How to improve part quality from your CNC machining center with ease -----A new technology Charles Wang Optodyne, Inc 1180 Mahalo Place Rancho Dominguez, California 90220 WWW.optodyne.com Outline • Introduction • What are the 3D volumetric positioning errors? • How to measure the 3D volumetric positioning errors? • What is the vector technique or sequential step diagonal measurement? • How to compensate 3D volumetric positioning errors. • Experimental verification • Summary and conclusion 1 Why measure and compensate 3D volumetric positioning errors? • Worldwide competition and quality standards ISO 9000 and QS 9000. • Tighter tolerance on machines and parts. • Twenty years ago, Linear errors, lead screw pitch and thermal expansion are the major errors. • Now, squareness and straightness are the major errors. • To achieve higher positioning accuracy, the measurement and compensation of squareness and straightness errors are very important. Linear Errors x(x) A B x C For x-axis motion A: Starting position B: Programmed position C: Actual position BC: Linear Error BC = x(x) x(x): error in x-direction as function of x ( Lead screw pitch error) Similarly for y-axis and z-axis motion y(y): error in y-direction as function of y z(z): error in z-direction as function of z Volumetric Errors z C y z(x) A B y(x) x(x) x For x-axis motion A:Starting position B:Programmed position C:Actual position BC: Volumetric error BC = x(x) ex + y(x) ey + z(x) ez x(x): error in x-direction as function of x y(x): error in y-direction as function of x (horizontal straightness) z(x): error in z-direction as function of x (vertical straightness) Similarly for y-axis and z-axis motion x(y): error in x-direction as function of y y(y): error in y-direction as function of y z(y): error in z-direction as function of y x(z): error in x-direction as function of z y(z): error in y-direction as function of z z(z): error in z-direction as function of z 2 The 21 rigid body errors For a 3-axis machine, there are 21 rigid body errors • 3 Linear displacement errors: Dx(x), Dy(y), and Dz(z) • 3 Vertical straightness errors: Dy(x), Dx(y), and Dx(z) • 3 Horizontal straightness errors: Dz(x), Dz(y), and Dy(z) • 3 Roll angular errors: Ax(x), Ay(y), and Az(z) • 3 Pitch angular errors: Ay(x), Ax(y), and Ax(z) • 3 Yaw angular errors: Az(x), Az(y), and Ay(z) • 3 Squareness errors: Øxy, Øyz, Øzx, 6 errors per axis 3 squareness errors 3 What are 3D volumetric positioning errors? The volumetric positioning errors are: 3 displacement errors Dx(X), Dy(Y), and Dz(Z) 6 straightness errors Dy(X), Dx(Y), Dx(Z) Dz(X), Dz(Y), Dy(Z) 3 squareness errors Φxy, Φyz, Φzx A total of 12 errors. Total errors in each direction are: Dx(x,y,z) = Dx(x) + Dx(y) + Dx(z) Dy(x,y,z) = Dy(x) + Dy(y) + Dy(z) + Øxy*x/X Dz(x,y,z) = Dz(x) + Dz(y) + Dz(z) + Øyz*y/Y + Øzx*x/X The vector sum of positioning errors • The error in each axis direction is the sum of errors caused by all 3 axes movement plus the errors caused by the non -perpendicular of the 3 axes. • The positioning error in an arbitrary point within the working volume is composed by the positioning errors of the individual axes in all 3 axis directions. • The total error at each point is the vector sum of errors in all 3 axis directions. How to measure the 3D volumetric positioning errors? Conventional laser interferometer very complex and expensive optics (Wollaston Prism) difficult to setup and align and very time consuming Laser vector technique* simple and efficient easy setup, alignment and operation saves time, measurement in hours instead of days * A vector measurement method and apparatus. US Patent 6,519,043, February 11, 2003. 4 Spindle Wallaston Prism Straightness Reflector Optical Square Laser Straightness & Squareness Measurement Using a Wollaston Prism and Optical Square Measurement of the diagonal displacement accuracy ASME B5 and ISO 230-6 Body diagonal displacement errors before the compensation. The total error is 90 micron. 5 ASME B5.54 or ISO 230-6 body diagonal displacement error measurement • The volumetric positioning errors, including 3 displacement errors, 6 straightness errors and 3 squareness errors, will show as the 4 body diagonal displacement errors. • It is a good measure of volumetric accuracy. But do not have enough data to determine the displacement error, vertical straightness error and horizontal straightness error of each axis. What is the vector technique? Laser vector technique developed by Optodyne US Patent # 6,519,043, 2/11/2003 Measures the volumetric positioning errors, 3 displacement errors 6 straightness errors and 3 squareness errors, in 4 body diagonal sequential steps displacement measurement. Measurement can be performed in a few hours instead of a few days. Laser Vector (or Sequential step diagonal) Measurement Technique • Sequential Step Body Diagonal Displacement errors • Separate X-axis, Y-axis and Z-axis movement. • 3 times more data, or 12 sets of data. • All variables are separated. • Solve the 3 displacement errors, 6 straightness errors and 3 squareness errors. 6 Laser vector method Sequential diagonal path Results: - straightness errors Dy(x), Dz(x), Dx(y), Dz(y), Dx(z), Dy(z) - squareness errors Bxy, Bzx, Byz - diagonal displacement test Ed Major advantages of single aperture optical arrangement • Reduced size of optical components. Hence the laser system is smaller and more compact. • Able to use a flat-mirror as target for large lateral movement. Hence the laser vector and laser ballbar measurement are possible. 7 Volumetric compensation • Compensate 3D volumetric positioning errors by high-end CNC controllers, such as Fanuc 15, 16/18, 30i/31i/32i, Siemens 840D/810D, Heidenhain 450, Fagor, Fidia, etc. • Compensate 3D volumetric positioning errors by modifying the part program for CNC machines with low-end controllers. The measurement volume only has to be larger than the part volume, which usually is less than 20% of the working volume. This further reduces the measurement time. Experimental Verifications X-axis errors • • • • • • • • • • • • Target 0.0 25.0 50.0 75.0 100.0 775.0 800.0 825.0 850.0 875.0 900.0 DXX 0.0000147 -0.0010466 -0.0021427 -0.0028001 -0.0041913 -0.0218803 -0.0215804 -0.0219705 -0.0216299 -0.0210416 -0.0207334 DXY DXZ 0.0 0.0 0.0003849 -0.0011529 0.0014003 -0.0023086 0.0020966 -0.0029604 0.0030704 -0.0032527 0.0041541 0.0027603 0.0037406 0.0028455 0.0034518 0.0035008 0.003313 0.0038701 0.0028759 0.0036788 0.0026314 0.0034715 8 Y-axis errors • Target DYY • • • • • • • • • • • • • 0.0000118 -0.0032729 -0.0048146 -0.0060457 -0.0066843 -0.006398 -0.0171938 -0.0159006 -0.015133 -0.0135387 -0.0133751 -0.0136334 -0.0144286 0.0 20.0 40.0 60.0 80.0 100.0 600.0 620.0 640.0 660.0 680.0 700.0 720.0 DYX 0.0000352 -0.0008479 -0.0014667 -0.0018009 -0.0022469 -0.0023742 -0.0038179 -0.0033269 -0.0033682 -0.0028901 -0.0027834 -0.002417 -0.0019177 DYZ 0.0 -0.0007612 -0.0015055 -0.0024554 -0.0026467 -0.0032861 0.0050573 0.0056786 0.0065169 0.0073864 0.0075783 0.0082402 0.0085888 Z-axis errors • Target DZZ DZX • • • • • • • • • • • • • 0.0000118 -0.010674 -0.018841 -0.0195394 -0.0194431 -0.0193279 -0.0158113 -0.0154574 -0.0158641 -0.015632 -0.0156527 -0.0154328 -0.0160066 -0.0001535 -0.000179 -0.0005031 -0.000539 0.0007003 -0.0020058 0.0013789 -0.0037519 0.0019572 -0.0052592 0.0025898 -0.006708 0.0214316 -0.0265376 0.021957 -0.0272654 0.0221578 -0.0279952 0.0229769 -0.0290042 0.0232969 -0.0304087 0.0237272 -0.0317971 0.0246671 -0.0327949 0.0 20.0 40.0 60.0 80.0 100.0 600.0 620.0 640.0 660.0 680.0 700.0 720.0 DZY Part program without compensation (left) and with compensation (right) 9 Parts machined without compensation (left) and with compensation (right) Measured parts accuracy with and without compensation • The errors in X and Y directions are relatively small. This is because the machine was compensated for lead screw pitch errors. • Without compensation, the squareness error is rather large. Errors in + 45 degrees and -45 degrees are differed by 0.0015” (0.038 mm), which corresponds to a squareness errors of 70.5 arcsec. • With compensation, errors in +45 degrees and – 45 degrees are differed by 0.0003” which corresponds to a squareness error of 14.1 arcsec, a significant improvement. Summary and conclusion The advantages of compensate part program are: • Improves the parts accuracy for any CNC machining centers without high-end controllers. • No need to measure over the whole machine working volume. Only over the part volume is measured. It saves measurement time, more accurate, and more compensation points. • Works in a real shop environment, such as in summer or winter. The measured positioning errors include the effect of material thermal expansions and distortions, and also the angular errors. • It is a more viable or economic approach to improve parts accuracy. 10
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