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2 Journal of Machine Engineering

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An investigation of the relationship between encoder difference and thermo-elastic machine tool deformation

Brecher Christian, Dehn Mathias, Neus Stephan

Journal of Machine Engineering

2023

Vol. 23, No. 3

26--37

New approaches, using machine learning to model the thermo-elastic machine tool error, often rely on machine internal data, like axis speed or axis position as input data, which have a delayed relation to the thermo-elastic error. Since there is no direct relation to the thermo-elastic error, this can lead to an increased computation inaccuracy of the model or the need for expensive sensor equipment for additional input data. The encoder difference is easy to obtain and has a direct relationship with the thermo-elastic error and therefore has a high potential to improve the accuracy thermo-elastic error models. This paper first investigates causes of the encoder difference and its relationship with the thermo-elastic error. Afterwards, the model is presented, which uses the encoder difference to compute the thermo-elastic error. Due to the complexity of the relationship, it is necessary, to use a machine learning approach for this. To conclude, the potential of the encoder difference as an input of the model is evaluated.

Increasing productivity of cutting processes by real-time compensation of tool deflection due to process forces

Brecher Christian, Wetzel Arndt, Berners Thomas, Epple Alexander

Journal of Machine Engineering

2019

Vol. 19, No. 1

16--27

The Internet of Production (IoP) describes a vision in which a broad range of different production data is available in real-time. Based on this data, for example, new control types can be implemented, which improve individual manufacturing processes directly at the machine. A possible application scenario is a tool deflection compensation. Although the problem of tool deflection is well known in the industrial field, a process-parallel compensation is not common in industrial applications. State-of-the-art solutions require time and cost consuming tests to determine necessary cutting parameters. An NC-integrated compensation that adapts the tool path in real-time will make these tests obsolete and furthermore enables higher chip removal rates. In this paper, a control-internal real-time compensation of tool deflection is described, which is based on a process-parallel measurement of process forces. The compensation software is designed as an extension to the NC kernel and thereby integrated into the position control loop of an in-series NC. The compensation movements are generated by manipulating the reference values of the feed axes. The approach is investigated by experiments with linear axis movements. During these tests, a significantly reduction of geometrical machining errors is possible.