In order to obtain all the geometric errors of rotary axes for a five-axis machine tool systematically and easily, a geometric error identification approach with ballbar measurement, six-circle technology, is developed. The influences of geometric errors of rotary axes on the integrated errors of five-axis CNC machine tools were obtained based on the geometric error model. By comparing with the nine-line method of linear axes, six-circle technology was established due to the characteristic of ballbar. This approach identified all the ten errors of each axis, including squareness errors and offset errors through analyzing the property of geometric errors. The impact of the set-up errors of ballbar was analyzed to improve the accuracy of six-circle technology. The set-up errors were obtained using the least square method, and they were removed from the measured data of ballbar. He simulation validated that elimination of set-up errors is appropriate enough. Six-circle technology was used to identify the geometric errors of rotary axes for five-axis machine tools. The measured data with compensation of geometric errors of rotary axis were compared with those without compensation. The measured errors with compensation decreased about from 50% to 80%. The experiments show that six-circle technology is precise in a systematic way and can identify different types of rotary axes.
FU Guo-qiang, FU Jian-zhong, SHEN Hong-yao. One novel geometric error identification of rotary axes for five-axis machine tool. JOURNAL OF ZHEJIANG UNIVERSITY (ENGINEERING SCIENCE), 2015, 49(5): 848-857.
［1］ SHEN H, FU J, HE Y, et al. On-line asynchronous compensation methods for static/quasi-static error implemented on CNC machine tools ［J］. International Journal of Machine Tools and Manufacture, 2012. 60(0): 14-26．
［2］ 王金栋, 郭俊杰, 费致根, 等. 基于激光跟踪仪的数控机床几何误差辨识方法［J］. 机械工程学报, 2011(14):13-19．
WANG Jin-dong, GUO Jun-jie, FEI Zhi-gen, et al. Method of geometric error identification for numerical control machine tool based on laser tracker ［J］. Chinese Journal of Mechanical Engineering, 2011. 47(14): 13-19．
［3］ 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．
［4］ FU G, FU J, XU Y, et al. Product of exponential model for geometric error integration of multi-axis machine tools ［J］. The International Journal of Advanced Manufacturing Technology, 2014. 71(9/12): 1653-1667．
［5］ LEI W T, HSU Y Y. Error measurement of five-axis CNC machines with 3D probe–ball ［J］. Journal of Materials Processing Technology, 2003. 139(1/3): 127-133．
［6］ WEIKERT S. R-Test, A new device for accuracy measurements on five axis machine tools ［J］. CIRP Annals - Manufacturing Technology, 2004. 53(1): 429-432．
［7］ ZARGARBASHI S H H, MAYER J R R, Assessment of machine tool trunnion axis motion error, using magnetic double ball bar ［J］. International Journal of Machine Tools and Manufacture, 2006. 46(14): 1823-1834．
［8］ TSUTSUMI 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．
［9］ TSUTSUMI M, SAITO A. Identification of angular and positional deviations inherent to 5-axis machining centers with a tilting-rotary table by simultaneous four-axis control movements ［J］. International Journal of Machine Tools and Manufacture, 2004. 44(12/13): 1333-1342．
［10］ TSUTSUMI M, TONE S, KATO N, et al. Enhancement of geometric accuracy of five-axis machining centers based on identification and compensation of geometric deviations ［J］. International Journal of Machine Tools & Manufacture, 2013,68: 1120．
［11］ LEE K I, LEE D M, YANG S H. Parametric modeling and estimation of geometric errors for a rotary axis using double ball-bar ［J］. International Journal of Advanced Manufacturing Technology, 2012. 62(5/8): 741-750．
［12］ LEE K I, YANG S H. Robust measurement method and uncertainty analysis for position-independent geometric errors of a rotary axis using a double ball-bar ［J］. International Journal of Precision Engineering and Manufacturing, 2013. 14(2): 231-239．
［13］ LEE K I, YANG S H. Measurement and verification of position-independent geometric errors of a five-axis machine tool using a double ball-bar ［J］. International Journal of Machine Tools and Manufacture, 2013. 70(0): 45-52．
［14］ 胡建忠, 王波雷, 王民,等. 基于双频激光干涉仪的DM1007数控铣床几何误差辨识的实验研究［J］. 制造技术与机床, 2010(04): 103-106．
HU Jian-zhong, WANG Bo-lei, WANG Min, et al. The study of geometric error identification of DM1007 milling machine based on laser interferometer ［J］. Manufacturing Technology & Machine Tool, 2010(4): 103-106．
［15］ HE Z Y, FU J Z, YAO X H. Volumetric error modeling and Analysis for CNC machine tool based on multi-body system ［J］. Key Engineering Materials, 2010. 426-427: 441-446．
［16］ LIN Y, SHEN Y. Modelling of five-axis machine tool metrology models using the matrix summation approach ［J］. The International Journal of Advanced Manufacturing Technology, 2003. 21(4): 243-248.
