identification of geometric errors of a mikron 5-axis

Laboratoire commun de métrologie LNE-Cnam

Fabien VIPREY – LNE – LURPA [email protected]

[email protected]

Personal professional page on LURPA website

Christophe TOURNIER – LURPA

Sylvain LAVERNHE – LURPA

Hichem NOUIRA – LNE

Identification of geometric errors of a MIKRON 5-axis machine-tool using the 3D

hole-bar standard and laser tracer interferometer system

Laboratoire Universitaire en Production Automatisée ENS Cachan

mailto:[email protected]




http://www.lurpa.ens-cachan.fr/version-anglaise/people/ph-d-students/fabien-viprey-222452.kjsp?RH=ZYZYZYZYZYZYZYZYZYZYZY






Causes of this effect:

Introduction : Volumetric accuracy

5-axis machine-tool (Mikron UCP710 at LURPA)

Kinematic Architecture

Rotary Table

Swiveling axis

Gap between theoretical

kinematic and real kinematic

Geometric errors

Thermo-mechanical phenomena

Environmental hazards

Dynamic forces

Heats

CNC

Vibrations

…

[Mekid2012]

[Schwenke2008]

Workshop at NPL: Identification of geometrics errors of a MIKRON 5-axis machine-tool using

the 3D hole-bar standard and laser tracer interferometer system

2

Introduction : Volumetric accuracy

International standard [ISO230-1,2012]:

The aim of this study is to develop a material standard to 21 errors evaluation [Bourdet87]:

- Usable on CMM, 3 or 5 machine-tool, by on-line measurement with accuracy

of the results

- With large field of its application: Metrology room or Manufacturing shop

- With constraint of time: Adjustment + Measurement < 10 + 15 min



3

Outline

Literature review

Stage of development

Design of pattern: Hole Bar

Technical attributes

Mesurement process

Calibration and strategy of error measurement with hole bar

Evaluation of 21 geometric errors: Hole bar

Evaluation of 21 geometric errors: Laser Tracer

Results

Geometric errors: Laser Tracer

Geometric errors: Hole bar

Conclusion and further works



4

Conscious decision: Development of bar with pattern which allow to maximize ,

minimizing maintenance downtime

Reference

Metrology

room and

Shop

= Evaluated errors/Number

of standard position

Time of adjustment

and measurement

Accuracy and size

of error mapping

1 [Trapet1991]

[Bringmann2009] /

/

21/4 = 5,25

21/5 = 4,2 /

/

/

/

2 [Zhang1991]

[Lim2005] /

/

21/?

21/17 = 1,23 ?

/

/?

/

3 [ISO 230-1] / ≤ 1 / /

4 [Schwenke2005]

[Chen1999] /

/

21/6 = 3,5

21/3 = 7 /

?/

/

/?

Introduction : Literature review

Hole plate

Conventional method

2 4

3 Ball plate Ball Bar

1 Hole Bar

Laser Interferometry (On-line measurement)



5

Outline

Literature review




Mesurement process




Results




Workshop at NPL: Identification of geometrics errors of a

MIKRON 5-axis machine-tool using the 3D hole-bar standard

and laser tracer interferometer system

6

Design of pattern: Hole bar

The pattern is composed of planes, cylinders and holes:

Assessment:

3 intrinsic errors: 1 linear positioning error, 2 two straightness errors between Oi and Oi+1

Issue: On-line measurements can be performed in harsh environment:

ships, oils, temperature gradient, risk of collision

Necessity to choose technical attributes

[ISO 5459:2011]

Workshop at NPL: Identification of geometrics errors of a

MIKRON 5-axis machine-tool using the 3D hole-bar standard

and laser tracer interferometer system

7

(Xi, Yi, Zi)

Solution:

- All geometry entity and

number of pattern

can be parameterized


Material Proposed

geometry

Assembly on

CMM or MT

Constraints:

- Harsh environment

- Gradient of temperature

- Risk of collision

Solution: INVAR

- CTE < 1,5 µm.K-1.m-1

- Ni-Fe alloy has a better

toughness and a less

brittleness than ceramic

engineering or Zerodur

Constraints:

- Harsh environment

- Risk of collision

- Accessibility

- Mistake-proofing

Constraints:

- Consider all admissible

positionning

- Minimize distortion of hole bar

Solution:

- Assembly with modular

inspection equipment system

L

Metrology

room/Shop

= Evaluated error/Number


Time of adjustment

and measurement

Accuracy/size of

error mapping

Hole bar / ? / ?



8

Outline

Literature review




Mesurement process




Results






9

Calibration of hole bar

10

Calibration was performed on CMM by reversal method [Evans1996]

Hole bar (no reversal)

Hole bar (after reversal)



Linear positioning error motion of holes

Straightness error motion of holes

in Y-direction

Straightness error motion of holes

in Z-direction

Strategy of error measurement with hole bar

Real time

probing

Developed end user interface

F=33,33 kHz

T=30 µs

Resolution = 10 nm

U(k=2) RMP600 = 0,25 µm

Udelay max at 240mm/min = 0,47µm

Probing

trajectory

Vf rapid = 1000 mm/min

Vf probing = 240 mm/min

Mikron UCP710



11


Assessment:

11 positions of hole bar 21 errors in 3-axis machine-tool;

7 positions of hole bar 21 errors in 3-axis machine-tool + A,C axis (5-axis positional machine).

+ -

+ -

+ -

Eax(X), Ebx(X)

Exx(X), Eyx(X), Ezx(X)

Ecx(X) (Eax(X))

differential

straightness

measurement

[ISO 230-1]

differential

straightness

measurement

[ISO 230-1]

Calibration

Metrology

room/Shop

= Evaluated error/Number


Time of adjustment

and measurement

Accuracy/size of

error mapping

Hole bar, 3-axis MT

Hole bar , 3-axis + (A,C) / 21/11 = 1,91

21/7 = 3 / ?

Calibration



12


tracking interferometer using the multilateration method

6 positions of Laser with 4 positions of reflector:

Pos 1 285 points of measure | 15 min






Laser Tracer U(k=2) = 0,3 µm

[Schwenke2005]

[Linares2014]



13

Outline

Literature review




Mesurement process




Results






14


Xm

µm

Linear positioning error motion of X-axis

EXX

for programmed XYZ

EXX

for measured XYZ encoders

Xm

µm

Straightness errors motion of X-axis

EYX

Xm

µm


EZX

Xm

µm


EXX

for programmed XYZ

EXX

for measured XYZ encoders

Xm

µm


EYX

Xm

µm


EZX



15

Linear positioning error motion Exx of X-axis Straightness error motion Eyx of X-axis

Straightness error motion Ezx of X-axis

Xm

µm


Exx for X-programmed

Exx for X-encoders

Exx enc - Exx prog

Siemens MSECX

Xm

µm

Residu between Exx enc - Exx prog

and Siemens MSECX

Ymµm

Linear positioning error motion of Y-axis

Eyy for Y-programmed

Eyy for Y-encoders

Eyy enc - Eyy prog

Siemens MSECY

Ym

µm

Residu between Eyy enc - Eyy prog

and Siemens MSECY

Zm

µm

Linear positioning error motion of Z-axis

Ezz for Z-programmed

Ezz for Z-encoders

Ezz enc - Ezz prog

Siemens MSECX

Zm

µm

Residu between Ezz enc - Ezz prog

and Siemens MSECZ




16

Linear positioning error motion EXX of X-axis Linear positioning error motion EYY of Y-axis Linear positioning error motion EZZ of Z-axis

Residu between EXX enc – EXX prog

and Siemens MSECX

Residu between EYY enc – EYY prog

and Siemens MSECY

Residu between EZZ enc – EZZ prog

and Siemens MSECZ

Xm

µm

Linear positioning error motion Exx of X-axis

1

2

3

4

5

Xm

µm

Straightness error motion Eyx of X-axis

1

2

3

4

5

Xm

µm


1

2

3

4

5

Xm

µm

Linear positioning error motion Exx of X-axis

1

2

3

4

5

Xm

µm

Straightness error motion Eyx of X-axis

1

2

3

4

5

Xm

µm


1

2

3

4

5

17 Workshop at NPL: Identification of geometrics errors of a MIKRON 5-axis machine-tool using



Linear positioning error motion Exx of X-axis Straightness error motion Eyx of X-axis


Outline

Literature review




Mesurement process




Results






18

Conclusion

The aim of this study was to develop a material standard to 21 errors evaluation:

- Usable on CMM, 3 or 5 machine-tool, by on-line measurement, with large field of its

application: Metrology room or Manufacturing shop

material and design to face up to harsk environment and temperature gradient

- With constraint of time: Adjustment + Measurement < 10 + 15 min

Using modular inspection equipment system and rotary axis to manage adjustment

Using of developped real time 5-axis probing interface and CAM process on Matlab to

manage measurement

- Accuracy of the results

Comparison of results with well known multilateration measurement process (eTALON)

Tracability of calibration on CMM?

Repeatability of RMP600 (as new)?

Reliability of post-processing?

Validate the various post-processing steps

IMPACT: The 2nd MACROSCALE conference, Wien (Austria), Oct 2014

Reference

Metrology

room and

Shop

= Evaluated error/Number of

standard position

Time of adjustment

and measurement

Accuracy and size

of error mapping

Hole bar, 3-axis MT

Hole bar , 3-axis + (A,C)

/

21/11 = 1,91

21/7 = 3 / ?



19

Further works

Evaluation of temperature influence measures under variable temperature

Expression of uncertainty in measurement (adaptative MC – GUM S1)

Evaluation of errors motion of rotary axis With hole bar or an other novel strategy

Evaluation of others squareness errors on 5-axis machine-

tool (in work) Litterature review

Geometric error modeling

Virtual Nominal/non ideal Machine Tool

Physical procedure for identification

Model for compensation

Compensation



20

IMPACT:

The 11th International Conference

LAMDAMAP 2015, University of

Huddersfield, (UK), March 2015

Laboratoire commun de métrologie LNE-Cnam

Thank you for your attention!

The authors sincerely thank the EMRP organization. The EMRP is jointly funded

by the EMRP participating countries within EURAMET and the European Union

(IND62: JRP-TIM)

Laboratoire Universitaire en Production Automatisée ENS Cachan

Fabien VIPREY – LNE – LURPA [email protected]

[email protected]

Personal professional page on LURPA website

Christophe TOURNIER – LURPA

Sylvain LAVERNHE – LURPA

Hichem NOUIRA – LNE





References

[Bourdet, 1987] Bourdet (1987). Contribution a la Mesure Tridimensionnelle : Modèle d’identification geométrique des surfaces,

Métrologie fonctionnelle des pièces mécaniques, Correction geométrique des machines a mesurer tridimensionnelles. Doctorat

d’etat et sciences physiques, Univ. NANCY 1.

[Bringmann2009] B. Bringmann, W. Knapp, Machine tool calibration: Geometric test uncertainty depends on machine tool

performance, Precision Engineering, Vol. 33, Issue 4, 2009, pp. 524-529

[Chen1999] Jenq Shyong Chen et al., Geometric error calibration of multi-axis machines using an auto-alignment laser

interferometer, Precision Engineering, Vol. 23, Issue 4, 1999, pp. 243-252

[Evans1996] Chris J. Evans et al., Self-Calibration: Reversal, Redundancy, Error Separation, and ‘Absolute Testing’, CIRP

Annals - Manufacturing Technology, Vol. 45, Issue 2, 1996, pp. 617-634

[ISO 230-1] ISO 230-1:2012, Test code for machine tools -- Part 1: Geometric accuracy of machines operating under no-load or

quasi-static conditions

[ISO 5459:2011] ISO 5459:2011, Geometrical product specifications (GPS) -- Geometrical tolerancing -- Datums and datum

systems

[Lim2005] C.K Lim, M. Burdekin, Rapid volumetric calibration of coordinate measuring machines using a hole bar artefact,

Proceedings of the Institution of Mechanical Engineers. Part B. Journal of engineering manufacture, 2002, Vol. 216, Issue 8,

2002, pp. 1083-1093

[Linares2014] Jean-Marc Linares et al., Impact of measurement procedure when error mapping and compensating a small CNC

machine using a multilateration laser interferometer, Precision Engineering, Vol. 38, Issue 3, 2014, pp 578-588

[Mekid2012] S. Mekid, T. Ogedengbe, A review of machine tool accuracy enhancement through error compensation in serial and

parallel kinematic machines, International Journal of Precision Technology, Vol. 1, Issue 3, 2010, pp. 251-286

[Schwenke2005] H. Schwenke et al., Error mapping of CMMs and machine tools by a single tracking interferometer, CIRP Annals

- Manufacturing Technology, Vol. 54, Issue 1, 2005, pp. 475-478

[Schwenke2008] H. Schwenke et al., Geometric error measurement and compensation of machines—An update, CIRP Annals -

Manufacturing Technology, Vol. 57, Issue 2, 2008, pp. 660-675

[Trapet1991] E Trapet, F Wäldele, A reference object based method to determine the parametric error components of coordinate

measuring machines and machine tools, Measurement, Vol. 9, Issue 1, 1991, pp. 17-22

[Zhang1991] G.X. Zhang, Y.F. Zang, A Method for Machine Geometry Calibration Using 1-D Ball Array, CIRP Annals -

Manufacturing Technology, Vol. 40, Issue 1, 1991, pp. 519-522



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identification of geometric errors of a mikron 5-axis

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