Thermal error caused by the thermal deformation is one of the most significant factors influencing the accuracy of the machine tool. Among all the heat sources which lead to the thermal distortions, the spindle is the main one. This paper presents an overview of the research about the compensation of the spindle thermal error. Thermal error compensation is considered as a more convenient, effective and cost-efficient way to reduce the thermal error compared with other thermal error control and reduction methods. Based on the analytical calculation, numerical analysis and experimental tests of the spindle thermal error, the thermal error models are established and then applied for implementing the thermal error compensation. Different kinds of methods adopted in testing, modeling and compensating are listed and discussed. In addition, because the thermal key points are vital to the temperature testing, thermal error modeling, and even influence the effectiveness of compensation, various approaches of selecting thermal key points are introduced as well. This paper aims to give a basic introduction of the whole process of the spindle thermal error compensation and presents a summary of methods applied on different topics of it.

A review on spindle thermal error compensation in machine tools

Design for precision : current status and trends

Improving CNC machine tool accuracy has received significant attention recently. This paper intends to provide an introduction of the real-time error compensation methods as applied to reduce both geometric and thermally induced quasistatic machine tool errors. An illustrative example is used to demonstrate the use of error compensation systems for a horizontal machining center. Although several industrial applications of these error compensation systems have achieved significant results, a few major barriers have prevented this promising technology from being applied widely in manufacturing. Several ongoing research activities aimed at overcoming the barriers are also presented.

CNC Machine Accuracy Enhancement Through Real-Time Error Compensation

Since laser technology has considerable synergy with machining technologies, Laser Machining (LM) and Laser Assisted Machining (LAM) are relevant research topics. This paper attempts to give an overview of recent developments and research trends. Although scientific work on this area has contributed to the understanding of the process, there are still unresolved problems regarding the limitations of the techniques, optimum machining conditions, etc. The outcome of experimental investigations on LAM shows potential applications for this process but there are several issues to be resolved.

Laser Assisted Machining: An Overview

For thermal error compensation technology of CNC machine tools, the collinearity between temperature sensitive points is the main factor for determining the predicted robustness of thermal error model. The temperature sensitive points are input variables of the thermal error model. This paper studies the thermal error of Leaderway V-450 type CNC machine tools during different seasons. It is found that although the commonly used temperature sensitive point selection methods can significantly reduce the collinearity between temperature sensitive points, the correlation between some of the selected temperature-sensitive points and thermal error is weak. This causes the temperature-sensitive points to be variable and the predicted accuracy and robustness of thermal error to be reduced. Therefore, in this paper, the temperature sensitive points are selected directly by their correlation with thermal error to eliminate variability. However, the experimental results also show that the collinearity between temperature sensitive points is very large. Hence, the ridge regression algorithm is used to establish a thermal error model to inhibit the bad influence of collinearity on the thermal error predicted robustness. Thus, the “robustness ridge regression machine tool thermal error modeling method” is proposed, the “RRR method” for short. In addition, in the “RRR method”, the correlation coefficient is used to measure the correlation between temperature sensitive points and thermal error instead of the commonly used gray correlation; because this paper finds that the gray correlation algorithm is essentially inapplicable for measuring a negative correlation. Based on the thermal error experiment data for the whole year, the “RRR method” is compared with two currently used methods, and the results show that the “RRR method” can significantly enhance the long-term predicted accuracy and robustness of thermal error. Finally, the application effect of practical compensation shows that the “RRR method” is usable and effective.

Robust modeling method for thermal error of CNC machine tools based on ridge regression algorithm

A neural network based on Artificial Resonance Theory (ART-map) was used to predict and compensate the tool point errors of a 3-axis machining center using discrete temperature readings from the machine’s structure as inputs. A combination of kinematic error modeling, curve fitting, and the neural network were used to maintain the machine’s three-dimensional (3-D) accuracy within ±7.4 μm, regardless of the thermal state. The network model was evaluated with diagonal measurements and part machining tests. A laser ball bar was used to take the necessary measurements for training the neural network.

Neural network thermal error compensation of a machining center

A buffer zone (56) disposed between the TOBI discharge cavity (50) and the forward rotor cavity (42) of a gas turbine engine serves to maintain the TOBI air relatively pollutant free by judiciously controlling the flow to maintain the pressure of the buffer cavity (56) below the adjacent cavities. The buffer cavity air and the forward rotor cavity air are bled to the dead rim area (90) of the turbine rotor disk (44) through tangentially oriented discharge ports (88) formed in the circumferentially spaced plenums (80) formed in the stator support. Plates (82) on the bottom of some of the plenums (80) block off the flow from the forward rotor cavity (42) and buffer air from the buffer cavity (56) flows through these closed off plenums (80) through openings (84) to maintain the proper pressure relationship amongst the cavities.

Anti-contamination thrust balancing system for gas turbine engines

A ball bar gage for obtaining the accuracy of numerical control machines and the like including telescoping means integrated with an interferometer and the method of measuring the distances between two locations including an initialization process that ascertains the absolute length of the distance being measured from the differential changes in length measured by the interferometer and a computer that calculates by a trilateration computation 2 or 3 dimensional coordinates by computing the measurements obtained by the ball bar gage. A laser beam or other light source are contemplated to energize the interferometer. Similar calculations are performed with the ball bar gage and computer over a number of spatial locations commensurate with determining the accuracy of the machine being evaluated.

Measurement instrument with interferometer and method

Machine tool software error correction has been successfully demonstrated in laboratories for at least the last 20 years. However, no results could be found that evaluate the durability of such an approach. To be cost beneficial for industry, the time consuming measurement procedure needs to be as infrequent as possible. This study attempts to quantify the durability of such an approach on a commercial 3-Axis machining center. A traditional correction model is created and implemented inside the control system along with a first order thermal correction of the scales. Measurements are made with the Laser Ball Bar, which minimizes data collection to less than 30 min. The compensation system was evaluated over a 9 month period in which the machine experienced normal machining and common mishaps (tool crash). The results show that during this 9 month period, the compensation system was still capable of significantly reducing the machine's inherent errors.

Durability evaluation of software error correction on a machining center

Current techniques for mapping the volumetric positioning errors of machine tools are time and labor intensive To address these shortcomings, a linear displacement measuring device is introduced to rapidly and easily determine tool positions via trilateration The laser ball bar (LBB) consists of a laser interferometer aligned within a telescoping ball bar The design of the device is discussed and an error budget is developed to estimate its predicted accuracy Results of repeatability and linear accuracy test of the assembled prototype LBB are given The LBB is used to map the volumetric errors of a two-axis turning center Comparison of the LBB error map and the error map obtained through parametric error measurements shows the LBB can accurately map the machine errors in a timely manner

The laser ball bar: a new instrument for machine tool metrology

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