Error Sensitivity Analysis of Motion Axis for Five-axis CNC Machine Tools with Geometric Error Contribution

Abstract

Abstract: Aiming at the problems that the sensitivity analysis of the existing error elements was not closely related to the subsequent error compensation，the geometric error contribution modeling of the motion axes and error sensitivity analysis of the motion axes were built to obtain the key motion axes whose geometric errors had great influence on the accuracy of the five-axis CNC machine tool. The geometric error contributions of all motion axes were established based on the error sensitivity matrix by using POE(product of exponential) theory and the transforming differential changes among coordinate frames. The integrated geometric error model of the CNC machine tool was the summation of the error contribution of all motion axes. The weight components and the comprehensive weight of error contribution for all motion axes were calculated to realize the error sensitivity analysis of the axes. The motion axis with the maximum mean comprehensive weight was selected as the key motion axis of the CNC machine tool, and the error compensation method of the key motion axis was analyzed and discussed. Finally, simulations and real cutting experiments were carried out on five-axis CNC machine tool of JINGDIAO. The results show that geometric error contribution modeling and error sensitivity evaluations of the motion axis are effective, and only compensating the geometric error contribution of the key motion axis may effectively improve the accuracy of the five-axis CNC machine tool.

Key words: five-axis CNC machine tool, error modeling, geometric error contribution, error sensitivity of motion axis, weight of error contribution of motion axis, error compensation

摘要： 针对现有误差元素灵敏度分析与后续误差补偿关联性不强的问题，建立运动轴几何误差贡献值模型并提出运动轴几何误差灵敏度分析方法，以获得本身几何误差对机床精度有很大影响的关键运动轴。结合指数积理论和坐标系微分运动理论建立基于误差敏感矩阵的运动轴几何误差贡献值模型，各运动轴几何误差贡献值相加得到机床综合误差模型；计算各运动轴误差权重分量和误差综合权重实现运动轴误差灵敏度分析，选择误差综合权重平均值最大的运动轴为机床关键运动轴，并对关键运动轴的误差补偿方法进行分析讨论。最后，在北京精雕集团的五轴加工中心上进行仿真实验验证。研究结果表明：所建立模型和所提出分析方法是有效的，且只补偿关键运动轴的几何误差贡献值能有效地提高五轴机床加工精度。

关键词: 五轴数控机床, 误差建模, 几何误差贡献值, 运动轴误差灵敏度, 运动轴误差权重, 误差补偿

CLC Number:

TG156

FU Guoqiang, RAO Yongjian, XIE Yunpeng, GAO Hongli, DENG Xiaolei. Error Sensitivity Analysis of Motion Axis for Five-axis CNC Machine Tools with Geometric Error Contribution[J]. China Mechanical Engineering.

付国强, 饶勇建, 谢云鹏, 高宏力, 邓小雷. [误差建模及精度保证方法]几何误差贡献值影响下五轴数控机床运动轴误差灵敏度分析方法[J]. 中国机械工程.

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