Skip to main content
Disciplines
Automotive Business IT + Informatics Construction + Real Estate Electrical Engineering + Electronics Energy + Sustainability Insurance + Risk Finance + Banking Management + Leadership Marketing + Sales Mechanical Engineering + Materials
Events
DE
EN
Books
Journals
Topic Page
Marketing
Start single access now
Access for companies
EXTENDED SEARCH
Log in
Top
The International Journal of Advanced Manufacturing Technology

13-12-2019 | ORIGINAL ARTICLE

Dynamic error of CNC machine tools: a state-of-the-art review

Authors: Dun Lyu, Qing Liu, Hui Liu, Wanhua Zhao

Published in: The International Journal of Advanced Manufacturing Technology

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

The dynamic error of CNC machine tools, which often exceeds the quasi-static error at high-speed machining, becomes the main reason affecting the machining error of the sculptured surface parts. Although much research efforts have been dedicated to dynamic error, there is a lack of systematical summaries. In this review, firstly, the dynamic error is defined as the deviation of actual displacement of effector end of axis relative to reference displacement during feed motion. Secondly, according to the mechanical and control structure of the servo feed system, the dynamic error is divided into two components: dynamic error inside the servo loop (component 1) and dynamic error outside the servo loop (component 2). Based on the two components, the causes resulting in the dynamic error are analyzed from the points of view of the servo feed system itself and its input (setpoints). Thirdly, the basic strategies for reducing the dynamic error of individual axis, as well as for reducing the trajectory dynamic error by coordinating the dynamic error of individual axis, are summarized. Finally, the problems and future research directions on dynamic error are analyzed. It is concluded that resolving the contradiction between the setpoints and the servo feed system is still a great challenge for dynamic error in high-speed machining. To achieve high dynamic accuracy at high-speed machining, the control strategies on the dynamic error outside the servo loop should be further developed and integrated into dynamic error inside the servo loop-oriented control strategies. Meanwhile, the servo feed system itself and its input need to be investigated as a whole, so that the servo feed system of each axis can adapt to the differences and changes of the setpoints, and the differences in the servo dynamics of each axis can be considered in the setpoints.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

inform now
Literature
1.
Huo F, Poo A-N (2013) Precision contouring control of machine tools. Int J Adv Manuf Technol 64:319–333
2.
3.
Weekers WG, Schellekens PHJ (1995) Assessment of dynamic errors of CMMs for fast probing. CIRP Ann Manuf Technol 44(1):469–474
4.
Ma J, Lu D, Zhao W (2015) Assembly errors analysis of linear axis of CNC machine tool considering component deformation. Int J Adv Manuf Technol 12:1–9
5.
Li Y, Zhao W, Lan S, Ni J, Wu W, Lu B (2015) A review on spindle thermal error compensation in machine tools. Int J Mach Tool Manu 95:20–38
6.
7.
8.
9.
Ibaraki S, Knapp W (2012) Indirect measurement of volumetric accuracy for three-axis and five-axis machine tools: a review. Int J Autom Technol 6(2):110–124
10.
11.
12.
Neugebauer R, Denkena B, Wegener K (2007) Mechatronic systems for machine tools. Ann CIRP 56(2):657–686
13.
Schmitz TL, Ziegert JC, Canning JS, Zapata R (2008) Case study: a comparison of error sources in high-speed milling. Precis Eng 32:126–133
14.
15.
16.
Altintas Y, Verl A, Brecher C, Uriarte L, Pritschow G (2011) Machine tool feed drives. CIRP Ann Manuf Technol 60:779–796
17.
Koren Y, Lo CC (1992) Advanced controllers for feed drives. Annals of the CIRP 41(2):689–698
18.
Koren Y (1997) Control of machine tools. J Manuf Sci Eng Trans ASME 119(11):749–755
19.
Ramesh R, Mannan MA, Poo AN (2005) Tracking and contour error control in CNC servo systems. Int J Mach Tool Manu 45:301–326
20.
Tang L, Landers RG (2013) Multiaxis contour control—the state of the art. IEEE Trans Control Syst Technol 21(6):1997–2010
21.
Liang T, Lu D, Yang X, Zhang J, Ma X, Zhao W (2016) Feed fluctuation of ball screw feed systems and its effects on part surface quality. Int J Mach Tool Manu 101:1–9
22.
Kamalzadeh A, Erkorkmaz K (2007) Accurate tracking controller design for high speed drives. Int J Mach Tool Manu 47(9):1393–1400
23.
Yang XJ, Lu D, Zhang J, Zhao WH (2015) Investigation of the displacement fluctuation of the linear motor feed system considering the linear encoder vibration. Int J Mach Tool Manu 98:33–40
24.
Mutilba U, Gomez-Acedo E, Kortaberria G, Olarra A, Yagüe-Fabra JA (2017) Traceability of on-machine tool measurement: a review. Sensors 17:1–38
25.
26.
27.
Chiu GTC, Yao B (1997) Adaptive robust contour tracking of machine tool feed drive systems—a task coordinate frame approach. Paper presented at the Proceedings of the American Control Conference, Albuquerque, New Mexico, June 1997
28.
29.
30.
31.
32.
33.
34.
Zhao W, Zhang J, Liu H, Yang X (2013) New evaluation method on the precision of NC machine tools. Eng Sci 15(1):93–98
35.
Slamani M, Mayer R, Balazinski M, Zargarbashi SHH, Engin S, Lartigue C (2010) Dynamic and geometric error assessment of an XYC axis subset on five-axis high-speed machine tools using programmed end point constraint measurements. Int J Adv Manuf Technol 50:1063–1073
36.
Slamani M, Mayer R, Balazinski M (2013) Concept for the integration of geometric and servo dynamic errors for predicting volumetric errors in five-axis high-speed machine tools: an application on a XYC three-axis motion trajectory using programmed end point constraint measurements. Int J Adv Manuf Technol 65:1669–1679
37.
Zhong L, Bi Q, Huang N, Wang Y (2018) Dynamic accuracy evaluation for five-axis machine tools using S trajectory deviation based on R-test measurement. Int J Mach Tools Manuf 125:20–33
38.
39.
Kono D, Weikert S, Matsubara A, Yamazaki K (2012) Estimation of dynamic mechanical error for evaluation of machine tool structures. Int J Autom Technol 6(2):147–153
40.
41.
42.
43.
Sugie T, Iwasaki T, Nakagawa H, Kohda S (1999) Compensation for the exponential type lost motion to improve the contouring accuracy of NC machine tools. Paper presented at the IECON’99. Conference Proceedings. 25th Annual Conference of the IEEE Industrial Electronics Society (Cat. No.99CH37029), 29 Nov.-3 Dec. 1999
44.
Sugie T, Iwasaki T, Nakagawa T, Kohda T (2000) Compensation for position-varying lost motion to improve the contouring accuracy of NC machine tools. Paper presented at the 2000 26th Annual Conference of the IEEE Industrial Electronics Society. IECON 2000. 2000 IEEE International Conference on Industrial Electronics, Control and Instrumentation. 21st Century Technologies, 22–28 Oct. 2000
45.
46.
47.
Wu N, Hu R, Sun Q (2004) Influence of rigidity of feed system with ball screw in NC lathe on positioning precision. Eng Sci 6(9):46–49
48.
Dong C, Zhang C, Wang B, Zhang G (2002) Prediction and compensation of dynamic errors for coordinate measuring machines. J Manuf Sci Eng Trans Asme 124(3):509–514
49.
Weekers W (1996) Compensation for dynamic errors of coordinate measuring machines. Eindhoven University of Technology
50.
Ahmadian MT, Vossoughi GR, Ramezani S (2007) Dynamic error analysis of gantry type coordinate measuring machines. Sci Iran 14(3):278–290
51.
Bringmann B, Maglie P (2009) A method for direct evaluation of the dynamic 3D path accuracy of NC machine tools. CIRP Ann Manuf Technol 58:343–346
52.
Parenti P, Albertelli P, Cau N, Bianchi G, Monno M (2011) A mechatronic study on a model-based compensation of inertial vibration in high speed machine tool. J Mach Eng 11(4):91–104
53.
Knapp W, Weikert S (1999) Testing the contouring performance in 6 degrees of freedom. Ann CIRP 48:433–436
54.
55.
Thoma SM, Haas T, Nguyen H, Weikert S, Wegener K (2015) In- and cross-talk evaluation of different machine concepts. Paper presented at the 11th international conference and exhibition on laser metrology, coordinate measuring machine and machine tool performance, LAMDAMAP 2015, Huddersfield, UK, March 17–18, 2015
56.
Nguyen MH, Weikert S, Wegener K (2012) Evaluation method of acceleration correlated position errors in machine tools. Br Med J 1(5):1327–1328
57.
58.
Mu YH, Ngoi BKA (1999) Dynamic error compensation of coordinate measuring machines for high-speed measurement. Int J Adv Manuf Technol 15:810–814
59.
ISO (2009) Test code for machine tools. Part 8. Determination of vibration levels. ISO/DIS 230-8. Geneva
60.
Andolfatto L, Lavernhe S, Mayer JRR (2011) Evaluation of servo, geometric and dynamic error sources on five-axis high-speed machine tool. Int J Mach Tool Manu 51:787–796
61.
62.
63.
Koren Y (1980) Cross-coupled biaxial computer control for manufacturing systems. ASME Trans J Dyn Syst Meas Control 102:265–272MATH
64.
Tomizuka M (1987) Zero phase error tracking algorithm for digital control. ASME Trans J Dyn Syst Meas Control 109(1):65–68MATH
65.
Funahashi Y, Yamada M (1993) Zero phase error tracking controllers with optimal gain characteristics. J Dyn Syst Meas Control Trans Asme 115(3):311–318MATH
66.
Rahaman M, Seethaler R, Yellowley I (2015) A new approach to contour error control in high speed machining. Int J Mach Tool Manu 88:42–50
67.
Li XW, Zhang J, Zhao WH, Lu BH (2016) A zero phase error tracking based path pre-compensation method for high speed machining. J Mech Eng Sci 230(2):230–239
68.
Chen X, Liu C, Zhou N, Wang B (2014) Controller design based on ZPETC-FF and DOB for precision motion platform. J Harbin Inst Technol 46(1):1–6MathSciNet
69.
Wang L, Li X (2014) Zero phase adaptive robust control of direct drive XY table. J Shenyang Univ Technol 36(2):121–126MathSciNet
70.
Smith DA (1999) Wide bandwidth control of high-speed milling machine feed drives. University of Florida
71.
Chen YC, Tlusty J (1995) Effect of low friction guideways and leadscrew flexibility on dynamics of high-speed machines. CIRP Ann Manuf Technol 44(1):353–356
72.
Erkorkmaz K, Kamalzadeh A (2007) Compensation of axial vibrations in ball screw drives. CIRP Ann Manuf Technol 56(1):373–378
73.
Erkorkmaz K, Kamalzadeh A (2006) High bandwidth control of ball screw drives. CIRP Ann Manuf Technol 55(1):393–398
74.
Altintas Y, Erkorkmaz K, Zhu WH (2000) Sliding mode controller design for high speed feed drives. CIRP Ann Manuf Technol 49:265–270
75.
Okwudire C, Altintas Y (2009) Minimum tracking error control of flexible ball screw drives using a discrete-time sliding mode controller. ASME Trans J Dyn Syst Meas Control 131:051006
76.
Pritschow G, Croon N (2013) Ball screw drives with enhanced bandwidth by modification of the axial bearing. CIRP Ann Manuf Technol 62:383–386
77.
Verl A, Frey S (2012) Improvement of feed drive dynamics by means of semi-active damping. CIRP Ann Manuf Technol 61(1):351–354
78.
Sun Z, Pritschow G, Lechler A (2016) Enhancement of feed drive dynamics using additional table speed feedback. CIRP Ann Manuf Technol 65(1):357–360
79.
Sun Z, Zahn P, Verl A, Lechler A (2017) A new control principle to increase the bandwidth of feed drives with large inertia ratio. Int J Adv Manuf Technol 91:1747–1752
80.
Sun Z, Pritschow G, Zahn P, Lechler A (2018) A novel cascade control principle for feed drives of machine tools. CIRP Ann Manuf Technol
81.
Sencer B, Dumanli A (2017) Optimal control of flexible drives with load side feedback. CIRP Ann Manuf Technol 66(1):357–360
82.
Liu H, Zhang J, Zhao W (2017) An intelligent non-collocated control strategy for ball-screw feed drives with dynamic variations. Engineering 3:107
83.
84.
FANUC FANUC AC Servo Motor αi series, FANUC AC Servo Motor βi series, FANUC Linear Motor LiS series, FANUC Synchronous Built-In Servo Motor DiS series parameter manual. B-65270EN/07 edn.
85.
HEIDENHAIN (2013) Dynamic precision—machining dynamically and with high accuracy
86.
van Loon SJLM, Hunnekens BGB, Simon AS, van de Wouw N, Heemels WPMH (2018) Bandwidth-on-demand motion control. IEEE Trans Control Syst Technol 26(1):265–273
87.
Wang L, Liu H, Yang L, Zhang J, Zhao W, Lu B (2015) The effect of axis coupling on machine tool dynamics determined by tool deviation. Int J Mach Tool Manu 88:71–81
88.
89.
90.
91.
Steinlin M, Weikert S, Wegener K (2010) Open loop inertial cross-talk compensation based on measurement data. Paper presented at the 25th annual meeting of the American Society for Precision Engineering, ASPE 2010, Atlanta, GA, United States, October 31, 2010 - November 4, 2010
92.
93.
94.
95.
Weck M, Ye G (1990) Sharp corner tracking using the IKF control strategy. CIRP Ann Manuf Technol 39(1):473–441
96.
97.
Shpitalni M, Koren Y, Lo CC (1994) Realtime curve interpolators. Comput Aided Des 26(11):832–838MATH
98.
99.
100.
101.
102.
Wang YS, Yang DS, Liu YZ (2014) A real-time look ahead interpolation algorithm based on Akima curve fitting. Int J Mach Tool Manu 85:122–130
103.
Wang JB, Yau HT (2014) Universal real-time NURBS interpolator on a PC-based controller. J Adv Manuf Technol 71(4):497–507
104.
105.
106.
107.
Lin MT, Lee MC, Lee JC, Lee CY, Jian ZW (2016) A look-ahead interpolator with curve fitting algorithm for five-axis tool path. Paper presented at the 2016 IEEE international conference on advanced intelligent mechatronics, Banff, Alberta, Canada, July 12-15, 2016
108.
Shi J, Bi QZ, Zhu LM, Wang YH (2015) Corner rounding of linear five-axis tool path by dual PH curves blending. Int J Mach Tool Manu 88:223–236
109.
110.
111.
Sencer B, Shamoto E (2014) Curvature-continuous sharp corner smoothing scheme for Cartesian motion systems. Paper presented at the 2014 IEEE 13th international workshop on advanced motion control (AMC), 14–16 March 2014
112.
113.
Zhao H, Zhu L, Ding H (2013) A real-time look-ahead interpolation methodology with curvature-continuous B-spline transition scheme for CNC machining of short line segments. Int J Mach Tool Manu 65:88–98
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
Sun YW, Bao YR, Kang KX, Guo DM (2013) An adaptive feedrate scheduling method of dual NURBS curve interpolator for precision five axis CNC machining. Int J Adv Manuf Technol 68:1977–1987
126.
127.
Jin YA, He Y, Fu JZ (2013) A look-ahead and adaptive speed control algorithm for parametric interpolation. Int J Adv Manuf Technol 69:2613–2620
128.
129.
Qiao ZF, Wang HH, Liu ZZ, Wang TY, Hu M (2015) Nanoscale trajectory planning with flexible Acc/Dec and look-ahead method. Int J Adv Manuf Technol 96:94–105
130.
131.
132.
133.
Wang YS, Yang DS, Gai RL, Wang SH, Sun SJ (2015) Design of trigonometric velocity scheduling algorithm based on pre-interpolation and look-ahead interpolation. Int J Mach Tool Manu 96:94–105
134.
135.
136.
137.
138.
139.
Singer NC, Seering WP (1990) Preshaping command inputs to reduce system vibration. J Dyn Syst Meas Control Trans ASME 112(1):76–82
140.
Dietmair A, Verl A (2009) Drive based vibration reduction for production machines. Mod Mach Sci J 3:130–134
141.
Altintas Y, Khoshdarregi MR (2012) Contour error control of CNC machine tools with vibration avoidance. CIRP Ann Manuf Technol 61:335–338
142.
143.
144.
AI Nano CNC for high-speed high-accuracy machining, FANUC series 31i/32i/30i/35i-Model B, FANUC series 31i-Model B5-datasheet (2004). FANUC Corporation
145.
Milling with SIMUMERIK: mold making with 3- to 5-axis simultaneous milling manual (2013) Siemens Corporation
146.
iTNC 530 HSCI NC Software 606 420-02, 606 421-02-technique manual (2012) Heidenhain Corporation
147.
148.
149.
150.
Koren Y, Lo CC (1991) Variable-gain cross-coupling controller for contouring. CIRP Ann Manuf Technol 40(1):371–374
151.
Shih Y-T, Chen C-S, Lee A-C (2002) A novel cross-coupling control design for Bi-axis motion. Int J Mach Tool Manu 42:1539–1548
152.
153.
154.
Kulkarni PK, Srinivasan K (1989) Optimal contouring control of multi-axial feed drive servomechanisms. J Dyn Syst Meas Control Trans ASME 111:140–147
155.
Chung HY, Liu CH (1992) A model-referenced adaptive control strategy for improving contour accuracy of multiaxis machine tools. IEEE Trans Ind Appl 28:221–227
156.
Yeh ZM (1998) A cross-coupled bistage fuzzy logic controller for biaxis servomechanism control. Fuzzy Sets Syst 97:265–275
157.
Yeh SS, Hsu PL (1999) Theory and applications of the robust crosscoupled control design. ASME J Dyn Syst Meas Control 121:524–530
158.
Srinivasan K, Kulkarni PK (1990) Cross-coupled control of biaxial feed drive servomechanisms. J Dyn Syst Meas Control Trans ASME 112(2):225–232
159.
Lo CC (2002) A tool-path control scheme for five-axis machine tools. Int J Mach Tools Manuf 42:79–88
160.
Altintas Y, Sencer B (2010) High speed contouring control strategy for five-axis machine tools. CIRP Ann Manuf Technol 59(1):417–420
161.
Yang JX, Altintas Y (2013) Generalized kinematics of five-axis serial machines with non-singular tools path generation. Int J Mach Tool Manu 75:119–132
162.
Yang JX, Altintas Y (2015) A generalized on-line estimation and control of five-axis contouring errors of CNC machine tools. Int J Mach Tool Manu 88:9–23
163.
Yang JX, Zhang HT, Ding H (2017) Contouring error control of the tool center point function for five axis machine tools based on model predictive control. Int J Adv Manuf Technol 88:2909–2919
164.
Li XF, Zhao H, Zhao X, Ding H (2016) Dual sliding mode contouring control with high accuracy contour error estimation for five-axis CNC machine tools. Int J Mach Tool Manu 108:74–82
165.
Dong B, Liu Y, Wang Z (2014) Study on 5-axis CNC system cross-coupled controller based on double NURBS hybrid parametric interpolation algorithm. China Mech Eng 25(22):3038–3044
166.
167.
168.
Poo AN, Bollinger JG, Younkin GW (1972) Dynamic errors in type 1 contouring systems. IEEE Trans Ind Appl IA-8(4):477–484
169.
Xi XC, Poo AN, Hong GS (2009) Improving contouring accuracy by tuning gains for a bi-axial CNC machine. Int J Mach Tool Manu 49:395–460
170.
171.
Lei WT, Paung IM, Yu CC (2009) Total ballbar dynamic tests for five axis CNC machine tools. Int J Mach Tool Manu 49:488–499
172.
173.
Lin MT, Wu SK (2013) Modeling and analysis of servo dynamics errors on measuring paths of five axis machine tools. Int J Mach Tool Manu 66:1–14
174.
Wang W, Zhang X, Zheng C, Zhao X, Bian Z, Jiang Z (2014) Analysis for machining precision prediction and influencing factors of complex surface in aviation. J Univ Electron Sci Technol China 43(5):787–793
175.
Jiang Z, Ding JX, Song ZY (2016) Modeling and simulation of surface morphology abnormality of S test piece machined by five axis CNC machine tool. Int J Adv Manuf Technol 85:2745–2759
176.
177.
Marciniak K (1987) Influence of surface shape on admissible tool positions in 5-aixs face milling. Comput Aided Des 19(5):233–236MATH
178.
Kruth JP, Klewais P (1994) Optimization and dynamic adaptation of the cutter inclination during five-axis milling of sculptured surfaces. CIRP Ann Manuf Technol 43(1):443–448
179.
Chiou CJ, Lee YS (2002) A machining potential field approach to tool path generation for multi-axis sculptured surface machining. Comput Aided Des 34(5):357–371MATH
180.
Kim T, Sarma SE (2002) Tool path generation along directions of maximum kinematic performance; a first cut at machine-optimal paths. Comput Aided Des 34(6):453–468
181.
Giri V, Bezbaruah D, Bubna P, Choudhury AR (2005) Selection of master cutter paths in sculptured surface machining by employing curvature principle. Int J Mach Tool Manu 45(10):1202–1209
182.
Lim EM, Menq CH (1997) Integrated planning for precision machining of complex surfaces. Part 1: cutting-path and feedrate optimization. Int J Mach Tool Manu 37(1):61–75
183.
184.
Yuen A, Altintas Y (2016) Trajectory generation and control of a 9 axis CNC micromachining center. CIRP Ann Manuf Technol 65:349–352
185.
Fernandez-Gauna B, Ansoategui I, Etxeberria-Agiriano I, Graña M (2014) Reinforcement learning of ball screw feed drive controllers. Eng Appl Artif Intell 30:107–117
186.
Hou ZS, Wang Z (2013) From model-based control to data-driven control: survey, classification and perspective. Inf Sci 235:3–35MathSciNetMATH
Metadata
Title
Dynamic error of CNC machine tools: a state-of-the-art review
Authors
Dun Lyu
Qing Liu
Hui Liu
Wanhua Zhao
Publication date
13-12-2019
Publisher
Springer London
Published in
The International Journal of Advanced Manufacturing Technology
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI
https://doi.org/10.1007/s00170-019-04732-9

Premium Partners

    Image Credits