spindle as well as the tilting rotary table, respectively. For each rotary axis, only a single measuring pattern is implemented to measure the PDGEs with a single setup, which delineates the advantages of efficient and automated identifying procedures in each periodical measurement. By implementing the proposed measurement method, 12 PDGEs can be numerically identified based on the measurement algorithm, which is built through a kinematic error model as well as a least square method. Finally, the proposed measurement method is experimentally conducted on a commercial five-axis machine tool. Moreover, after consequently performing the proposed measurement method, the PDGEs of the rotary axes were quantitatively compensated by the commercial controller to validate its feasibility. The experimental results have clearly delineated that the linear errors and angular errors are reduced from at most 37.81 μm and 10.23 mdeg to 0.9 μm and 0.26 mdeg, respectively. Consequently, the experimental results have demonstrated that the proposed measurement method is efficient and precise.

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Funding

The authors gratefully acknowledge the financial support provided to this study by the Ministry of Science and Technology of Taiwan under Grant Nos. MOST 106-2218-E-194-011, 106-3114-8-194-001, 106-2628-E-006-010-MY3, and 107-2218-E-194 -002.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Chung Cheng University, No.168, University Road, Minhsiung Township, Chiayi County, 62102, Taiwan

    Yu-Ta Chen, Pruthvikumar More, Chien-Sheng Liu & Chih-Chun Cheng

  2. Department of Mechanical Engineering, National Cheng Kung University, No. 1, University Road, Tainan City, 70101, Taiwan

    Chien-Sheng Liu

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  1. Yu-Ta Chen
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  2. Pruthvikumar More
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  3. Chien-Sheng Liu
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  4. Chih-Chun Cheng
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Correspondence to Chien-Sheng Liu.

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Chen, YT., More, P., Liu, CS. et al. Identification and compensation of position-dependent geometric errors of rotary axes on five-axis machine tools by using a touch-trigger probe and three spheres. Int J Adv Manuf Technol 102, 3077–3089 (2019). https://doi.org/10.1007/s00170-019-03413-x

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  • DOI: https://doi.org/10.1007/s00170-019-03413-x

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