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An integrated method for compensating and correcting nonlinear error in five-axis machining utilizing cutter

Liangji Chen1, Haohao Xu2, Qiang Huang1

  • 1Key Laboratory of Advanced Manufacturing and Automation Technology (Guilin University of Technology), Education Department of Guangxi Zhuang Autonomous Region, Guilin, 541006, China.

Scientific Reports
|April 16, 2024
PubMed
Summary
This summary is machine-generated.

This study introduces a new method to reduce errors in five-axis CNC machining. The technique significantly improves accuracy and surface quality by correcting nonlinear and contour errors, making parts smoother.

Keywords:
CC point trajectory nonlinear errorCNC machiningCompensating and correctingContour errorFive-axis linear interpolation

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Area of Science:

  • Manufacturing Engineering
  • Mechanical Engineering
  • Control Systems

Background:

  • Five-axis CNC machining often approximates ideal tool paths with linear segments, leading to nonlinear errors.
  • Rotation axes in five-axis machining introduce deviations between the actual and ideal cutter contact (CC) point trajectories.

Purpose of the Study:

  • To propose an integrated method for compensating and correcting contour and nonlinear errors in five-axis CNC machining.
  • To enhance the accuracy and surface quality of machined parts by addressing CC point trajectory deviations.

Main Methods:

  • Analyzing spatial relationships between tool posture and CC point path during five-axis linear interpolation.
  • Calculating ideal and actual CC points, distances, and unit vectors for error compensation.
  • Implementing a two-phase compensation strategy for contour and nonlinear errors using MATLAB.

Main Results:

  • Contour error reduced by 76%.
  • Nonlinear error of CC point trajectory decreased to below 0.88 μm.
  • Comprehensive nonlinear error reduced by 93% (from 19 to 1.5 μm).
  • Average surface roughness decreased from 1.133 to 0.220 μm.
  • Maximum surface roughness decreased from 6.667 to 1.240 μm.

Conclusions:

  • The proposed integrated method effectively compensates for contour and nonlinear errors in five-axis CNC machining.
  • The method significantly enhances machining accuracy and improves the surface quality of machined parts.
  • The validated results demonstrate substantial practical value for industrial applications.