This study develops an automated geometric error measurement and compensation system for the dual rotary axes (A- and B-axes) of a horizontal five-axis machining center in accordance with ISO 230 standards. A single-point touch probe, homogeneous transformation matrices, and a two-stage batch analysis strategy are employed to identify location and motion-dependent errors. The system integrates OPC UA communication to automatically generate and import volumetric compensation data into the CNC controller. Experimental results and NAS979 cutting tests confirm that the proposed approach significantly improves rotary-axis accuracy and overall volumetric precision.
In today’s landscape, where smart manufacturing has become the core competitive advantage of the industry, machining simulation and verification have evolved from auxiliary tools to critical components ensuring the reliability and efficiency of digital manufacturing. With the rapid popularization of automation and AI, the design of toolpaths and machining parameters is shifting from manual expertise toward algorithmic generation. While this significantly enhances design efficiency and innovation speed, it introduces a pivotal challenge: how to verify that automatically generated data can be executed safely on actual production lines while maintaining quality.
With the advancement of modern manufacturing technology and the increasing demand for high-precision and high-efficiency machining, five-axis machine tools have been widely applied in aerospace, automotive manufacturing, and other industries. However, high-precision machining also introduces complex challenges in error control, which directly affect product quality and machine tool lifespan. Therefore, the measurement of errors in five-axis machine tools has become an important research topic.
This article explores the positioning accuracy of Tsudakoma’s cradle-type tilting axis, measured using an angular swing inspection instrument. It compares the differences between enabling and disabling the angle encoder. Results show that when the encoder is enabled, positioning accuracy and repeatability are excellent, with compensated error reduced to 4.7 arc-seconds. When the encoder is disabled, non-linear errors occur within the ±10° range, reaching up to 155 arc-seconds. The study indicates that 1° incremental measurement can reveal structural characteristics, providing valuable reference for five-axis machine development.
This study investigates the accuracy of domestic five-axis machine tools, measuring linear axis six degrees of freedom, rotary axis positioning, circular interpolation, spatial diagonal accuracy, and tool-tip synchronous motion. Results indicate most machines meet ISO 10791 standards, with some achieving half the tolerance limits. Rotary axis errors are linked to geometric accuracy, rotary center alignment, and control parameters. Compensation and parameter adjustments are recommended to optimize precision and enhance machining quality.
