A method for enhancing the effectiveness and robustness of process-intermittent inspection is presented. The method is developed first using mathematical models and measurements closely related to the real parts, thus reducing the uncertainty in both the error estimation and compensation for multi-axis machines. A predictive search algorithm is then developed to identify the minimum number of appropriate measuring points (with respect to the designated tolerance) for arbitrarily shaped manufacturing parts. The identified measuring points are robust in that they least sensitive to uncertainties in measurement and modeling. The search algorithm uses computer simulation with information obtained from previous measurements. Consequently, the measurement effort involved in error modeling has been greatly reduced. The error model derived from the method can be used to correct the process-intermittent probing data for a more accurate assessment of workpiece dimensions. Although the method is designed for general application in multi-axis machines (i.e., machine tools, robots, and coordinate measuring machines), this paper focuses on the specific application of a machining center. Experimental results demonstrate the effectiveness of the error modeling method for accuracy improvement of the machining center for process-intermittent inspection.
Issue Section:
Research Papers
1.
Belforte
G.
Bona
B.
Donati
E.
Ferraris
F.
Gorini
I.
Morei
S.
Peisino
M.
Sartori
S.
1987
, “Coordinate Measuring Machines and Machine Tool Selfcalibration and Error Correction
,” CIRP
, Vol. 36
, No. 1
, pp. 359
–364
.2.
Broderick
P.
Cipra
R.
1988
, “A Method for Determining and Correcting Robot Position and Orientation Errors Due to Manufacturing
,” ASME Journal of Mechanisms, Transmissions, and Automation in Design
, Vol. 110
, pp. 10
10
.3.
Bryan
J.
1982
, “A Simple Method for Testing Measuring Machines and Machine Tools, Part I: Principles and Applications
,” Precision Engineering
, Vol. 4
, pp. 61
–69
.4.
Busch
K.
Kunzmann
H.
Waldele
F.
1985
, “Calibration of Coordinate Measuring Machines
,” Precision Engineering
, Vol. 7
, pp. 139
–144
.5.
Chen
J. S.
Yuan
J. S.
Ni
J.
Wu
S. M.
1993
, “Real-time Compensation for Time-variant Volumetric Errors on a Machine Center
,” ASME Journal of Engineering for Industry
, Vol. 115
, pp. 472
–479
.6.
Donmez
A.
Blomquist
D.
Hocken
R.
Liu
C.
Barash
M.
1986
, “A General Methodology for Machine Tool Accuracy Enhancement by Error Compensation
,” Precision Engineering
, Vol. 8
, pp. 187
–195
.7.
Ferreira
P.
Liu
C.
1986
, “A Contribution to the Analysis and Compensation of the Geometric Error of a Machining Center
,” CIRP
, Vol. 35
, pp. 259
–262
.8.
Hocken
R.
Simpson
A.
Borchardt
B.
Lazar
J.
Reeve
C.
Stein
p.
1977
, “Three Dimensional Metrology
,” CIRP
, Vol. 26
, pp. 403
–408
.9.
Hocken, R., 1980, “Technology of Machine Tools,” Vol. 5: Machine Tool Accuracy, UCRL-52960-5, Lawrence Livermore Laboratory, University of California, Livermore, CA.
10.
Hollerbach, J., 1988, “A Survey of Kinematic Calibration,” Robotics Review, O. Khatib, J. Craig, and T. Lozano-Perez, eds., MIT Press.
11.
Jouy
F.
1986
, “Theoretical Modelisation and Experimental Identification of the Geometrical Parameters of Coordinate-Machines by Measuring a Multi-Directed Bar
,” CIRP
, Vol. 35
, pp. 393
–396
.12.
Knapp
W.
1983
, “Circular Test for Three Coordinate Measuring Machines and Machine Tools
,” Precision Engineering
, Vol. 5
, pp. 115
–124
.13.
Kunzmann
H.
Waldele
F.
1983
, “On Testing Coordinate Measuring Machines (CMM) with Kinematic Reference Standards (KRS)
,” CIRP
, Vol. 32
, pp. 465
–468
.14.
Kunzmann
H.
Trapet
E.
Waldele
F.
1990
, “A Uniform Concept for Calibration, Acceptance Test, and Periodic Inspection of Coordinate Measuring Machines Using Reference Objects
,” CIRP
, Vol. 39
, No. 1
, pp. 561
–564
.15.
Kurtoglu
A.
1990
, “The Accuracy Improvement of Machine Tools
,” CIRP
, Vol. 39
, No. 1
, pp. 417
–419
.16.
Lee, S., 1986, “Accuracy Improvement of a CNC Machining Center by Using a Touch-Trigger Probe and a Metrology Pallet,” Ph.D. Dissertation, Purdue University, W. Lafayette, IN.
17.
Leete
D.
1961
, “Automatic Compensation of Alignment Errors in Machine Tools
,” Int. J. Mach. Tool Des. Res.
, Vol. 1
, pp. 293
–324
.18.
Love, W., and Scarr, A., 1973, “The Determination of the Volumetric Accuracy of Multi-Axis Machines,” M.T.D.R. Conference Proceedings, Vol. 14, pp. 307–315.
19.
Menq
C.
Born
J.
1989
, “Statistical Characterization of Position Errors of an Ensemble of Robots and Its Applications
,” ASME Journal of Mechanisms, Transmissions, and Automation in Design
, Vol. 111
, pp. 215
–222
.20.
Mou, J., 1992, “An Adaptive Methodology for Monitoring and Controlling of Precision Machining and On-machine Inspection,” Ph.D. Dissertation, Purdue University, West Lafayette, IN.
21.
Mou, J., and Liu, C. R., 1995, “An Adaptive Methodology for Machin Tool Errors Correction,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY.
22.
Mou, J., Donmez, M. A., and Cetinkunt, S., 1995, “An Adaptive Methodology Using Features-Based Analysis Techniques for Machine Error Correction: Part I—Theory Derivation,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY.
23.
Mou, J., Donmez, M. A., and Cetinkunt, S., 1995, “An Adaptive Methodology Using Features-Based Analysis Techniques for Machine Error Correction: Part II—Experimental Verification,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY.
24.
Okushima
K.
Kakino
Y.
Higashimoto
A.
1975
, “Compensation of Thermal Displacement by Coordinate System Correction
,” CIRP
, Vol. 24
, No. 1
, pp. 327
–331
.25.
Roth
Z.
Mooring
B.
Ravani
B.
1987
, “An Overview of Robot Calibration
,” IEEE J. Robotics and Automation
, Vol. 3
, No. 5
, pp. 377
–385
.26.
Roe, J., 1986, “Probing for Precision and Productivity,” Biennial International Machine Tool Technical Conference, Vol. 12, pp. 173–180.
27.
Sata
T.
Takeuchi
Y.
Sakamoto
M.
Week
M.
1981
, “Improvement of Working Accuracy on NC Lathe by Compensation for the Thermal Expansion of Tool
,” CIRP
, Vol. 30
, No. 1
, pp. 445
–449
.28.
Schultschik
R.
1977
, “The Components of Volumetric Accuracy
,” CIRP
, Vol. 25
, pp. 223
–227
.29.
Shamma
J.
Whitney
D.
1987
, “A Method for Inverse Robot Calibration
,” ASME Journal of Dynamic Systems, Measurement, and Control
, Vol. 109
, pp. 36
–43
.30.
Sheth
P.
Uicker
J.
1972
, “IMP (Integrated Mechanisms Program), a Computer-Aided Design Analysis System for Mechanisms and Linkages
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 94
, pp. 454
–464
.31.
Takeuchi
Y.
Sakamoto
M.
Sata
Y.
1982
, “Improvement in the Working Accuracy of an NC Lathe by Compensating for Thermal Expansion
,” Precision Engineering
, Vol. 4
, No. 1
, pp. 19
–24
.32.
Teeuwsen
J.
Soons
J.
Schellekens
P.
1989
, “A General Method for Error Description of CMMs Using Polynomial Fitting Procedures
,” CIRP
, Vol. 38
, No. 1
, pp. 505
–510
.33.
Tlusty, J., 1980, “Testing of Accuracy of Machine Tools,” UCRL-52960-Supp. 1, Lawrence Livermore Laboratory, University of California, Livermore, CA.
34.
Week, M., 1984, “Metrological Analysis and Performance Tests,” Handbook of Machine Tools, Vol. 4, Wiley, New York.
35.
Veitschegger
W.
Wu
C.
1988
, “Robot Calibrationand Compensation
,” IEEE J. Robotics and Automation
, Vol. 4
, No. 6
, pp. 643
–656
.36.
Wu
C.
1984
, “A Kinematic CAD Tool for the Design and Control of a Robot Manipulator
,” Int. J. Robotics Research
, Vol. 3
, No. 1
, pp. 58
–67
.37.
Zhang
G.
Ouyang
R.
Lu
B.
Hocken
R.
Veale
R.
Donmez
A.
1988
, “A Displacement Method for Machine Geometric Error of Machining Center
,” CIRP
, Vol. 37
, pp. 515
–518
.38.
Zhuang
H.
Roth
Z.
1991
, “A Unified Approach to Kinematic Modeling, Identification and Compensation for Robot Calibration
,” Control and Dynamic Systems
, C. Leondes, ed., Vol. 39
, pp. 71
–128
.
This content is only available via PDF.
Copyright © 1996
by The American Society of Mechanical Engineers
You do not currently have access to this content.
