<p>With advancements in high-tech industries, such as aerospace, semiconductor, and medical applications, along with electric vehicles, the design of machine parts used in these industries has become extremely complicated, and the required geometric accuracy has been rapidly refined. To achieve the accuracy requirements, the necessity of 5-axis machine tools has been rising owing to their orientation flexibility between the cutting tool and workpiece through the rotational axes. When manufacturing machine parts using a 5-axis machine tool, the geometric accuracy of the machine parts can be degraded by a discrepancy between the cutting tool and workpiece, that is, volumetric error. This study develops a volumetric accuracy enhancement method by combining sensitivity analysis and an extraction algorithm to minimize and control the volumetric error. First, to formulate the discrepancy between the cutting tool and workpiece, volumetric error modeling is performed based on rigid-body kinematics and a homogeneous transformation matrix. Subsequently, a sensitivity analysis is developed to quantify the influence of kinematic errors and identify critical kinematic errors on volumetric error. And then, an extraction algorithm is developed to extract the kinematic errors occurring in the target machine using the transformation error and eight measurement data obtained by a single measurement setup. Finally, utilizing an R-test, the validity of the volumetric accuracy enhancement method is verified through a comparison of volumetric errors before and after compensation. Compared to existing method, the proposed method demonstrated superior compensation performance, reducing the volumetric error from approximately 25 to 12&#xa0;mm.</p>

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Development of Volumetric Accuracy Enhancement Method for a 5-Axis Machine Tool Based on Sensitivity Analysis and Extraction Algorithm

  • Sungtae Kim,
  • Yangjin Kim,
  • Heung Ki Jeon,
  • Tae Soo Jang,
  • Chang Ho Lee,
  • Naohiko Sugita

摘要

With advancements in high-tech industries, such as aerospace, semiconductor, and medical applications, along with electric vehicles, the design of machine parts used in these industries has become extremely complicated, and the required geometric accuracy has been rapidly refined. To achieve the accuracy requirements, the necessity of 5-axis machine tools has been rising owing to their orientation flexibility between the cutting tool and workpiece through the rotational axes. When manufacturing machine parts using a 5-axis machine tool, the geometric accuracy of the machine parts can be degraded by a discrepancy between the cutting tool and workpiece, that is, volumetric error. This study develops a volumetric accuracy enhancement method by combining sensitivity analysis and an extraction algorithm to minimize and control the volumetric error. First, to formulate the discrepancy between the cutting tool and workpiece, volumetric error modeling is performed based on rigid-body kinematics and a homogeneous transformation matrix. Subsequently, a sensitivity analysis is developed to quantify the influence of kinematic errors and identify critical kinematic errors on volumetric error. And then, an extraction algorithm is developed to extract the kinematic errors occurring in the target machine using the transformation error and eight measurement data obtained by a single measurement setup. Finally, utilizing an R-test, the validity of the volumetric accuracy enhancement method is verified through a comparison of volumetric errors before and after compensation. Compared to existing method, the proposed method demonstrated superior compensation performance, reducing the volumetric error from approximately 25 to 12 mm.