MODELING GEOMETRIC AND THERMAL ERRORS IN A 5-AXIS CNC MACHINE-TOOL

The total volumetric error within the workspace of a machine tool is induced by the propagation of both scalar and position dependent geometrical errors, as well as time-variant thermal errors. This paper presents a compact volumetric error model which can be used as a basis for a practical compensation scheme; The broad objective is to increase the achievable accuracy of an industrial five-axis CNC machine tool. In place of using Denavit-Hartenberg (D-H) transformations, the method used here directly considers the shape and joint transformations for inaccurate links and joints using small angle approximations and then finds the total volumetric error in the workspace as a function of all the possible errors. The development of the model shows that angular deviations are independent of translational errors. However, the tool point deviations are dependent on both translational and rotational errors. The model has been used for the design and testing of a compensation strategy. The simulation studies indicate that CNC compensation for errors in X, Y and Z axes is possible. However, the capability of the CNC compensation for pitch, roll and yaw errors is dependent on the positioning of the rotary axes on the machine tool. This is shown by an example using the compensation scheme developed.