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<p>Contour error is a critical factor influencing machining quality. This paper proposes a combined contour error control method for five-axis machine tools based on digital twin. The proposed method combines pre-compensation implemented in digital twin with feedback control in the real-time controller. After obtaining the tool path input, the digital twin performs interpolation and applies model predictive pre-compensation control to the interpolated commands to control modeled errors. The pre-compensated commands and interpolation data are sent to the real-time controller where contour error is estimated and controlled in each control cycle through feedback control to control unmodeled errors. Using the S-shaped curve as the test case, the maximum tool tip position contour error is reduced by 77.78%, with an average reduction of 83.90%. The maximum tool orientation contour error decreased by 79.05%, with an average reduction of 86.66%. The experimental results demonstrate that the proposed method significantly reduces tool contour error.</p>

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Combined contour error control method for five-axis machine tools based on digital twin

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年5月22日

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  • Liuquan Wang,
  • Ruijie Yang,
  • Shisheng Lv,
  • Zhiqi Yang,
  • Shuwei Xin,
  • Yanqiang Liu,
  • Qiang Liu

摘要

Contour error is a critical factor influencing machining quality. This paper proposes a combined contour error control method for five-axis machine tools based on digital twin. The proposed method combines pre-compensation implemented in digital twin with feedback control in the real-time controller. After obtaining the tool path input, the digital twin performs interpolation and applies model predictive pre-compensation control to the interpolated commands to control modeled errors. The pre-compensated commands and interpolation data are sent to the real-time controller where contour error is estimated and controlled in each control cycle through feedback control to control unmodeled errors. Using the S-shaped curve as the test case, the maximum tool tip position contour error is reduced by 77.78%, with an average reduction of 83.90%. The maximum tool orientation contour error decreased by 79.05%, with an average reduction of 86.66%. The experimental results demonstrate that the proposed method significantly reduces tool contour error.