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Geometric error measurement of facing head and machining verification on large horizontal boring and milling machine tool

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Abstract

With the aim of enhancing the machining accuracy of the horizontal boring and milling machine tool, this study proposes an on-machine measurement methodology for identification and compensation of geometric errors of the facing head by using a touch-trigger probe and a precise sphere. Based on the past machining experiences provided by the machine supplier, the geometric errors of the facing head lead to the serious problem: the inner and outer holes of the workpieces are not concentric during the boring process. This problem causes the poor machining accuracy of the workpieces. As a result, in this study, a robust algorithm for calibrating the four geometric errors of the facing head is proposed by establishing the mathematical measurement equations. Furthermore, the mathematical measurement equations are mainly built by applying forward and inverse kinematic approach as well as the least square method. Finally, the measurement and machining verifications are also performed for demonstrating the feasibility and accuracy of the proposed measurement method. The experimental measurement results show that the position errors and the orientation errors are at most about − 76.3 μm and − 37.6 arcsec, respectively. On the other hand, after identifying the four geometric errors of the facing head, they are compensated to the controller. Consequently, the machining verification results show that the concentricity of inner and outer holes of the boring workpiece with compensation is significantly reduced to 0.024 mm from 0.179 mm. Conclusively, the efficiency and effectiveness of the proposed measurement method have been demonstrated.

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Funding

The authors gratefully recognize the financial support provided to this study by the Ministry of Science and Technology of Taiwan under Grant Nos. MOST 110–2218-E-002–038, 110–2221-E-006–126-MY3, and 111–2222-E-218–001.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Southern Taiwan University of Science and Technology, No. 1, Nan-Tai Street, Yungkang Dist., Tainan City, 710301, Taiwan

    Yu-Ta Chen

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

    Tang-Chao Liu & Chien-Sheng Liu

  3. Academy of Innovative Semiconductor and Sustainable Manufacturing, National Cheng Kung University, No. 1, University Road, Tainan City, 70101, Taiwan

    Chien-Sheng Liu

Authors
  1. Yu-Ta Chen
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  2. Tang-Chao Liu
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Contributions

YTC: writing—original draft preparation, conceptualization, and writing—reviewing and editing; TCL: methodology, software, and validation; CSL: writing—reviewing and editing, supervision, and project administration.

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Correspondence to Chien-Sheng Liu.

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Chen, YT., Liu, TC. & Liu, CS. Geometric error measurement of facing head and machining verification on large horizontal boring and milling machine tool. Int J Adv Manuf Technol 121, 7439–7449 (2022). https://doi.org/10.1007/s00170-022-09856-z

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  • DOI: https://doi.org/10.1007/s00170-022-09856-z

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