A novel five-axis on-machine measurement optimization method for complex curved surfaces

Abstract

On-machine measurement (OMM) stands out as a pivotal technology in complex curved surface adaptive machining. However, the complex structure inherent in workpieces poses a significant challenge as the stylus orientation frequently shifts during the measurement process. Consequently, a substantial amount of time is allocated to calibrating pre-travel error and probe movement. Furthermore, the frequent movement of machine tools also increases the influence of machine errors. To enhance both accuracy and efficiency, an optimization strategy for the OMM process is proposed. Based on the kinematic chain of the machine tools, the relationship between the angle combination of rotary axes, the stylus orientation, and the calibration position of pre-travel error is disclosed. Additionally, an OMM efficiency optimization model for complex curved surfaces is developed. This model is solved to produce the optimal efficiency angle combinations for each to-be-measured point. Within each angle combination, the effects of positioning errors on measurement results are addressed by coordinate system offset and measurement result compensation method. Finally, the experiments on an impeller are used to demonstrate the practical utility of the proposed method.

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