Integrated error compensation method using OMM system for profile milling operation

This paper presents a methodology of machined surface error compensation based on an inspection database by using an on-machine measurement system in profile milling. First, we make compensation for the geometric errors of the machining center by using a closed-loop configuration for the improvement of machining and inspection accuracy. The probing errors are also taken into account. We manufacture a specimen workpiece and then inspect machined surface error distribution. In order to efficiently analyze the surface errors, two characteristic surface error parameters W-err and D-err are defined. Subsequently, it is possible to fit these parameters by using polynomial functions. These polynomial functions allow us to determine the surface errors in the domain of modeled cutting conditions. Based on these functional relationships between cutting conditions and surface errors, we try to correct the tool path in order to effectively reduce the errors by using an iterative algorithm. An iterative algorithm allows us to integrate changes of the cutting conditions according to the corrected tool path. To compensate for the surface errors, manufacturing tolerances are also taken into account. Experimentation is carried out in order to validate the approaches proposed in this paper. (C) 2002 Elsevier Science B.V. All rights reserved.