Mechanism analysis and suppression for chatter and surface location error induced by error compensation

doi:10.1007/s40436-024-00537-6

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (4): 750-767.doi: 10.1007/s40436-024-00537-6

• • 上一篇

Mechanism analysis and suppression for chatter and surface location error induced by error compensation

Guan-Yan Ge¹, Yu-Kun Xiao¹, Jun Lv^1,2, Zheng-Chun Du¹

1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People's Republic of China;
2. Auxiliary Equipment Technology Department, Genertec Machine Tool Engineering Research Institute Co., Ltd. Dalian Company, Dalian, 116000, Liaoning, People's Republic of China

收稿日期:2023-12-26 修回日期:2024-03-08 发布日期:2025-12-06
通讯作者: Zheng-Chun Du Email:E-mail:zcdu@sjtu.edu.cn E-mail:zcdu@sjtu.edu.cn
作者简介:Guang-Yan Ge is a postdoctoral fellow at the School of Mechanical Engineering, Shanghai Jiao Tong University, China. His research interests revolve around advancing the measurement, modeling, and compensation of machining errors during the milling of thin-walled parts.
Yu-Kun Xiao is a Ph.D. student at the School of Mechanical Engineering, Shanghai Jiao Tong University, China. His research interests include the modeling of cutting forces in five-axis milling and the compensation of cuttingforce-induced errors.
Jun Lv is a Ph.D. student at the School of Mechanical Engineering, Shanghai Jiao Tong University, China. His research focuses on advancing the measurement and modeling of thermal errors in NC machining centers.
Zheng-Chun Du is an Associate Professor at the School of Mechanical Engineering, Shanghai Jiao Tong University, China. He received his Ph.D. in Mechanical Engineering from Southeast University. His research interests include the measurement, modeling, and compensation of the comprehensive errors of machine tools, onmachine measurement, and intelligent manufacturing.
基金资助:
This study was supported by the National Natural Science Foundation of China (Grant Nos. 52405556, U22B2086, 52375504), the China Postdoctoral Science Foundation (Grant Nos. 2024M751963, GZC20241006), the Science and Technology Major Project of Genertec (Grant No. GTZD-2022-014), and the Research and Industrialization Entrepreneurship Team Fund for High-Speed and High-Precision Direct Drive Swivel Head of Advanced Five-Axis Machine Tool (Grant No. 2021R02007).

Mechanism analysis and suppression for chatter and surface location error induced by error compensation

Guan-Yan Ge¹, Yu-Kun Xiao¹, Jun Lv^1,2, Zheng-Chun Du¹

1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People's Republic of China;
2. Auxiliary Equipment Technology Department, Genertec Machine Tool Engineering Research Institute Co., Ltd. Dalian Company, Dalian, 116000, Liaoning, People's Republic of China

Received:2023-12-26 Revised:2024-03-08 Published:2025-12-06
Contact: Zheng-Chun Du Email:E-mail:zcdu@sjtu.edu.cn E-mail:zcdu@sjtu.edu.cn
Supported by:
This study was supported by the National Natural Science Foundation of China (Grant Nos. 52405556, U22B2086, 52375504), the China Postdoctoral Science Foundation (Grant Nos. 2024M751963, GZC20241006), the Science and Technology Major Project of Genertec (Grant No. GTZD-2022-014), and the Research and Industrialization Entrepreneurship Team Fund for High-Speed and High-Precision Direct Drive Swivel Head of Advanced Five-Axis Machine Tool (Grant No. 2021R02007).

摘要/Abstract

摘要： Error compensation is an economical and effective technique for achieving high machining accuracy. However, a new phenomenon has been detected in its application: error-compensation excited vibrations and further decreased surface quality in some cases. The mechanism of this phenomenon is important but remains unclear, and its main influencing factor remains an open question. To reveal this mechanism, a stability and surface quality analysis model of the dynamic milling process that considers the influence of error compensation is proposed for the first time. Error compensation can be considered as a quasi-static, periodic forcing term added to the milling system. The quasi-static part changes the cutting width, whereas the periodic forcing part mainly influences the instantaneous undeformed chip thickness, based on which the milling stability and surface location error are derived. Numerical simulations and milling experiments were conducted to validate the proposed model. The experimental results show that error compensation has little influence on milling stability but may decrease the surface quality when the compensation values between compensation cycles change significantly. The proposed method shows great potential for estimating and optimizing error compensation paths and improving the quality of machined surfaces.

The full text can be downloaded at https://doi.org/10.1007/s40436-024-00537-6

关键词: Error compensation, Milling stability, Surface location error

Abstract: Error compensation is an economical and effective technique for achieving high machining accuracy. However, a new phenomenon has been detected in its application: error-compensation excited vibrations and further decreased surface quality in some cases. The mechanism of this phenomenon is important but remains unclear, and its main influencing factor remains an open question. To reveal this mechanism, a stability and surface quality analysis model of the dynamic milling process that considers the influence of error compensation is proposed for the first time. Error compensation can be considered as a quasi-static, periodic forcing term added to the milling system. The quasi-static part changes the cutting width, whereas the periodic forcing part mainly influences the instantaneous undeformed chip thickness, based on which the milling stability and surface location error are derived. Numerical simulations and milling experiments were conducted to validate the proposed model. The experimental results show that error compensation has little influence on milling stability but may decrease the surface quality when the compensation values between compensation cycles change significantly. The proposed method shows great potential for estimating and optimizing error compensation paths and improving the quality of machined surfaces.

The full text can be downloaded at https://doi.org/10.1007/s40436-024-00537-6

Key words: Error compensation, Milling stability, Surface location error

Guan-Yan Ge, Yu-Kun Xiao, Jun Lv, Zheng-Chun Du. Mechanism analysis and suppression for chatter and surface location error induced by error compensation[J]. Advances in Manufacturing, 2025, 13(4): 750-767.

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Mechanism analysis and suppression for chatter and surface location error induced by error compensation

Mechanism analysis and suppression for chatter and surface location error induced by error compensation

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