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A systematic spatial-variably volumetric error model and machining optimization method based on continuous moving support variation of machine tool

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Abstract

The real-time support variation of the machine tool is a source of systematic errors that cannot be ignored and has a great impact on the machining accuracy. The calculation and representation of moving support variation are important basis for improving machining accuracy. Different from the traditional data-based methods of static deformation measurement and compensation, this paper proposes a real-time continuous moving support deformation error model-based method to establish a systematic spatial-variably volumetric error model, which realizes the model decoupling of complex error sources of machine tools. The real-time deformation of moving support under multiple working conditions by FEM simulation is converted into the joint surface deformation of the moving system, and the translational and rotational position-dependent geometric errors (PDGE) are analyzed through the positional geometry of four sliders as joint surface, and the continuous moving variation errors along the single-axis and dual-axis motion space is generated. Further, based on the homogeneous transformation theory, the multi-axis 6-DOF PDGE are fused to construct a spatial-variably volumetric error model. In addition, this paper adopts a machining optimization method, which can efficiently identify the optimal machining space for the machine tool according to the machining features of the workpiece and the spatial-variably volumetric error model. In the case study, the proposed method is applied to a horizontal machining center, the detailed characterization of the spatial-variably error is given, and the optimal machining space is identified for different sample workpieces, which proves that it can effectively improve the machining accuracy of the machine tool.

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Acknowledgments

The authors strongly acknowledge the support from the Zhejiang Provincial Natural Science Foundation of China, the “Pioneer” R&D Program of Zhejiang, the Natural Science Foundation of Ningbo, and the Science and Technology Major Project of Ningbo. The authors also thank the reviewers and the editors for their insightful comments, which help improve the paper’s quality.

Funding

The work was supported by the Zhejiang Provincial Natural Science Foundation of China (LZ22E050008), the “Pioneer” R&D Program of Zhejiang (2023C01060), the Natural Science Foundation of Ningbo (2021J150), and the Science and Technology Major Project of Ningbo (2021Z110).

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Authors and Affiliations

  1. Ningbo Innovation Center, State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Ningbo, 315100, China

    Xiaojian Liu, Jiarun Xu, Yang Wang, Shuyou Zhang & Jianrong Tan

  2. School of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China

    Xiaojian Liu, Yang Wang, Lemiao Qiu, Shuyou Zhang & Jianrong Tan

  3. Engineering Research Center for Design Engineering and Digital Twin of Zhejiang Province, Hangzhou, 310027, China

    Xiaojian Liu, Lemiao Qiu & Shuyou Zhang

  4. Quality & Technology Management Department, JIER Machine-Tool Group Co., Ltd., Jinan, 250022, China

    Zhaolei He

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  1. Xiaojian Liu
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Xiaojian Liu, Jiarun Xu, Yang Wang, and Lemiao Qiu. The first draft of the manuscript was written by Xiaojian Liu and Jiarun Xu and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Yang Wang or Lemiao Qiu.

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Liu, X., Xu, J., Wang, Y. et al. A systematic spatial-variably volumetric error model and machining optimization method based on continuous moving support variation of machine tool. Int J Adv Manuf Technol 129, 1189–1211 (2023). https://doi.org/10.1007/s00170-023-12302-3

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