Identification and verification of location errors of rotary axes on five-axis machine tools by using a touch-trigger probe and a sphere

Yu Ta Chen, Pruthvikumar More, Chien-Sheng Liu

Research output: Contribution to journalArticle

6 Citations (Scopus)

Abstract

As a foundation to enhance the machining accuracy of five-axis machine tools, a robust, efficient, and precise method to measure the location errors of rotary axes on five-axis machine tools has been proposed in this study. This precise identification and calibration methodology for on-machine measurement of location errors of rotary axes is achieved by using a touch-trigger probe and a precise sphere installed on a tilting rotary table. Compared to commercially available devices, such as the double ball bar and R-test, the proposed measurement method has the advantages of efficient and automated calibration procedures in each periodical measurement. This proposed calibration algorithm builds a kinematic error model and measurement equations by using a forward and inverse kinematic approach and estimates the location errors by applying the least squares method. Moreover, the proposed calibration algorithm defines the location errors of the two rotary axes so they can be estimated and separated individually to avoid coupling effects. All the location errors of the rotary axes measured using the proposed measurement method were identified after compensation to improve the accuracy of the five-axis machine tool. A simulation was implemented to inspect the influence of uncertainties on the identified location errors of the rotary axes. Finally, an experimental demonstration on a five-axis machine tool with a tilting rotary table validates the feasibility of the proposed measurement method.

Original languageEnglish
Pages (from-to)2653-2667
Number of pages15
JournalInternational Journal of Advanced Manufacturing Technology
Volume100
Issue number9-12
DOIs
Publication statusPublished - 2019 Feb 25

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Machine tools
Calibration
Inverse kinematics
Machining
Kinematics
Demonstrations

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

Cite this

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abstract = "As a foundation to enhance the machining accuracy of five-axis machine tools, a robust, efficient, and precise method to measure the location errors of rotary axes on five-axis machine tools has been proposed in this study. This precise identification and calibration methodology for on-machine measurement of location errors of rotary axes is achieved by using a touch-trigger probe and a precise sphere installed on a tilting rotary table. Compared to commercially available devices, such as the double ball bar and R-test, the proposed measurement method has the advantages of efficient and automated calibration procedures in each periodical measurement. This proposed calibration algorithm builds a kinematic error model and measurement equations by using a forward and inverse kinematic approach and estimates the location errors by applying the least squares method. Moreover, the proposed calibration algorithm defines the location errors of the two rotary axes so they can be estimated and separated individually to avoid coupling effects. All the location errors of the rotary axes measured using the proposed measurement method were identified after compensation to improve the accuracy of the five-axis machine tool. A simulation was implemented to inspect the influence of uncertainties on the identified location errors of the rotary axes. Finally, an experimental demonstration on a five-axis machine tool with a tilting rotary table validates the feasibility of the proposed measurement method.",
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AB - As a foundation to enhance the machining accuracy of five-axis machine tools, a robust, efficient, and precise method to measure the location errors of rotary axes on five-axis machine tools has been proposed in this study. This precise identification and calibration methodology for on-machine measurement of location errors of rotary axes is achieved by using a touch-trigger probe and a precise sphere installed on a tilting rotary table. Compared to commercially available devices, such as the double ball bar and R-test, the proposed measurement method has the advantages of efficient and automated calibration procedures in each periodical measurement. This proposed calibration algorithm builds a kinematic error model and measurement equations by using a forward and inverse kinematic approach and estimates the location errors by applying the least squares method. Moreover, the proposed calibration algorithm defines the location errors of the two rotary axes so they can be estimated and separated individually to avoid coupling effects. All the location errors of the rotary axes measured using the proposed measurement method were identified after compensation to improve the accuracy of the five-axis machine tool. A simulation was implemented to inspect the influence of uncertainties on the identified location errors of the rotary axes. Finally, an experimental demonstration on a five-axis machine tool with a tilting rotary table validates the feasibility of the proposed measurement method.

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