TY - JOUR

T1 - Model Based Compensation of Geometrical Deviations Due to Process Forces

AU - Denkena, Berend

AU - Dahlmann, Dominik

AU - Peters, René

AU - Witt, Matthias

N1 - Funding information: The results presented in this paper were obtained within the Collaborative Research Centre 1153 “Process chain to produce hybrid high performance components by Tailored Forming” in the subproject B5. The authors would like to thank the German Research Foundation (DFG) for the financial and organisational support of this project.

PY - 2017/1/1

Y1 - 2017/1/1

N2 - Machining accuracy can be considerably affected by deflections of machine tool components and the workpiece. This work presents a new approach for real-time deflection compensation, based on control integrated models. A real-time material removal rate (MRR) simulation determines the depth of cut which is used for process force calculation by Kienzle-Equations. Machine tool and workpiece deflections are then derived from a mechanical model using the calculated process forces. For this purpose, control based signals are used as model inputs. The total deviation is sent to the position controller as a setpoint offset. A dynamometer was applied to validate the simulated process forces. The presented approach was validated for cylindrical turning operations on chucked steel shafts. The experiments were carried out on a high-precision slant bed lathe. The results show, that geometrical errors could be reduced by more than 70% on average.

AB - Machining accuracy can be considerably affected by deflections of machine tool components and the workpiece. This work presents a new approach for real-time deflection compensation, based on control integrated models. A real-time material removal rate (MRR) simulation determines the depth of cut which is used for process force calculation by Kienzle-Equations. Machine tool and workpiece deflections are then derived from a mechanical model using the calculated process forces. For this purpose, control based signals are used as model inputs. The total deviation is sent to the position controller as a setpoint offset. A dynamometer was applied to validate the simulated process forces. The presented approach was validated for cylindrical turning operations on chucked steel shafts. The experiments were carried out on a high-precision slant bed lathe. The results show, that geometrical errors could be reduced by more than 70% on average.

KW - Model based compensation

KW - Real-time model

KW - Reduction of geometrical errors

UR - http://www.scopus.com/inward/record.url?scp=85015313887&partnerID=8YFLogxK

M3 - Article

AN - SCOPUS:85015313887

VL - 17

SP - 5

EP - 16

JO - Journal of Machine Engineering

JF - Journal of Machine Engineering

SN - 1895-7595

IS - 1

ER -