Abstract：Thin-walled parts are widely used in aeronautical, aerospace and automotive applications due to their high performance-to-weight ratio. The thin walls in these parts also lead to low rigidity during machining, making them susceptible to deformation under the influence of the cutting force and/or the clamping force. As a result of spring-back effect after machining, significant machining error occurs in the thin-walled workpiece in its stress-free state. Analytical solution and FEM analysis of the deformation phenomenon are not robust against various machining conditions. To address this issue, a comprehensive error compensation scheme is proposed to predict and compensate for three major error sources, i.e. geometric error, thermal error, and force-induced error. The geometric and thermal errors of the machine tool are modeled and compensated to provide high motion precision for on-machine measurement. The force-induced error is obtained using on-machine measurement data. Comprehensive compensation of all three error sources is achieved by transforming individual compensation values into the same coordinate system. A real-time compensation system is developed based on the numerical control system of the machine tool. Compensation experiments carried out on two types of thin-walled parts show (i) a reduction of machining errors by at least 74% and (ii) an improvement of machining productivity by at least 41%, which validates the proposed compensation scheme.
冯晓冰，杜正春，葛广言，肖域坤，朱梦瑞，杨建国. 基于在机测量的薄壁件加工综合误差建模与补偿[J]. 航空制造技术, 2022, 65(6): 14-21.
FENG Xiaobing, DU Zhengchun, GE Guangyan, XIAO Yukun, ZHU Mengrui, YANG Jianguo. Comprehensive Error Modeling and Compensation in Manufacturing of Thin-Walled Parts Based on On-Machine Measurement. Aeronautical Manufacturing Technology, 2022, 65(6): 14-21.
2022, 
