Compensation and learning control method of machining error is proposed to solve the deformation problem in thin-walled part processing. Based on elastic deformation, the nonlinear function between machining error and nominal depth of cut is established. Utilizing the idea of error compensation, the general compensation model of thin-walled part cutting error is developed, which means the calculation method of next nominal depth of cut. After that, four different solutions for compensation model are presented using mathematical and physical principles. Considering the mass process of multi-parts with single-step and the advantages of four solutions, the secant method with initial point is chosen to construct the discrete control system of error compensation. Applying the feedback principle, the offline learning of compensation coefficient is implemented to control machining error exactly. Finally, the flank milling is applied to verify the effectiveness of compensation model.
HOU Yaohua
,
ZHANG Dinghua
,
ZHANG Ying
. Error Compensation Modeling and Learning Control Method for Thin-walled Part Milling Process[J]. Journal of Mechanical Engineering, 2018
, 54(17)
: 108
-115
.
DOI: 10.3901/JME.2018.17.108
[1] LEE J H,LIU Y,YANG S H. Accuracy improvement of miniaturized machine tool:Geometric error modeling and compensation[J]. International Journal of Machine Tools & Manufacture,2006,46(12-13):1508-1516.
[2] ZHU Shaowei,DING Guofu,QIN Shengfeng,et al. Integrated geometric error modeling,identification and compensation of CNC machine tools[J]. International Journal of Machine Tools & Manufacture,2012,52(1):24-29.
[3] 王维,杨建国,姚晓栋,等. 数控机床几何误差与热误差综合建模及其实时补偿[J]. 机械工程学报,2012,48(7):165-170. WANG Wei,YANG Jianguo,YAO Xiaodong,et al. Synthesis modeling and real-time compensation of geometric error and thermal error for cnc machine tools[J]. Journal of Mechanical Engineering,2012,48(7):165-170.
[4] YU Jianhua,CHEN Zhitong,JIANG Zepeng. A control process for machining distortion by using an adaptive dual-sphere fixture[J]. International Journal of Advanced Manufacturing Technology,2016,86(9-12):3463-3470.
[5] YI Wei,JIANG Zhaoliang,SHAO Weixian,et al. Error compensation of thin plate-shape part with prebending method in face milling[J]. Chinese Journal of Mechanical Engineering,2015,28(1):88-95.
[6] RAO V S,RAO P V M. Tool deflection compensation in peripheral milling of curved geometries[J]. International Journal of Machine Tools & Manufacture,2006,46(15):2036-2043.
[7] HABIBI M,AREZOO B,NOJEDEH M V. Tool deflection and geometrical error compensation by tool path modification[J]. International Journal of Machine Tools and Manufacture,2011,51(6):439-449.
[8] RATCHEV S,NIKOV S,MOUALEK I. Material removal simulation of peripheral milling of thin wall low-rigidity structures using FEA[J]. Advances in Engineering Software,2004,35(8):481-491.
[9] RATCHEV S,LIU S,HUANG W,et al. Milling error prediction and compensation in machining of low-rigidity parts[J]. International Journal of Machine Tools and Manufacture,2004,44(15):1629-1641.
[10] RATCHEV S,LIU S,BECKER A A. Error compensation strategy in milling flexible thin-wall parts[J]. Journal of Materials Processing Technology,2005,162:673-681.
[11] RATCHEV S,LIU S,HUANG W,et al. An advanced FEA based force induced error compensation strategy in milling[J]. International Journal of Machine Tools and Manufacture,2006,46(5):542-551.
[12] 万敏,张卫红. 铣削过程中误差预测与补偿技术研究进展[J]. 航空学报,2008,29(5):1340-1349. WAN Min,ZHANG Weihong. Overviews of technique research progress of form error prediction and error compensation in milling process[J]. Acta Aeronautica et Astronautica Sinica,2008,29(5):1340-1349.
[13] WANG Minghai,SUN Yue. Error prediction and compensation based on interference-free tool paths in blade milling[J]. International Journal of Advanced Manufacturing Technology,2014,71(5-8):1309-1318.
[14] CHEN Weifang,XUE Jianbin,TANG Dunbing,et al. Deformation prediction and error compensation in multilayer milling processes for thin-walled parts[J]. International Journal of Machine Tools and Manufacture,2009,49(11):859-864.
[15] GAO Yuanyuan,MA Jianwei,JIA Zhenyuan,et al. Tool path planning and machining deformation compensation in high-speed milling for difficult-to-machine material thin-walled parts with curved surface[J]. The International Journal of Advanced Manufacturing Technology,2016,84(9-12):1757-1767.
[16] CHO M W,SEO T I,KWON H D. Integrated error compensation method using OMM system for profile milling operation[J]. Journal of Materials Processing Technology,2003,136(136):88-99.
[17] CHO M W,KIM G H,SEO T I,et al. Integrated machining error compensation method using OMM data and modified PNN algorithm[J]. International Journal of Machine Tools & Manufacture,2006,46(12-13):1417-1427.
[18] CHEN Yueping,GAO Jian,DENG Haixiang,et al. Spatial statistical analysis and compensation of machining errors for complex surfaces[J]. Precision Engineering,2013,37(1):203-212.
[19] PONIATOWSKA M. Free-form surface machining error compensation applying 3D CAD machining pattern model[J]. Computer-Aided Design,2015,62:227-235.
[20] HUANG Nuodi,BI Qingzhen,WANG Yuhan,et al. 5-axis adaptive flank milling of flexible thin-walled parts based on the on-machine measurement[J]. International Journal of Machine Tools & Manufacture,2014,84(6):1-8.
[21] MARINESCU V,CONSTANTIN I,Apostu C,et al. Adaptive dimensional control based on in-cycle geometry monitoring and programming for CNC turning center[J]. The International Journal of Advanced Manufacturing Technology,2011,55(9):1079-1097.
[22] 杨建华,张定华,吴宝海. 考虑加工过程的复杂薄壁件加工综合误差补偿方法[J]. 航空学报,2014,35(11):3174-3181. YANG Jianhua,ZHANG Dinghua,WU Baohai. A comprehensive error compensation approach considering machining process for complex thin-wall parts machining[J]. Acta Aeronautica et Astronautica Sinica,2014,35(11):3174-3181.
