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A hybrid monitoring-simulation system for contour error prediction on complex surfaces manufacturing

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Abstract

Recent studies show the entire CNC virtualization chain as a potential strategy to predict the contour error, but since the CNC manufacturers do not disclose information about the trajectories’ generation, it becomes difficult to replicate contouring error simulation on commercial machines. In this paper, a hybrid approach allows simplifying the monitoring and simulation tasks by providing a less intrusive strategy to interface commercial machine tools. The developed system takes advantage from the positioning set points generated by the machine CNC and uses them as input data to simulate the tool-center point (TCP) movements and to preview the expected contour error, considering also the behavior of the control system and feed drives. In summary, the proposed approach adds on previous virtual CNC developments since the monitored CNC set points are fed directly into the simulation model. The use of the developed hybrid system in commercial machine tools shows a maximum deviation of 3 μm between the observed and the simulated contour error, showing therefore its adequacy to preview the contour error of commercial machine tools.

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Authors and Affiliations

  1. Centro de Engenharia, Modelagem e Ciências Sociais Aplicadas - CECS, Universidade Federal do ABC - UFABC, São Bernardo do Campo, SP, Brazil

    Erik Gustavo del Conte

  2. Laboratório de Sistemas Computacionais para Projeto e Manufatura - SCPM, Universidade Metodista de Piracicaba - UNIMEP, Santa Bárbara d’Oeste, SP, Brazil

    Klaus Schützer

  3. Empresa Brasileira de Pesquisa e Inovação Industrial - Embrapii, Brasília, DF, Brazil

    Alvaro Jose Abackerli

Authors
  1. Erik Gustavo del Conte
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  2. Klaus Schützer
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  3. Alvaro Jose Abackerli
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Correspondence to Erik Gustavo del Conte.

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del Conte, E.G., Schützer, K. & Abackerli, A.J. A hybrid monitoring-simulation system for contour error prediction on complex surfaces manufacturing. Int J Adv Manuf Technol 77, 321–329 (2015). https://doi.org/10.1007/s00170-014-6465-4

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  • DOI: https://doi.org/10.1007/s00170-014-6465-4

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