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Systematic analysis of 5-axis machine error budgets: Decreasing the calibration effort without decreasing the machining accuracy

: Brecher, C.; Flore, J.; Wenzel, C.

Blunt, L. ; European Society for Precision Engineering and Nanotechnology -EUSPEN-:
Laser metrology and machine performance X : 10th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM & Robotic Performance, Lamdamap 2013. 20 - 21 March 2013, Chicheley Hall, Newport Pagnell, Bucks, Buckinghamshire, UK
Cranfield: Euspen, 2013
ISBN: 978-0-9566790-1-7
International Conference and Exhibition on Laser Metrology, Coordinate Measuring Machine and Machine Tool Performance (LAMDAMAP) <10, 2013, Newport Pagnell>
Conference Paper
Fraunhofer IPT ()

An efficient 5-axis machining process requires a recurrent metrological calibration and controller based compensation of the machine axes to capacitate a sustained machining accuracy. However the metrological identification of the geometrical axis errors still necessitates a huge time and device related effort. Consequently the goal of current research work is to reduce the necessary metrological effort without decreasing the achievable improvement of the machining accuracy. This paper deals with an approach for systematic analyses of the axis error impact on the overall 5-axis machining accuracy. The bases for the analyses are mathematical models that represent the transformation of the single axis errors on the overall three-dimensional machining accuracy. Within systematic analyses the impact of each single axis error can be evaluated independent of the error amount but in consideration of the axis configuration, the machine size as well as further parameters like tool and work piece size. The results show that the specific impact depends particularly on the machine size and the axis configuration. Besides this a metrological approach will be presented that capacitates the validation of the impact analyses results. This approach also gives the chance to realise a quick check calibration procedure by exploiting the developed mathematical models and the information about inferior and superior errors.