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Technical Briefs

Identification and Compensation of Dynamic Scale Mismatches in High-Speed End Mill Boring Trajectory on CNC Machines

[+] Author and Article Information
Mohamed Slamani, Rene Mayer, Marek Balazinski

Department of Mechanical Engineering, École Polytechnique de Montréal, C.P. 6079, Montreal, H3C3A7, QC, Canada

Serafettin Engin

Department of Manufacturing Technology Development, Pratt & Whitney Canada Corporation, Longueuil, J4H3Y3, QC, Canada

J. Manuf. Sci. Eng 132(3), 034501 (Jun 15, 2010) (6 pages) doi:10.1115/1.4001412 History: Received February 17, 2009; Revised March 12, 2010; Published June 15, 2010; Online June 15, 2010

During high-speed end mill boring, dynamic scale mismatch originates from the difference in the dynamic response of each axis and, at high feedrates, causes a trajectory ovalization along the axis with the fastest dynamic response. To investigate this error, an experimental approach is used at different feedrates and trajectory radii for a high-speed machine tool with linear motor drives. Results show that dynamic scale mismatch causes out-of-roundness and radius size errors. A simple second order model is used successfully to predict the dynamic scale mismatch and a strategy is proposed and tested to compensate it at the G-code level. An experimental trial reveals the usefulness of the approach.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

KGM grid encoder mounted on the tested machine tool

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Figure 2

Experimental and predicted contouring form errors (average size effect removed); in CW and CCW direction at different feedrates for radius R=5 mm

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Figure 3

Experimental and predicted radius size error as function of programmed centripetal acceleration for various radii

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Figure 4

Experimental and predicted out-of-roundness error as function of programmed centripetal acceleration for various radii

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Figure 5

Contouring form errors (average size effect removed): before errors compensation, R=20 mm, and F=10,000mm/min

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Figure 6

Contouring form errors (average size effect removed); after errors compensation

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Figure 7

Experimental, predicted and compensated radius size error as function of programmed centripetal acceleration for radius R=20 mm

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Figure 8

Experimental, predicted and compensated out-of-roundness as function of programmed centripetal acceleration for radius R=20 mm

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