摆头转台型五轴机床旋转轴运动误差测量与辨识
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摘要
为了快速、系统地辨识摆头转台型五轴机床旋转轴几何误差中的12项运动误差,提出了一种基于球杆仪(Double ball bar,DBB)五次安装的运动误差测量辨识方法。首先,结合摆头转台型五轴机床旋转轴分布特征,基于多体系统理论及齐次坐标变换方法建立了旋转轴局部坐标系下的测量模型,表征了空间误差向量与几何误差项之间的映射关系。其次,通过设置DBB初始安装位置及方向,实现了不同测量模式之间的连续切换,从而构造了五次安装法,辨识了摆头转台型五轴机床2个旋转轴共计12项运动误差,降低了DBB安装误差对测量及辨识结果准确性的影响。最后,在摆头转台型五轴机床上利用五次安装法进行基于DBB的运动误差测量辨识实验以及虚拟圆锥台轨迹测量实验,利用辨识值进行误差补偿,结果显示两个旋转轴的几何误差平均降低了48. 89%和51. 49%,虚拟圆锥台测量轨迹的半径偏差降低了50. 52%。误差补偿结果验证了测量、辨识的准确性和有效性。
In order to quickly and systematically identify the 12 geometric errors of the rotary axes of fiveaxis machine tool with a swiveling head,a five installation method for measuring and identifying geometric error based on the double ball bar( DBB) was proposed. Firstly,based on the distribution characteristics of the rotary axes of five-axis machine tool with swiveling head,the measurement models under the local coordinate systems of the rotary axes were established based on the multi-body system theory and the homogeneous coordinate transformation method,and the mapping relationship between the volume error vectors and the geometric error terms was established,which can also be used for geometric error compensation. Secondly,initial installation position and direction of the DBB were set,the continuous switching between different measurement modes was realized,and then the five installation method was proposed,which can realize the identification of the total 12 motion errors of the two rotary axes of fiveaxis machine tool with swiveling head,and it reduced the impact of installation errors on the accuracy of measurement and identification. Finally,the DBB-based motion errors measurement and identification experiments were carried out on the five-axis machine tool with swiveling head by using five installation methods. The geometric errors of five-axis machine tool with a turntable-tilting head were compensated with the identification values,and the average of motion errors of the two rotary axes were reduced by48. 89% and 51. 49%,respectively. The accuracy and validity of five installation method were verified.
In order to quickly and systematically identify the 12 geometric errors of the rotary axes of fiveaxis machine tool with a swiveling head,a five installation method for measuring and identifying geometric error based on the double ball bar( DBB) was proposed. Firstly,based on the distribution characteristics of the rotary axes of five-axis machine tool with swiveling head,the measurement models under the local coordinate systems of the rotary axes were established based on the multi-body system theory and the homogeneous coordinate transformation method,and the mapping relationship between the volume error vectors and the geometric error terms was established,which can also be used for geometric error compensation. Secondly,initial installation position and direction of the DBB were set,the continuous switching between different measurement modes was realized,and then the five installation method was proposed,which can realize the identification of the total 12 motion errors of the two rotary axes of fiveaxis machine tool with swiveling head,and it reduced the impact of installation errors on the accuracy of measurement and identification. Finally,the DBB-based motion errors measurement and identification experiments were carried out on the five-axis machine tool with swiveling head by using five installation methods. The geometric errors of five-axis machine tool with a turntable-tilting head were compensated with the identification values,and the average of motion errors of the two rotary axes were reduced by48. 89% and 51. 49%,respectively. The accuracy and validity of five installation method were verified.
引文
[1]杨建国,范开国,杜正春.数控机床误差实时补偿技术[M].北京:机械工业出版社,2013.
[2] LEE K I,YANG S H. Robust measurement method and uncertainty analysis for position-independent geometric errors of a rotaryaxis using a double ball-bar[J]. International Journal of Precision Engineering and Manufacturing,2013,14(2):231-239.
[3] HE Zhengya,FU Jianzhong,YAO Xinhua,et al. A new error measurement method to identify all six error parameters of arotational axis of a machine tool[J]. International Journal of Machine Tools and Manufacture,2015,88:1-8.
[4] WANG J,GUO J. Algorithm for detecting volumetric geometric accuracy of NC machine tool by laser tracker[J]. ChineseJournal of Mechanical Engineering,2013,26(1):166-175.
[5] BI Q,HUANG N,SUN C,et al. Identification and compensation of geometric errors of rotary axes on five-axis machine by on-machine measurement[J]. The International Journal of Advanced Manufacturing Technology,2016,84(1):505-512.
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[8]齐继宝,杨伟民.基于微分变化构造法的数控机床几何误差补偿方法[J/OL].农业机械学报,2016,47(9):398-405.QI Jibao,YANG Weimin. Differential change construction based geometric error compensation for machine tools[J/OL].Transactions of the Chinese Society for Agricultural Machinery,2016,47(9):398-405. http:∥www. j-csam. org/jcsam/ch/reader/view_abstract. aspx? file_no=20160953&flag=1&journal_id=jcsam. DOI:10. 6041/j. issn. 1000-1298. 2016. 09. 053.(in Chinese)
[9]郭世杰,梅雪松,姜歌东,等.数控机床几何误差相关性分析方法研究[J/OL].农业机械学报,2016,47(10):383-389.GUO Shijie,MEI Xuesong,JIANG Gedong,et al. Correlation analysis of geometric error for CNC machine tool[J/OL].Transactions of the Chinese Society for Agricultural Machinery,2016,47(10):383-389. http:∥www. j-csam. org/jcsam/ch/reader/view_abstract. aspx? file_no=20161050&flag=1&journal_id=jcsam. DOI:10. 6041/j. issn. 1000-1298. 2016. 10. 050.(in Chinese)
[10] ANDOLFATTO L,LAVERNHE S,MAYER J R R. Evaluation of servo,geometric and dynamic error sources on five-axishigh-speed machine tool[J]. International Journal of Machine Tools and Manufacture,2011,51(10-11):787-796.
[11] TSUSUMI M,TONE S,KATO N,et al. Enhancement of geometric accuracy of five-axis machining centers based onidentification and compensation of geometric deviations[J]. International Journal of Machine Tools and Manufacture,2013,68:11-20.
[12] ISO 230-1. Test code for machine tools-part 1:geometric accuracy of machines operating under no-load or quastic-staticconditions[S]. 2012.
[13] TSUSUMI M,SAITO A. Identification and compensation of systematic deviations particular to 5-axis machining centers[J].International Journal of Machine Tools and Manufacture,2003,43(8):771-780.
[14] LEE K I,YANG S H. Compensation of position-independent and position-dependent geometric errors in the rotary axes of five-axis machine tools with a tilting rotary table[J]. The International Journal of Advanced Manufacturing Technology,2016,85(5-8):1677-1685.
[15] ZARGARBASHI S H H,MAYER J R R. Single setup estimation of a five-axis machine tool eight link errors by programmedend point constraint and on the fly measurement with Capball sensor[J]. International Journal of Machine Tools andManufacture,2009,49(10):759-766.
[16] ZARGARBASHI S H H,MAYER J R R. Assessment of machine tool trunnion axis motion error,using magnetic double ballbar[J]. International Journal of Machine Tools and Manufacture,2006,46(14):1823-1834.
[17] JIANG L,DING G,LI Z,et al. Geometric error model and measuring method based on worktable for five-axis machine tools[J]. Proc IMech E Part B Journal of Engineering Manufacture,2013,227(1):32-44.
[18] FU G,FU J,XU Y,et al. Accuracy enhancement of five-axis machine tool based on differential motion matrix:geometricerror modeling,identification and compensation[J]. International Journal of Machine Tools and Manufacture,2015,89:170-181.
[19]田文杰,郭龙真,刘海涛.数控机床几何误差源的快速辨识方法[J].天津大学学报(自然科学与工程技术版),2016,49(2):171-177.TIAN Wenjie,GUO Longzhen,LIU Haitao. Rapid identification method for geometric errors of CNC machine tools[J]. Journalof Tianjin University(Science and Technology),2016,49(2):171-177.(in chinese)
[20] ZHU S,DING G,QIN S,et al. Integrated geometric error modeling,identification and compensation of CNC machine tools[J]. International Journal of Machine Tools and Manufacture,2012,52(1):24-29.
[21] CHEN D,DONG L,BIAN Y,et al. Prediction and identification of rotary axes error of non-orthogonal five-axis machine tool[J]. International Journal of Machine Tools and Manufacture,2015,94:74-87.
[22] LI H,GUO J,DENG Y,et al. Identification of geometric deviations inherent to multi-axis machine tools based on the posemeasurement principle[J]. Measurement Science and Technology,2016,27(12):125008.
[23] HONG C,IBARAKI S,OYAMA C. Graphical presentation of error motions of rotary axes on a five-axis machine tool by staticR-test with separating the influence of squareness errors of linear axes[J]. International Journal of Machine Tools andManufacture,2012,59:24-33.
[24] GUO S,JIANG G,ZHANG D,et al. Position-independent geometric error identification and global sensitivity analysis for therotary axes of five-axis machine tools[J]. Measurement Science and Technology,2017,28(4):045006.
[25] XIANG S,ALTINTAS Y. Modeling and compensation of volumetric errors for five-axis machine tools[J]. International Journalof Machine Tools and Manufacture,2016,101:65-78.
[2] LEE K I,YANG S H. Robust measurement method and uncertainty analysis for position-independent geometric errors of a rotaryaxis using a double ball-bar[J]. International Journal of Precision Engineering and Manufacturing,2013,14(2):231-239.
[3] HE Zhengya,FU Jianzhong,YAO Xinhua,et al. A new error measurement method to identify all six error parameters of arotational axis of a machine tool[J]. International Journal of Machine Tools and Manufacture,2015,88:1-8.
[4] WANG J,GUO J. Algorithm for detecting volumetric geometric accuracy of NC machine tool by laser tracker[J]. ChineseJournal of Mechanical Engineering,2013,26(1):166-175.
[5] BI Q,HUANG N,SUN C,et al. Identification and compensation of geometric errors of rotary axes on five-axis machine by on-machine measurement[J]. The International Journal of Advanced Manufacturing Technology,2016,84(1):505-512.
[6]褚宁,张为民.基于张量理论的数控机床误差补偿模型[J/OL].农业机械学报,2017,48(10):408-416.CHU Ning,ZHANG Weimin. Error compensation model of CNC machine tool based on tensor theory[J/OL]. Transactions ofthe Chinese Society for Agricultural Machinery,2017,48(10):408-416. http:∥www. j-csam. org/jcsam/ch/reader/view_abstract. aspx? file_no=20171052&flag=1. DOI:10. 6041/j. issn. 1000-1298. 2017. 10. 052.(in Chinese)
[7]余文利,付国强,孙磊,等.数控加工中心空间误差场建模与仿真软件设计[J/OL].农业机械学报,2016,47(4):382-390.YU Wenli,FU Guoqiang,SUN Lei,et al. Error field modeling and simulation software development for CNC machining center[J/OL]. Transactions of the Chinese Society for Agricultural Machinery,2016,47(4):382-390. http:∥www. j-csam. org/jcsam/ch/reader/view_abstract. aspx? file_no=20160450&flag=1&journal_id=jcsam. DOI:10. 6041/j. issn. 1000-1298.2016. 04. 050.(in Chinese)
[8]齐继宝,杨伟民.基于微分变化构造法的数控机床几何误差补偿方法[J/OL].农业机械学报,2016,47(9):398-405.QI Jibao,YANG Weimin. Differential change construction based geometric error compensation for machine tools[J/OL].Transactions of the Chinese Society for Agricultural Machinery,2016,47(9):398-405. http:∥www. j-csam. org/jcsam/ch/reader/view_abstract. aspx? file_no=20160953&flag=1&journal_id=jcsam. DOI:10. 6041/j. issn. 1000-1298. 2016. 09. 053.(in Chinese)
[9]郭世杰,梅雪松,姜歌东,等.数控机床几何误差相关性分析方法研究[J/OL].农业机械学报,2016,47(10):383-389.GUO Shijie,MEI Xuesong,JIANG Gedong,et al. Correlation analysis of geometric error for CNC machine tool[J/OL].Transactions of the Chinese Society for Agricultural Machinery,2016,47(10):383-389. http:∥www. j-csam. org/jcsam/ch/reader/view_abstract. aspx? file_no=20161050&flag=1&journal_id=jcsam. DOI:10. 6041/j. issn. 1000-1298. 2016. 10. 050.(in Chinese)
[10] ANDOLFATTO L,LAVERNHE S,MAYER J R R. Evaluation of servo,geometric and dynamic error sources on five-axishigh-speed machine tool[J]. International Journal of Machine Tools and Manufacture,2011,51(10-11):787-796.
[11] TSUSUMI M,TONE S,KATO N,et al. Enhancement of geometric accuracy of five-axis machining centers based onidentification and compensation of geometric deviations[J]. International Journal of Machine Tools and Manufacture,2013,68:11-20.
[12] ISO 230-1. Test code for machine tools-part 1:geometric accuracy of machines operating under no-load or quastic-staticconditions[S]. 2012.
[13] TSUSUMI M,SAITO A. Identification and compensation of systematic deviations particular to 5-axis machining centers[J].International Journal of Machine Tools and Manufacture,2003,43(8):771-780.
[14] LEE K I,YANG S H. Compensation of position-independent and position-dependent geometric errors in the rotary axes of five-axis machine tools with a tilting rotary table[J]. The International Journal of Advanced Manufacturing Technology,2016,85(5-8):1677-1685.
[15] ZARGARBASHI S H H,MAYER J R R. Single setup estimation of a five-axis machine tool eight link errors by programmedend point constraint and on the fly measurement with Capball sensor[J]. International Journal of Machine Tools andManufacture,2009,49(10):759-766.
[16] ZARGARBASHI S H H,MAYER J R R. Assessment of machine tool trunnion axis motion error,using magnetic double ballbar[J]. International Journal of Machine Tools and Manufacture,2006,46(14):1823-1834.
[17] JIANG L,DING G,LI Z,et al. Geometric error model and measuring method based on worktable for five-axis machine tools[J]. Proc IMech E Part B Journal of Engineering Manufacture,2013,227(1):32-44.
[18] FU G,FU J,XU Y,et al. Accuracy enhancement of five-axis machine tool based on differential motion matrix:geometricerror modeling,identification and compensation[J]. International Journal of Machine Tools and Manufacture,2015,89:170-181.
[19]田文杰,郭龙真,刘海涛.数控机床几何误差源的快速辨识方法[J].天津大学学报(自然科学与工程技术版),2016,49(2):171-177.TIAN Wenjie,GUO Longzhen,LIU Haitao. Rapid identification method for geometric errors of CNC machine tools[J]. Journalof Tianjin University(Science and Technology),2016,49(2):171-177.(in chinese)
[20] ZHU S,DING G,QIN S,et al. Integrated geometric error modeling,identification and compensation of CNC machine tools[J]. International Journal of Machine Tools and Manufacture,2012,52(1):24-29.
[21] CHEN D,DONG L,BIAN Y,et al. Prediction and identification of rotary axes error of non-orthogonal five-axis machine tool[J]. International Journal of Machine Tools and Manufacture,2015,94:74-87.
[22] LI H,GUO J,DENG Y,et al. Identification of geometric deviations inherent to multi-axis machine tools based on the posemeasurement principle[J]. Measurement Science and Technology,2016,27(12):125008.
[23] HONG C,IBARAKI S,OYAMA C. Graphical presentation of error motions of rotary axes on a five-axis machine tool by staticR-test with separating the influence of squareness errors of linear axes[J]. International Journal of Machine Tools andManufacture,2012,59:24-33.
[24] GUO S,JIANG G,ZHANG D,et al. Position-independent geometric error identification and global sensitivity analysis for therotary axes of five-axis machine tools[J]. Measurement Science and Technology,2017,28(4):045006.
[25] XIANG S,ALTINTAS Y. Modeling and compensation of volumetric errors for five-axis machine tools[J]. International Journalof Machine Tools and Manufacture,2016,101:65-78.