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GEOMETRIC ERROR MODELING June 03, 2011

GEOMETRIC ERROR MODELING June 03, 2011. Ronnie R. Fesperman Science Based Manufacturing Group Intelligent Systems Division National Institute of Standards and Technology Gaithersburg, MD.

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GEOMETRIC ERROR MODELING June 03, 2011

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  1. GEOMETRIC ERROR MODELINGJune 03, 2011 Ronnie R. Fesperman Science Based Manufacturing Group Intelligent Systems Division National Institute of Standards and Technology Gaithersburg, MD The full descriptions of the procedures used in this presentation may require the identification of certain commercial products and their suppliers. The inclusion of such information should in no way be construed as indicating that such products or suppliers are endorsed by NIST or are recommended by NIST or that they are necessarily the best materials, instruments, software or suppliers for the purposes described.

  2. Manufacturing Loop Developing methods, models, sensors, and data to improve metrology, machines, and processes 2

  3. Z Y z z z z z F y y y y y z z C y y DMG 70 5-Axis Milling Z Z Y Y z z z z z z z z F F X X Z Z Y Y y y y y y y y y z z s y z T y y w z z C C y y B B 3

  4. +Z +X +Y X +Z +Z +Z +Z +Z +Z +Z +Z +X +X +X +X +X +X +X +X +Y +Y +Y +Y +Y +Y +Y +Y B F Y W Z S C T PT E PW Transformation Chain 1 Chain 2 4

  5. Translation & Rotation 5

  6. +z +Y +X EZX EXX ECX EYX EAX EBX Linear Axis Errors EAX – rotation about the x-axis (roll) EBX – rotation about the y-axis (yaw) ECX – rotation about the z-axis (pitch) EXX – linear positioning in x-axis EYX – straightness in y-axis EZX – straightness in z-axis E offset 6

  7. Measurement 7

  8. Error Plot Example 8

  9. Functional Point Example See Separate Document 9

  10. +z +Y +X +Z COX COY +Z +Z EZX Y0Y EXX ECX +X +Y +Y EYX +X +X +Y ECY EZY EAX EBX EYY AOY AOZ BOX BOZ EZZ EXY EXZ ECZ EBY EAY EYZ EAZ EBZ Alignment Errors 10

  11. Linear Axes Transformations 11

  12. Measurement 12

  13. +Za C EZC ECC EYC EXC EBC EAC +Ya +Xa Rotary Axis Error EAC – angular error motion about the X-axis EBC – angular error motion about the Y-axis ECC – angular position error motion of C EXC – radial error motion of C in the X-axis direction EYC – radial error motion of C in the Y-axis direction EZC – axial error motion of C in the Z-axis direction 13

  14. +Za C COC YOC XOC BOC AOC +Ya +Xa Rotary Axis Error AOC – orientation error about the X-axis BOC – orientation error about the Y-axis COC – angular location error of C-zero XOC – radial location error of C in the X-axis direction YOC – radial location error of C in the Y-axis direction 14

  15. Measurements 15

  16. +Z +X +Y X +Z +Z +Z +Z +Z +Z +Z +Z +X +X +X +X +X +X +X +X +Y +Y +Y +Y +Y +Y +Y +Y B F Y W Z S C T PT E PW Transformation Chain 1 Chain 2 16

  17. Measurement Point Measurement Point 17

  18. Error Simulator Machine Specific XML File Cutter Location Data Geometric Error Model Feature Analysis Results 18

  19. Machine Tool Error Simulator 19

  20. Circular Contour Results 20

  21. Ballbar 21

  22. Deviation (mm) Rotary Table Angle (degrees) R-Test 22

  23. Tetrahedron 23

  24. Questions ? 24

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