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Volume 9, No. 28, Dec. 2015, pages 96102
Research Article
DOI: 10.12913/22998624/60793
Received: 2015.09.21
Accepted: 2015.11.14
Published: 2015.12.04
ABSTRACT
This paper presents the evaluation of the influence of the feedmotion speed on the
value of selected geometric errors of CNC lathe CTX 310 eco by DMG, indentified by QC 20 Ballbar system. Diagnostically evaluated were: the deviation of the
axis squareness, reversal spike, and backlash. These errors determine the forming
of the dimensional and shape accuracy of a machine tool. The article discusses
the process of the CNC diagnostic test, the diagnostic evaluation and formulates
guidelines on further CNC operation. The results of measurements were presented
in tables and diagrams.
Keywords: CNC machine tool, CNC Lathe QC 20 Ballbar, diagnostics systems, accuracy, geometric errors, deviation, squareness, reversal spike, backlash.
INTRODUCTION
The diagnostics of CNC machines is the main
task during the technological machine operation.
Each machine tool during operation is prone to
wearing down over a time span. Therefore, it
should be tested periodically and its geometric condition diagnosed at a required frequency.
Both the machines already in operation as well
as the machines ordered by buyers are diagnosed.
Each such machine is tested and checked before
it arrives at the customers. Both contact and noncontact methods are used in tests [110]. Frequently, some of the measured errors need specialist testing methods, and in general, these are
non-contact interferometric methods. The fundamental limitation of the stationary interferometric methods in the machine measurements is the
considerable time amount needed to set the interferometers optics, especially for the machines
of a tooling range over a few meters. The possibility of measuring the whole tooling axis and
obtaining error information at the full range motion [15] constitutes an undisputable advantage.
The second group of diagnostic tools are the tools
96
a)
b)
c)
Fig. 1. CNC diagnostic systems: a) QC 20 Ballbar Renishaw, b) Ballbar API Automated Precision Inc.
c) Ballbar DBB 110 by DMG [616]
97
a)
b)
c)
a)
b)
Fig. 5. CNC lathe diagnostics kit: a) tool holder and the holder spindle, b) system mounted on the lathe
98
Fig. 8. Reverse spike error diagram: a) process of circle measurement of reverse spike,
b) idea of error formation [14]
99
the QC Ballbar diagnostics system with the kinematic bar length R = 50 mm was used.
Figure 11 presents the diagram of changes of
the backlash as a function of feedmotion speed
variability. The diagram shows that the backlash
is of non-linear character. The smallest value for
the backlash in X-axis was observed for vf3 =
1500 mm/min and is 1 m, and for Z-axis for vf2
= 1000 mm/min and equals 1.9 m.
served specifically in lathes with indirect measuring system. To delete the error it is necessary to
remove the cause, that is to delete the backlashes
in the measurement or motor system. It is also
possible to compensate for the backlash directly
in the control system of the lathe but it requires
thorough measurement of the positioning accuracy along the entire length of the axis feedmotion
[14]. During the reversal spike error identification
CONCLUSIONS
The presented test results of the geometric accuracy relate to the numerically controlled CTX
310 eco lathe. QC20-W Ballbar diagnostic kit
was the measuring and control device. The tests
aimed at defining and characterising main geometric errors of the machine tool, i.e. roundness
error, axis squareness error, reverse spike and
backlash. Numerous different errors measurements may be carried out using QC20-W Ballbar
system. However, the errors analysed here, have
the greatest impact on the dimensional and shape
accuracy of machining.
Fig. 10. Schematic example of backlash: a) error diagram, b) reason for error formation [14]
Fig. 11. Backlash as function of feedmotion speed for: measuring radius R = 50 mm,
XZ measurement plane and test angle of 360
100
the feedmotion speed. It can result from an incorrect motor regulation, inter alia, wrongly selected
backlashes, as well as the backlashes resulting
from the lathes elements wear. The squareness
stems from the misalignment of the slideways
relative to each other, as well as their wear and
deformation. In order to avoid the error increase
it is necessary to control the slideways condition
and the correction of their alignment.
CTX 310 eco lathe meets expectations, however, it is hard to state it clearly for the reason that
the working area of the machine tool is limited. It
prevents more tests using various length of the kinematic bar, and therefore, the measurement had
to be made at one measurement position.
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