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1 s2.0 S0890695517301165 Main
1 s2.0 S0890695517301165 Main
1 s2.0 S0890695517301165 Main
A R T I C L E I N F O A B S T R A C T
Keywords: This paper proposes a new iterative compensation methodology of geometric errors to improve the machining
Machining accuracy accuracy of a non-orthogonal five-axis machine tool (NOFAMT). Firstly, based on homogeneous transform matrix
Non-orthogonal five-axis machine tool (HTM) and multi-body system (MBS) theory, the relative motion constraint equations (TRMCEs) of the tool tip
Iterative compensation methodology position and tool orientation vector related to a NOFAMT with a nutating rotary B axis are established. Then, by
The relative motion constraint equation utilizing TRMCEs, the mapping relationships between tool path and the numerical control (NC) command without
Geometric error
and with considering the geometric errors are constructed respectively. In order to truly reproduce tool motion
trajectory of the machine tool driven by the given NC command, the mapping relationship between the NC
command and tool cutting trajectory is also established. Meanwhile, procedures of iterative compensation are
described by using the aforementioned mapping relationships without the traditional inverse calculation, and the
actual NC code is generated in self-developed compensation software. It is not difficult to find that the new
approach takes the difference between tool path and tool cutting trajectory as the control objective and can
directly obtain the actual NC code controlling the machine tool to achieve the desired machining accuracy.
Finally, a cutting test is carried out on the DMU60P NOFAMT. Experimental results show the developed iterative
compensation methodology is precise and effective for NOFAMTs. Therefore, compared with the existing
methods, the new method is more direct and accurate. And its basic idea can be applied to other type of machine
tools.
* Corresponding author. College of Mechanical Engineering & Applied Electronics Technology, Beijing University of Technology, Ping Leyuan 100#, Chaoyang district, Beijing, 100124,
PR China.
E-mail addresses: piaoyanggh2003@163.com (C. Wu), jwfan@bjut.edu.cn (J. Fan).
https://doi.org/10.1016/j.ijmachtools.2017.07.008
Received 6 May 2017; Received in revised form 27 July 2017; Accepted 28 July 2017
Available online 31 July 2017
0890-6955/© 2017 Elsevier Ltd. All rights reserved.
C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Based on MBS theory, a machine tool can be assumed to be composed Classic body k 1 2 3 4 5 6 7 8 9
of various rigid bodies. Fig. 2 shows the topology structure map of the L0 ðkÞ 1 2 3 4 5 6 7 8 9
NOFAMT, where “Bi” means the i-th body. The lower body array for the L1 ðkÞ 0 1 2 3 1 5 6 7 8
researched machine tool can be figured out as shown in Table 2, and L2 ðkÞ 0 0 1 2 0 1 5 6 7
Table 3 depicts the degrees of freedom (DOFs) between the two adjacent L3 ðkÞ 0 0 0 1 0 0 1 5 6
parts, where “0” means no DOF and “1” means one DOF. As shown in L4 ðkÞ 0 0 0 0 0 0 0 1 5
L5 ðkÞ 0 0 0 0 0 0 0 0 1
Fig. 2, the kinematic chain of the NOFAMT can be divided into two
L6 ðkÞ 0 0 0 0 0 0 0 0 0
branches by considering the body of machine bed as a reference. One is
workpiece branch from machine bed to workpiece, and the other is tool
branch from machine bed to cutting tool. The two adjacent bodies are
Table 3
linked with each other in each branch. The transformation matrix of the
Adjacent body freedom of the NOFAMT.
relative movement between the two adjacent bodies is described as,
Adjacent body X Y Z A B C
½SIJ ¼ ½SIJp ½SIJpe ½SIJs ½SIJse (1) 1–2 0 1 0 0 0 0
2–3 0 0 0 0 0 1
3–4 0 0 0 0 0 0
½SIJðRÞ ¼ ½SIJp ðRÞ½SIJpe ðRÞ½SIJs ðRÞ½SIJse ðRÞ (2) 1–5 1 0 0 0 0 0
5–6 0 0 1 0 0 0
where I and J denote the adjacent higher and lower body respectively, 6–7 0 0 0 0 1 0
and ½SIJp ð½SIJp ðRÞÞ, ½SIJpe ð½SIJpe ðRÞÞ, ½SIJs ð½SIJs ðRÞÞ , ½SIJse ð½SIJse ðRÞÞ 7–8 0 0 0 0 0 0
8–9 0 0 0 0 0 0
describe the relative position (angular position) transformation matrix,
the relative position error(angular position error) transformation matrix,
the relative motion(angular motion) transformation matrix, the relative coordinate system (MCS)fMg , where fxg; fyg; fzgdenote the actual co-
motion error (angular motion error) transformation matrix between the ordinate system of the X; Y; Zdirection respectively, and
rigid body I and the adjacent lower body J respectively. εxy ; εyz ; εxz denote the perpendicularity error of between Xand Y,Yand Z,
X and Z respectively. Taking C rotary axis as an example, its schematic
2.3. Error components definition and setting of the coordinate systems diagram of PIGEs in the C-axis reference coordinate fCg is shown in
Fig. 4, where εxC ; εyC represent the perpendicularity error of between X; Y
According to the Ref. [27], geometric errors are usually composed of axis and C rotary axis respectively.
position-independent geometric errors (PIGEs), and position-dependent Based on the theory of the rigid body motion, each moving part of a
geometric errors (PDGEs). PIGEs don't vary with the moving position machine tool has six DOFs in the Cartesian coordinate system [28].
of the machine tool, but PDGEs are the opposite ones. Fig. 3 is the Hence, each moving axis of the NOFAMT has six PDGEs. Fig. 5 (a) shows
schematic diagram of PIGEs between linear axes in the machine six PDGEs of X-axis, and (b) represents six PDGEs of C-axis, where
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
δi ðxÞand εi ðxÞ (i ¼ x; y; z) represent the linear errors and the angular er- Fig. 4. The schematic diagram of PIGEs between X,Y axis and C rotary axis.
rors of X-axis along the i direction respectively, while δi ðCÞand εi ðCÞ
(i ¼ x; y; z) represent the linear errors and the angular errors of C-axis
along the i direction respectively. Therefore, all the geometric errors of adjacent bodies can be represented using a 44 HTM.
the NOFAMT are listed, as shown in the Table 4. Supposing that the coordinate of the cutting tool tip position and
For the convenience of this study, the setting of coordinate systems is orientation in the tool coordinate system (TCS) can be expressed as rt ¼
conducted as follows: (1) the assumption is made that the body reference ð 0 0 L 1 ÞT and vt ¼ ð 0 0 1 0 ÞT respectively, meanwhile,
coordinate system (BFCS) of each axis coincides with its motion reference the coordinate of the cutting tool tip position and orientation in the
coordinate system (MFCS) if the machine tool is at the home position (i.e. workpiece coordinate system (WCS) can be expressed as
the absolute zero point). (2) The direction of each coordinate system rw ¼ xw yw zw 1 T and vw ¼ ð xv yv zv 0 ÞT respectively.
should be identified. Firstly, the machine coordinate system (MCS), i.e.,
Moreover, at the home position, the coordinate of the workpiece cutting
the coordinate system of body 1 is selected as the base coordinate system
point in C-axis BFCS and the coordinate of oB in the MCS can be written as
(BCS), and it is presumed that the MFCS of body 2 and the BCS are in the T T
same direction. Secondly, let the BCS rotate around axisX and axis Y at qwx qwy qwz 1 and q7x q7y q7z 1 respectively. Where L
the perpendicularity of εyC and εxC respectively and let the BCS rotate indicates the length of the cutting tool between oB and the center point of
around axisZ at the perpendicularity of εxy , we can then determine the tool tip.
MFCS direction of body 3 and 5 respectively. Note that the coordinate As discussed in Section 2.3, the workpiece is fixed on the C axis. And
system of body 4 is in line with the coordinate system of body 3. In the spindle and cutting tool are fixed on the B axis. So the motion or
addition, the MFCS direction of body 6 can be also confirmed after the motion error transformation matrix between the workpiece and C axis
MFCS of body 5 rotates around axisX and axisY at the perpendicularity of can be considered as an identity matrix. Similarly, the motion or motion
εyz and εxz respectively. Lastly, after the coordinate system, which rotates error transformation matrix between the B axis, spindle and cutting tool
around axis X in the MFCS of body 6 at the angle of α rotates around axisX can also be considered as an identity matrix respectively. In addition, as
and axisZ at the perpendicularity of εzB andεxB respectively, the MFCS shown in Fig. 6, which is the schematic diagram of the BFCS relation
direction of body 7 is confirmed. Hence, the MFCS direction of body 8 and between body 6, 7 and 8, there is an included angle α between the B-axis
9 can be also identified after the MFCS of body 7 rotates around axis X at and the spindle. After rotate the BFCS of Z axis around X direction at the
the angle ofα: (3) the position of each coordinate system should be angle of α, the BFCS of B axis can be identified. While the rotation center
confirmed. Firstly, let the machine tool go back to the home position, then of B axis is Z direction. Hence, the position, position error, motion and
the geometrical center (oC ) of the end surface in body 3 is selected as the motion error transformation matrix between Z axis and B axis can be
origin of the BFCS and MFCS in body 1,2,3,5 and 6, while the origin of the obtained respectively. Similarly, the BFCS of spindle can be obtained
BFCS and MFCS in body 7, 8 and 9 is set at the intersection point (oB ) of through rotating the BFCS of B axis around X direction at the angle of
axis center line in body 6 and 9, as shown in Fig. 1. α:Then, the position transformation matrix between the B axis and
spindle can be given. Followed by analogy, the rest transformation
matrices between the adjacent bodies can be determined. Tables 5–8
2.4. Establishment of TRMCE show the transformation matrices for all of the adjacent bodies.
In tool branch, the cutting tool tip position can be described to MCS,
In MBS theory, the transformation relationship between the two as shown in Eq. 3.
" #
T Y
t¼1
PT ¼ PxT PyT PzT 1 ¼ SLt ðjÞLt1 ðjÞ p SLt ðjÞLt1 ðjÞ pe SLt ðjÞLt1 ðjÞ s SLt ðjÞLt1 ðjÞ se rt
t¼n;Ln ð6Þ¼1 (3)
¼ ½S15p ½S15pe ½S15s ½S15se ½S56p ½S56pe ½S56s ½S56se ½S67p ½S67pe ½S67s
½S78p ½S78pe ½S78s ½S78se ½S89p ½S89pe ½S89s ½S89se rt
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Table 4
Geometric errors of the NOFAMT.
Fig. 6. The schematic diagram of the BFCS relation between body 6, 7 and 8.
where PiT ði ¼ x; y; zÞ denotes the component of PT in i direction. high order terms are much smaller than other terms, the high order terms
Then, Eqs.( (4)–(6) can be obtained by substituting the corresponding are neglected in this process [29].
transformation matrices shown in Tables 5–8 into Eq. (3). Because the
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Table 5
Position and position error transformation matrix of the NOFAMT.
Table 6
Motion and motion error transformation matrix of the NOFAMT.
PxT ¼ δx ðxÞ þ δx ðzÞ þ q7x þ x þ z εy ðxÞ þ εxz þ δx ðBÞcosB þ δy ðBÞsin B þ q7z εy ðxÞ þ εy ðzÞ þ εxz
q7y ðεz ðxÞ þ εxy Þ þ Lðsin α sin B ðcos2 α þ sin2 αcosBÞðεy ðxÞ þ εy ðzÞ þ εxz Þ cosαðcosBεy ðBÞ
þsin Bεx ðBÞÞ cosα sin αðεz ðxÞ þ εz ðzÞ þ εxB þ εxy Þ þ sin αcosBεz ðBÞ þ cosα sin αcosBðεz ðxÞ þ εz ðzÞ þ εxB þ εxy ÞÞ (4)
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Table 7
Angular position and angular position error transformation matrix of the NOFAMT.
Adjacent body Angular position transformation matrix Angular position error transformation matrix
Table 8
Angular motion and angular motion error transformation matrix of the NOFAMT.
Adjacent body Angular motion transformation matrix Angular motion error transformation matrix
2 3
1–2 ½S12s ðRÞ ¼ I44 1 εz ðyÞ εy ðyÞ 0
Y-axis 6 εz ðyÞ 1 ε ðyÞ 0 7
½S12se ðRÞ ¼ 6
4 εy ðyÞ εx ðyÞ
x 7
1 05
0 0 0 1
2 3 2 3
2–3 cos C sin C 0 0 1 εz ðCÞ εy ðCÞ 0
C-axis 6 sin C cos C 0 07 6 εz ðCÞ 1 ε ðCÞ 0 7
½S23s ðRÞ ¼ 6
4 0
7 ½S23se ðRÞ ¼ 6 x 7
0 1 05 4 εy ðCÞ εx ðCÞ 1 05
0 0 0 1 0 0 0 1
3–4 ½S34s ðRÞ ¼ I44 ½S34se ðRÞ ¼ I44
workpiece
2 3
1–5 ½S15s ðRÞ ¼ I44 1 εz ðxÞ εy ðxÞ 0
X-axis 6 εz ðxÞ 1 εx ðxÞ 07
½S15se ðRÞ ¼ 6
4 εy ðxÞ εx ðxÞ
7
1 05
0 0 0 1
2 3
5–6 ½S56s ðRÞ ¼ I44 1 εz ðzÞ εy ðzÞ 0
Z-axis 6 εz ðzÞ 1 εx ðzÞ 07
½S56se ðRÞ ¼ 6
4 εy ðzÞ εx ðzÞ
7
1 05
0 0 0 1
2 3 2 3
6–7 cos B sin B 0 0 1 εz ðBÞ εy ðBÞ 0
B-axis 6 sin B cos B 0 07 6 εz ðBÞ 1 εx ðBÞ 07
½S67s ðRÞ ¼ 6
4 0
7 ½S67se ðRÞ ¼ 6 7
0 1 05 4 εy ðBÞ εx ðBÞ 1 05
0 0 0 1 0 0 0 1
2 3
7–8 1 0 0 0 ½S78se ðRÞ ¼ I44
spindle 6 0 cos α sin α 07
½S78s ðRÞ ¼ 6
4 0 sin α cos α
7
05
0 0 0 1
8–9 ½S89s ðRÞ ¼ I44 ½S89se ðRÞ ¼ I44
tool
PyT ¼ δy ðxÞ þ δy ðzÞ þ q7y þ xεxy z εx ðxÞ þ εyz q7z εx ðxÞ þ εx ðzÞ þ εyz þ q7x εz ðxÞ þ εz ðzÞ þ εxy
sin αδz ðBÞ þ cosαðcosBδy ðBÞ þ sin Bδx ðBÞÞ þ Lðsin2 αεx ðBÞ þ cosα sin α þ cos2 αðεx ðxÞ þ εx ðzÞ
þεBz þ εyz þ cosBεx ðBÞ sin Bεy ðBÞÞ þ sin2 αcosBðεx ðxÞ þ εx ðzÞ þ εyz þ εBz Þ þ sin α sin Bðεz ðxÞ
þεz ð0zÞ þ εxy þ εxB ÞÞ (5)
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
PzT ¼ δz ðxÞ þ δz ðzÞ þ q7z þ z þ cosαδz ðBÞ þ q7y εx ðxÞ þ εx ðzÞ þ εyz
where PiW and ViW ði ¼ x; y; zÞ denote the component of PW and VW in i
q7x εy ðxÞ þ εy ðzÞ þ εxz þ sin α cosBδy ðBÞ þ sin Bδx ðBÞ þ L
direction respectively.
cos2 α sin2 αcosB þ cosα sin α εBz εx ðBÞ þ εyz Substituting the corresponding transformation matrices shown in
sin α sin B εy ðxÞ þ εy ðzÞ þ εxz þ cosα sin αcosB εxB εx ðxÞ Tables 5–8 into Eqs.( (11) and (12), the following equations can be ob-
tained, as shown in Eqs.(13)–(18).
εx ðzÞ εBz εyz cosα sin α sin Bεy ðBÞ
(6)
Similarly, the cutting tool tip orientation can also be described to
MCS, as shown in Eq. (7).
PxW ¼ δx ððyÞÞ ðqwy þ yw Þðsin C þ cos Cεz ðCÞ þ cos Cεz ðyÞÞ þ ðqwx
where ViT ði ¼ x; y; zÞ denotes the component of VT in i direction.
Then, Eqs.( (8)–(10) can be obtained based on Eq. (7) as follows. þ xw Þðcos C sin Cεz ðCÞ sin Cεz ðyÞÞ þ ðqwz þ zw Þðεx ðCÞ
þ εy ðyÞ þ cos Cεy ðCÞ þ sin Cεx ðCÞÞ þ cos Cδx ðCÞ sin Cδy ðCÞ
VxT ¼ sin Bðsinα cos αεx ðBÞÞ þ cos Bðsinαεz ðBÞ cos αεy ðBÞ
(13)
sin2 αðεy ðxÞ þ εy ðzÞ þ εxz Þ þ cos αsinα εz ðxÞ þ εz ðzÞ þ εxB þ εxy
cos2 α εy ðxÞ þ εy ðzÞ þ εxz cos αsinαðεz ðxÞ þ εz ðzÞ þ εxB þ εxy Þ PyW ¼ δx ðyÞ þ y þ ðqwx þ xw Þðsin C þ cos Cεz ðCÞ þ cos Cεz ðyÞÞ þ ðqwy
(8) þ yw Þðcos C sin Cεz ðCÞ sin Cεz ðyÞÞ ðqwz þ zw Þðεx ðyÞ
þ εy ðCÞ þ cos Cδx ðCÞ sin Cδy ðCÞÞ þ cos Cδy ðCÞ þ sin Cδx ðCÞ
VyT ¼ cos2 αðεx ðxÞ þ εx ðzÞ þ εBz þ εyz Þ þ sin2 αεx ðBÞ þ cos αsinα
(14)
þ cos Bðcos αsinα þ cos2 αεx ðBÞ þ sin2 α εx ðxÞ þ εx ðzÞ þ εBz
þ εyz þ sin B sinαðεz ðxÞ þ εz ðzÞ þ εxB þ εxy cos2 αεy ðBÞ PzW ¼ δz ðCÞ þ δz ðyÞ þ qwz þ zw ðqwx þ xw Þðεy ðCÞ þ cos Cεx ðCÞ
þ cos αsinαεz ðBÞÞ þ cos Cεy ðyÞ þ sin Cεx ðyÞ þ sin Cεy ðCÞÞ þ ðqwy þ yw Þðεx ðCÞ
(9) þ cos Cεx ðyÞ þ cos Cεy ðCÞ þ sin Cεx ðCÞ þ sin Cεy ðyÞÞ
(15)
VzT ¼ cos αsinαðεx ðxÞ εx ðBÞ þ εx ðzÞ þ εBz þ εyz Þ cos2 α
cos Bðsin2 α þ cos αsinα εx ðxÞ εx ðBÞ þ εx ðzÞ þ εBz þ εyz VxW ¼ xv ðcosC sin Cεz ðCÞ sin Cεz ðyÞÞ þ zv εx ðCÞ þ εy ðyÞ
sin Bsinαðεy ðxÞ þ εy ðzÞ þ εxz sinαεz ðBÞ þ cos αεy ðBÞÞ þ cosCεy ðCÞ þ sin Cεx ðCÞ yv ðsin C þ cosCεz ðCÞ
(10) þ cosCεz ðyÞÞ (16)
In addition, in workpiece branch, the required tool position and
orientation of the workpiece cutting point in the MCS can be expressed in
Eqs.( (11) and (12) respectively.
" #
Y
t¼1
t t t t
PW ¼ ð PxW PyW PzW 1Þ ¼
T
ð SL ðjÞL ðjÞ p SL ðjÞL ðjÞ pe SL ðjÞL ðjÞ s SL ðjÞL ðjÞ se Þ rw
t1 t1 t1 t1
t¼n;Ln ð4Þ¼1
(11)
¼ ½S12p ½S12pe ½S12s ½S12se ½S23p ½S23pe ½S23s ½S23se ½S34p ½S34pe ½S34s ½S34se rw
T
VW ¼" VxW VyW VzW 0 #
Y
t¼1 t t t
¼ SL ðjÞL ðjÞ p ðRÞ SL ðjÞL ðjÞ pe ðRÞ SL ðjÞL ðjÞ s ðRÞ SL ðjÞL ðjÞ se ðRÞ vw
t t1 t1 t1 t1
(12)
t¼n;Ln ð4Þ¼1
¼ ½S12p ðRÞ½S12pe ðRÞ½S12s ðRÞ½S12se ðRÞ½S23p ðRÞ½S23pe ðRÞ½S23s ðRÞ½S23se ðRÞ
½S34p ðRÞ½S34pe ðRÞ½S34s ðRÞ½S34se ðRÞÞ vw
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
VyW ¼ yv ðcosC sin Cεz ðCÞ sin Cεz ðyÞÞ zv εx ðyÞ þ εy ðCÞ Evi ði ¼ x; y; zÞare displayed in Eqs. A1 and A2 in Appendix A respectively.
Epi denotes the component of TRMCE of the tool tip position in i direc-
þ cosCεx ðCÞ sin Cεy ðCÞ þ xv ðsin C þ cosCεz ðCÞ
tion. Evi denotes the component of TRMCE of tool orientation vector in
þ cosCεz ðyÞÞ (17) i direction.
VzW ¼ zv xv ðεy ðCÞ þ cosCεx ðCÞ þ cosCεy ðyÞ sin Cεx ðyÞ 3. Iterative compensation methodology based on TRMCE
sin Cεy ðCÞÞ þ yv ðεx ðCÞ þ εx ðyÞ þ cosCεy ðCÞ þ sin Cεx ðCÞ
In this work, the core idea of the new iterative compensation meth-
þ sin Cεy ðyÞÞ odology is that we only focus on how to obtain the actual NC codes
(18) controlling the machine tool to achieve the desired machining accuracy
without concerning the compensated values in machining process. In
During the practical machining process, to obtain the desired accu- order to implement the methodology, the mutual mapping relationships
racy of workpiece, the position and orientation of the cutting tool tip in between tool path, NC command and tool cutting trajectory based on
tool branch should be coincident with the required tool position and TRMCE should be established respectively.
orientation of the workpiece cutting point in workpiece branch at any Tool path refers to the theoretical tool center position curve, which is
moment in MCS, i.e.,PT ¼ PW ; VT ¼ VW . Therefore, TRMCE of the tool tip planned in WCS according to the design drawings, and has nothing to do
position and tool orientation vector related to the researched NOFAMT with the motion of a machine tool. Whereas, tool cutting trajectory refers
can be gotten with Eqs.( (19) and (20) respectively. to motion trajectory of the cutting tool in WCS, which can be divided into
2 3 ideal tool cutting trajectory and actual tool cutting trajectory. Ideal tool
Epx
6 Epy 7 cutting trajectory is the tool cutting trajectory obtained by theoretical
Ep ¼ 6 7
4 Epz 5 ¼ 0 (19) calculation based on the nominal motion model of a machine tool, while
1 actual tool cutting trajectory is the tool cutting trajectory generated in the
practical machining process of a machine tool. Fig. 7 shows the schematic
2 3 diagram of the relationships between tool path, NC command and tool
Evx cutting trajectory.
6 Evy 7
Ev ¼ 6 7
4 Evz 5 ¼ 0 (20)
3.1. Mapping relationship between tool path and NC command
0
Ignoring geometric errors in Eqs.( (19) and (20), the mapping rela-
where Ep and Ev represent the TRMCE of the tool tip position and tool
tionship between tool path and the ideal NC command can be repre-
orientation vector respectively. The algebraic expressions of Epi and
sented as,
Tool path
Mapping model of the actual machine Mapping model of the idea machine
tool considering geometric error tool not considering geometric error
Fig. 7. The schematic diagram of the mapping relationships between tool path, NC command and tool cutting trajectory.
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
2 3
2 3 qwx cos C qwy sin C L sin α sin B q7x machining. Hence, the mapping relationship between tool path and the
x 6 7
6 y 7 6 qwx sin C qwy cos C L cos α sin α cos B 7 actual NC command should be established.
6 7 ¼ 6 þL cos α sin α þ q7y 7 Taking into account the geometric errors and simplifying Eqs.( (19)
4z 5 6 7
4 qwz þ Lsin2 α cos B þ L cos α q7z 5 and (20), the mapping relationship between tool path in WCS and the
1
0 actual NC command of the tool tip position in MCS is represented by Eq.
2 32 3 (23), and the mapping relationship between tool orientation vector in
cos C sin C 0 0 xw
6 sin C cos C 0 0 76 yw 7 WCS and the actual NC command of the tool Angular position in MCS is
þ6 4 0
76 7 (21)
0 1 0 54 zw 5 represented by Eqs.( (24) and (25).
0 0 0 1 1
2q 7x ðεz ðxÞ
þ εz ðzÞÞ þ q7y q7z εx ðzÞ þ δy ðxÞ δy ðyÞ þ δy ðzÞ cos Cδy ðCÞ sin α 3
δz ðBÞ sin Cδx ðCÞ þ cosαcosBδx ðBÞ þ cosα sin Bδx ðBÞ þ Lðcosα sin α þ cos2 α
6 7
ðεx ðzÞ þ εBz Þ þ sin2 αεx ðBÞ þ cos2 αcosBεx ðBÞ þ sin2 αcosBðεx ðzÞ þ εBz Þ cos2 α
6 sin Bεy ðBÞ þ cosα sin αcosB þ sin α sin Bðεz ðxÞ þ εz ðzÞÞÞ
7
2 3 6 q þ q ðε ðxÞ þ ε ðzÞ þ ε Þ q ε ðzÞ þ δ ðyÞ δ ðxÞ δ ðzÞ cosBδ ðBÞ 7
x 6 7x 7y z z xy 7z y
7
6 y 7 6 þcos Cδ ðCÞ þ sin Bδ ðBÞ þ sin Cδ ðCÞ þ Lðsin α sin B þ cos αε ðzÞ þ sin α 7
x x y
x x x
2
y
x
2
6 7 ¼ cosBε ðzÞ þ cosαcosBε ðBÞ þ cosα sin Bε ðBÞ þ cosα sin αðε ðxÞ þ ε ðzÞþ
4z5 6 y y x
7 z z
2 3 2 3
cos C 0 temp1 cos C þ temp2 sin C ¼ temp3 (24)
6 sin C 7 6 0 7
6 7 6 7
4 cos B 5 ¼ 4 cot2 α 5 temp4 cos B ¼ temp5 (25)
0 0
2 3
sin α sin B cos α sin αð1 cos BÞ 0 0 where, the algebraic expressions of tempi(i ¼ 1, 2, 3, 4, 5) are displayed in
6 cos α sin αð1 cos BÞ sin α sin B 0 07 Eq. B1 in Appendix B.
þ4 6 7
0 0 csc2 α 05 Then, Eq. (26) is given by the simplification of Eq. (24).
0 0 0 1
2 xv 3 temp1 temp2
cos C pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi þ sin C pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2 2 temp1 þ temp2
2 2 temp12 þ temp22
6 xv þ yv 7
6 7
6 yv 7 temp3
¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
6 2 7 (26)
6 x þ y2 7 temp12 þ temp22
6 v v7
6 7
4 zv 5 Assuming C axis can rotate 3600 (0 C 3600 ), and B axis can rotate
0 1800 (0 B 1800 ), then the following conditions can be generated.
(22)
(1) When temp2 0, then θ ¼ arccos pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
temp1
; when temp2 < 0,
2 2 temp1 þtemp2
where x; y; z; B; C indicate the idea NC command in MCS, xw ; yw ; zw
indicate the position coordinates of tool path in WCS, xv ; yv ; zv indicate then θ ¼ 3600 arccos pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
temp1
.
2 temp1 þtemp2
2
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8
<x 0
w ¼ ux þ ðcos C sin Cðεz ðCÞ þ εz ðyÞ εxy ÞÞx ðsin C þ cos Cðεz ðCÞ þ εz ðyÞÞÞy þ ðsin Cðεx ðyÞ þ εy ðCÞ
εx ðxÞ εyz Þ cosCðεx ðCÞ þ εy ðyÞ þ εy ðxÞ þ εxz Þ εy ðCÞÞz
y0w ¼ uy ðsin C þ cos Cðεz ðCÞ þ εz ðyÞ εxy ÞÞx ðcos C sin Cðεz ðCÞ þ εz ðyÞÞÞy þ ðcosCðεx ðyÞ þ εy ðCÞ (27)
: εx ðxÞ εyz Þ þ sin Cðεx ðCÞ þ εy ðyÞ þ εy ðxÞ þ εxz Þ þ εx ðCÞÞz
z0w ¼ uz þ ðεx ðCÞ þ εy ðyÞ þ cos Cεy ðCÞ þ sin Cεx ðCÞÞx þ ðεy ðCÞ þ εx ðyÞ þ cos Cεx ðCÞ sin Cεy ðCÞÞy þ z
where xw' ; yw' ; zw' indicate the position coordinates of the actual tool tip
2 3 2 2 3
3
x'w ux x cutting trajectory, xv' ; yv' ; zv' indicate the actual tool orientation vector, the
6 y' 7 6 uy 7 6 7 algebraic expressions of ui (i ¼ 1; 2; 3; 4; 5),vj (j ¼ 1; 2; 3; 4; 5; 6) and uk
6 'w 7 ¼ 6 7 þ Tw 6 y 7 (28)
4z 5 4 uz 5 4z5 (k ¼ x; y; z) are displayed in Eqs. C1 and C2 in Appendix C respectively.
w
1 0 1 Tw ,Tv1 ,Tv2 are displayed in Appendix D.
Eqs.(27) and (28), from the physical sense, can provide the driving
Similarly, Eq. (29) is obtained by using Eq. (20) and substituting
model of an actual machine tool. Using the model, the tool motion tra-
xv' ; yv' ; zv' for xv ; yv ; zv respectively. Then, the mapping relationship be- jectory of the machine tool driven by the given NC command can be
tween the NC command of the tool angular position and the actual tool really reproduced.
orientation is represented in Eq. (30). Furthermore, the model can also be used to obtain volumetric error of
any position point in the workpiece directly. Fig. 8 shows the relative
8
>
> x0v ¼ cos2 αεy ðCÞ þ u1 cos B cos C þ ðsinα cos αεx ðBÞÞsin B cos C þ u2 sin B sin Cþ
>
>
>
> u3 cos B sin C þ v1 cos C þ v2 sin C þ sin2 αεy ðCÞcos
B
>
>
< yv ¼ cos αεx ðCÞ sin2 α þ u4 cos B cos C þ u5 sin B cos C εx ðCÞ þ εy ðyÞ cos B sin C
0 2
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whereEv denotes the coordinate vector of the volumetric error. Ex ,Ey ,Ez
denote the component of Ev in x; y; zdirection respectively. E denotes the
volumetric error size.
8
2 2
>
< cos B0 ¼ cot α zv csc α
> cos α xv cos α cos B0 yv sin B0 (34)
: tan C0 ¼
cos α þ xv sin B0 yv cos α cos B0
wi w z
(35) compensation software is developed. The flow chart displayed in Fig. 9
> x0 xv ϕx
>
> vi explains the iterative process. The tool path can be obtained by CAD/
>
> 0
: y0vi yv ϕy
> CAM software based on the designed drawing of workpiece.
z zv ϕz
vi
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Table 9
Key structure parameters of DMU60P.
Work stroke Inclined angle α Resolution ðqwx ; qwy ; qwz Þ ðq7x ; q7y ; q7z Þ LðmmÞ
ðmmÞ ðmmÞ
Fig. 12. Six basic geometric errors of Y- axis: (a) linear error (b) angular error.
Fig. 13. Six basic geometric errors of Z-axis:(a) linear error (b) angular error.
Fig. 11. Six basic geometric errors of X-axis: (a) linear error (b) angular error.
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
4. Experimental verification thermal error and improve the measurement stability. The geometric
errors of linear axes are shown in Figs. 11–13. The PIGEs are listed
4.1. Cutting experiment in Table 10.
The accuracy of workpiece is significantly influenced by machining
To verify the effectiveness of the proposed method, an experiment is accuracy of the machine tool. Therefore, to validate the compensation
carried out on a NOFAMT: DECKEL MAHO DMU60P, Germany. Table 9 methodology described in this paper, the cutting test is a very efficient
displays its structure parameters. The experiment mainly includes three method. Whereas, the S-shaped part is one of the most widely used
parts: the identification of geometric errors, the acquisition of the standard parts due to its additional features, which can greatly reflect the
compensated NC code and the machining and measurement of test part. machining accuracy of a machine tool. But, before the cutting test, tool
Fig. 10 shows the flow chart of the verification experiment. path, which is the prerequisite of the generation of the compensated NC
Obviously, all the geometric errors of the NOFAMT should be iden- code, should be obtained. Tool path planning in this paper is carried out
tified before error compensation. To obtain the 21 geometric errors of by CAD/CAM Pro/E software based on the S-shaped test part designed, as
three linear axes, the dual-frequency laser interferometer, XL-80 by shown in Fig. 14. Then, the cutter location file (CLF) is generated by the
Renishaw, is utilized with nine-line method [30]. The geometric errors of post process module of Pro/E software. Fig. 14(a) displays the 3D model
B and C axes are identified with the double bar ball, QC20-W by of the S-shaped test part. The diagram of tool path planning based on the
Renishaw, according to the method presented by the Ref. [8]. Since the S-shaped test part is displayed in Fig. 14(b).
researched NOFAMT in this paper is identical with the one in Ref. [8], the According to the identified error parameters and CLF, the compen-
identified results of geometric errors of rotary axes are not described sated NC codes are generated in self-developed compensation software
here. Note that the ambient temperature is controlled to around 20 , all using the iterative compensation methodology in Section 3.
data are measured three times, and then the final error values are the Finally, two same S-shaped test parts (as shown in Fig. 14(a)) are
average results of three times identified values to reduce the impact of machined using the studied NOFAMT with the ideal NC codes and the
Table 10
The value of PIGEs.(unit: rad).
Fig. 14. Application of the S-shaped test part in cutting experiment:(a) The 3D model of the S-shaped test part (b) Tool path planning based on the 3D model of the S-shaped test part.
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Table 11
The comparison of contour errors before and after compensation.
Fig. 15. The measuring diagram for the S-shaped test part at three different heights Z ¼ 3 mm 0.0405 0.0050 87.6
(unit: mm). Z ¼ 12 mm 0.0474 0.0074 84.4
Z ¼ 17 mm 0.0535 0.0181 81.2
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C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Fig. 19. Flow diagrams for software error compensation method: (a) the iterative or differential method; (b) the algebraic method; (c) the proposed method.
calculated on the basis of Eq. (32) respectively. Thus, the contour error of are suitable for other type of machine tools, especially for more than
the corresponding point before and after compensation is calculated. three-axis precision or ultra-precision machine tools. Hence, for any
Then, the contour errors of 75 points for the test part before and after machine tool structure, the core idea of the method can not only be
compensation are all obtained, as shown in Figs. 16–18. The comparison applied to compensate the geometric error conveniently and effectively,
of the test part before and after compensation is shown in Table 11. It can but also thermal error, load error, and so on. Furthermore, with the
be seen that the contour errors of all 75 points after compensation are change of the inclined angle α for the NOFAMT, the proposed method can
much smaller than that before compensation. The maximum error is be straightforwardly suitable for any type of machine tools with the same
decreased from 0.0532 mm to 0.0213 mm, from 0.0639 mm to topological structure.
0.0206 mm, and from 0.0718 mm to 0.0275 mm at Z ¼ 3 mm, 12 mm
and17 mm respectively. Note that the maximum error before and after 5. Conclusion
compensation is located at the measured point 23, 25 and 25 at
Z ¼ 3 mm, 12 mm and17 mm respectively. While the average error is This paper proposes a new iterative compensation method of geo-
reduced from 0.045 mm to 0.0050 mm, from 0.0474 mm to 0.0074 mm, metric errors to improve the machining accuracy of a non-orthogonal
and from 0.0535 mm to 0.0181 mm at Z ¼ 3 mm, 12 mm and17 mm five-axis machine tool (NOFAMT). Compared with previous methods
respectively. In other words, the accuracy of test part after compensation [3,5,12–18], The new approach has the following advantages: (1) it takes
is improved about 87.6%, 84.4% and 81.2% at Z ¼ 3 mm, 12 mm and the difference between tool path and tool cutting trajectory as the control
17 mm respectively. The average improvement after compensation is objective and can directly obtain the actual numerical control (NC) codes
about 84.2%. Therefore, it is obvious that the proposed iterative controlling the machine tool to achieve the desired machining accuracy,
compensation methodology based on TRMCE is precise and effective to (2) the real response of the machine tool on the NC codes obtained are
improve machining accuracy of non-orthogonal multi-axis ma- concerned and (3) it does not have the inverse calculation of tradi-
chine tools. tional methods.
To verify the effectiveness of the proposed method, a cutting exper-
4.2. Expanding discussion of the new iterative method iment is carried out. Experimental results show the machining accuracy
of an S-shaped test part with geometric error compensation is improved
At present, the commonly used methods of software compensation about 87.6%, 84.4% and 81.2% at Z ¼ 3 mm, 12 mm and 17 mm
mainly include iterative method, differential method and algebraic respectively, compared with that without compensation. Furthermore,
method, as shown in Table 1. In these methods, there are two ways to the average machining accuracy after compensation is improved about
modify the NC codes, one is to superimpose additional codes on the basis 84.2%. Therefore, there is no doubt that the method is accurate and
of the ideal NC code, such as the iterative method, differential method, effective for machining accuracy improvement. Similarly, if other error
and the other is to obtain the modified NC codes directly considering the sources are considered, the method can be executed as well. Further-
geometric errors of machine tools, such as algebraic method. They pay more, the proposed method in this paper can be straightforwardly suit-
much more attention to how to obtain the modified NC codes of tool path able for any type of machine tools with the same topological structure.
without concerning the real effect of the obtained NC codes on tool Despite the progress made in this work, only geometric errors are
cutting trajectory. Obviously, the new iterative method takes the differ- considered. However, some other errors, such as thermally induced error,
ence between tool path and tool cutting trajectory as the control target cutting-force-induced error, dynamic load-induced error etc., also affect
and can directly obtain the actual NC code, which can directly drive the the machining accuracy of machine tools. Therefore, further researches
machine tool to achieve the desired machining accuracy. What's more, it should be done for all of the errors, or at least most of them.
does not have the inverse calculation of traditional methods. Fig. 19
displays contrastive flow diagrams for the core ideas of these compen- Acknowledgements
sation methods. Therefore, the proposed method in this paper is more
direct and accurate. This work is financially supported by the National Natural Science
It is worth noting that different topological structures of a machine Foundation of China (No. 51775010 and 51705011), Science and
tool can be used to establish different TRMCEs, which leads to the Technology Major Projects of High-end CNC Machine Tools and Basic
different mathematical expressions of the iterative calculation method. Manufacturing Equipment of China (No.2014ZX04011031). The authors
Thanks for the MBS theory, which is a systematic and universal modeling appreciate the support from Key Scientific Research Project for Henan
method; the iterative calculation procedures of the actual NC command Province Higher school of China (No.16B460015 and 18A460036).
95
C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Appendix A
8 E ¼ δ ðxÞ þ δ ðzÞ þ q þ x þ zðε ðxÞ þ ε Þ þ δ ðBÞcosB þ δ ðBÞsin B þ q ðε ðxÞ þ ε ðzÞ þ ε Þ
>
px x x 7x y xz x y 7z y y xz
>
> q ðε ðxÞ þ ε Þ þ Lðsin α sin B ðcos α þ sin αcosBÞðε ðxÞ þ ε ðzÞ þ ε Þ cosαðcosBε ðBÞ
7y
2 2
>
z xy y y xz y
>
>
þsin Bε ðBÞÞ cosα sin αðε ðxÞ þ ε ðzÞ þ ε þ ε Þ þ sin αcosBε ðBÞ þ cosα sin αcosBðε ðxÞ
x z z xB xy z z
>
>
þε ðzÞ þ ε þ ε ÞÞ þ ðq þ y Þðsin C þ cos Cε ðCÞ þ cos Cε ðyÞÞ ðq þ x Þðcos C sin Cε ðCÞ sin C
z xB xy wy w z z wx w z
>
> ε ðyÞÞ ðq þ z Þðε ðCÞ þ ε ðyÞ þ cos Cε ðCÞ þ sin Cε ðCÞÞ cos Cδ ðCÞ þ sin Cδ ðCÞ δ ðyÞ
>
z wz w x y y x x y x
< Esin αδ
¼ δ ðxÞ þ δ ðzÞ þ q þ xε zðε ðxÞ þ ε Þ q ðε ðxÞ þ ε ðzÞ þ ε Þ þ q ðε ðxÞ þ ε ðzÞ þ ε Þ
py y y 7y
ðBÞ þ cosαðcosBδ ðBÞ þ sin Bδ ðBÞÞ þ Lðsin αε ðBÞ þ cosα sin α þ cos αðε ðxÞ þ ε ðzÞ
xy x yz 7z
2
x x yz 7x z
2
z xy
z y x x x x
þεBz þ εyz þ cosBεx ðBÞ sin Bεy ðBÞÞ þ sin2 αcosBðεx ðxÞ þ εx ðzÞ þ εyz þ εBz Þ þ sin α sin Bðεz ðxÞ (A1)
>
> þε ðzÞ þ ε þ ε ÞÞ δ ðyÞ y ðq þ x Þðsin C þ cos Cε ðCÞ þ cos Cε ðyÞÞ ðq þ y Þðcos C sin C
>
>
z xy xB x
ε ðCÞ sin Cε ðyÞÞ þ ðq þ z Þðε ðyÞ þ ε ðCÞ þ cos Cδ ðCÞ sin Cδ ðCÞÞ cos Cδ ðCÞ sin Cδ ðCÞ
wx w z z wy w
>
>
z z wz w x y x y y x
>
>
E ¼ δ ðxÞ þ δ ðzÞ þ q þ z þ cosαδ ðBÞ þ q ðε ðxÞ þ ε ðzÞ þ ε Þ q ðε ðxÞ þ ε ðzÞ þ ε Þ þ sin α
pz z z 7z z 7y x x yz 7x y y xz
>
> ðcosBδ ðBÞ þ sin Bδ ðBÞÞ þ Lðcos α sin αcosB þ cosα sin αðε ε ðBÞ þ ε Þ sin α sin B 2 2
>
y x Bz x yz
: ðε ðxÞ þ ε ðzÞ þ ε Þ þ cosα sin αcosBðε ε ðxÞ ε ðzÞ ε ε Þ cosα sin α sin Bε ðBÞÞ
y y xz
δz ðCÞ δz ðyÞ qwz zw þ ðqwx þ xw Þðεy ðCÞ þ cos Cεx ðCÞ þ cos Cεy ðyÞ þ sin Cεx ðyÞ þ sin Cεy ðCÞÞ
xB x x Bz yz y
ðqwy þ yw Þðεx ðCÞ þ cos Cεx ðyÞ þ cos Cεy ðCÞ þ sin Cεx ðCÞ þ sin Cεy ðyÞÞ
8 Evx ¼ sin Bðsinα cos αεx ðBÞÞ þ cos Bðsinαεz ðBÞ cos αεy ðBÞ sin2 αðεy ðxÞ þ εy ðzÞ þ εxz Þ
>> þcos αsinαðεz ðxÞ þ εz ðzÞ þ εxB þ εxy ÞÞ cos2 αðεy ðxÞ þ εy ðzÞ þ εxz Þ cos αsinαðεz ðxÞ
< þεz ðzÞ þ εxB þ εxy Þ xv ðcosC sin Cεz ðCÞ sin Cεz ðyÞÞ zv ðεx ðCÞ þ εy ðyÞ þ cosC
εy ðCÞ þ sin Cεx ðCÞÞ þ yv ðsin C þ cosCεz ðCÞ þ cosCεz ðyÞÞ
Evy ¼ cos2 αðεx ðxÞ þ εx ðzÞ þ εBz þ εyz Þ þ sin2 αεx ðBÞ þ cos αsinα þ cos Bðcos αsinαþ
cos2 αεx ðBÞ þ sin2 αðεx ðxÞ þ εx ðzÞ þ εBz þ εyz ÞÞ þ sin Bðsinαðεz ðxÞ þ εz ðzÞ þ εxB þ
>>
(A2)
εxy Þ cos2 αεy ðBÞ þ cos αsinαεz ðBÞÞ yv ðcosC sin Cεz ðCÞ sin Cεz ðyÞÞ þ zv ð
:
εx ðyÞ þ εy ðCÞ þ cosCεx ðCÞ sin Cεy ðCÞÞ xv ðsin C þ cosCεz ðCÞ þ cosCεz ðyÞÞ
Evz ¼ cos αsinαðεx ðxÞ εx ðBÞ þ εx ðzÞ þ εBz þ εyz Þ cos2 α cos Bðsin2 α þ cos αsinα
ðεx ðxÞ εx ðBÞ þ εx ðzÞ þ εBz þ εyz ÞÞ sin Bsinαðεy ðxÞ þ εy ðzÞ þ εxz sinαεz ðBÞ
þcos αεy ðBÞÞ zv þ xv ðεy ðCÞ þ cosCεx ðCÞ þ cosCεy ðyÞ sin Cεx ðyÞ sin Cεy ðCÞÞ
yv ðεx ðCÞ þ εx ðyÞ þ cosCεy ðCÞ þ sin Cεx ðCÞ þ sin Cεy ðyÞÞ
Appendix B
8 temp1 ¼ x ðsin αðε ðxÞ ε ðCÞ ε ðyÞ þ ε ðzÞ þ ε þ ε Þ cos αsin αðε ðCÞ
5 4
>
>
v z
ε ðxÞ þ ε ðyÞ ε ðzÞ ε ÞÞ þ y cos αsin αð3ε ðBÞ 2ε ðxÞ 2ε ðzÞþ
x z
4
z xB xy x
>
>
y
ε ðCÞ 2ε 2ε Þ þ z sin αε ðCÞ;
y y xy
5
v x x x
>
>
y Bz
5
xy
temp2 ¼ x ðsin αðε ðxÞ 1 þ ε ðzÞ þ ε þ ε Þ þ cos αsin αð3ε ðBÞ 2ε ðxÞ þ ε
v x
4
5
xy xz v
x
5
z
x x
þεz ðyÞ þ cos αsin αðεx ðCÞ þ εy ðyÞÞÞ zv sin αεy ðCÞ; Þ
temp3 ¼ zv ðsin5 αðεx ðxÞ þ εx ðyÞ þ εx ðzÞ þ εy ðCÞ þ εBz þ εyz Þ cos αsin4 αÞ þ cos α (B1)
>
> sin6 α þ εx ðBÞðsin7 α 4cos2 αsin5 α þ 3cos4 αsin3 αÞ þ ðεBz þ εyz Þð5cos2 α
>
> sin5 α cos4 αsin3 αÞ cos3 αsin4 α;
>
> temp4 ¼ y3v sin2 αεy ðCÞ x3v sin2 αðεy ðyÞ þ εx ðCÞÞ sin2 αðxv y2v ðεx ðCÞ þ εy ðyÞÞ
: x2v yv εy ðCÞÞ;
temp5 ¼ ðx3v ðεx ðCÞ þ εy ðyÞÞ y3v εy ðCÞ þ xv y2v ðεx ðCÞ þ εy ðyÞÞ x2v yv εy ðCÞÞðcos2 α
þzv Þ:
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Appendix C
8
> u1 ¼ sinαεz ðBÞ cos αεy ðBÞ þ sin2 αðεx ðCÞ εy ðxÞ þ εy ðyÞ εy ðzÞ εxz Þ;
>
>
>
> u2 ¼ ðsin αðεz ðCÞ þ εz ðxÞ εz ðyÞ þ εz ðzÞ þ εxB þ εxy Þ þ cos2 αεy ðBÞ cos α sin αεz ðBÞÞ;
>
> 2 2
> u3 ¼ cos αεx ðBÞ þ sin αðεx ðxÞ εx ðyÞ þ εx ðzÞ εy ðCÞ þ εBz þ εyz Þ cos α sin αð1 þ εz ðCÞ
>
>
>
> εz ðxÞ þ εz ðyÞ εz ðzÞ εxB εxy Þ;
> u4 ¼ cos2 αεx ðBÞ cos α sin α þ sin2 αðεx ðxÞ εx ðyÞ þ εx ðzÞ εy ðCÞ þ εBz þ εyz Þ;
>
>
>
< u5 ¼ sin αðεz ðxÞ εz ðCÞ εz ðyÞ þ εz ðzÞ þ εxB þ εxy Þ cos2 αεy ðBÞ;
v ¼ cos2 αðε ðCÞ ε ðxÞ þ ε ðyÞ ε ðzÞ ε Þ þ cos α sin αðε ðCÞ ε ðxÞ þ ε ðyÞ
1 (C1)
>
>
x
εz ðzÞ εxB εxy Þ;
y y y xz z z z
>
>
>
> v2 ¼ cos αsinα þ cos2 αðεx ðxÞ εx ðyÞ þ εx ðzÞ εy ðCÞ þ εBz þ εyz Þ þ sin2 αεx ðBÞ;
>
>
>
> v3 ¼ cos α sin α þ cos2 αðεx ðxÞ εx ðyÞ þ εx ðzÞ εy ðCÞ þ εBz þ εyz Þ þ sin2 αεx ðBÞ;
>
> v4 ¼ ðcos2 αðεx ðCÞ þ εy ðyÞÞ þ cos α sin αðεz ðCÞ þ εz ðyÞÞÞ;
>
>
>
> 2
: v5 ¼ cos α sin αðεx ðBÞ εx ðxÞ εx ðzÞ εBz εyz þ εx ðyÞ þ εy ðCÞÞ sin α;
v6 ¼ ðsin αðεy ðxÞ þ εy ðzÞ þ εxz εx ðCÞ εy ðyÞÞ þ sin2 αεz ðBÞ þ cos α sin αεy ðBÞÞ:
8
> ux ¼ q7x ðcosC sin Cðεz ðCÞ εz ðxÞ þ εz ðyÞ εz ðzÞ εxy ÞÞ þ q7y ðsin C þ cosCðεz ðCÞ
>
>
>
> εz ðxÞ þ εz ðyÞ εz ðzÞ εxy ÞÞ þ q7z ðcosCðεy ðxÞ εx ðCÞ εy ðyÞ þ εy ðzÞ þ εxz εx
>
>
> ðxÞÞ þ sin Cðεx ðyÞ εx ðzÞ þ εy ðCÞ εyz Þ εy ðCÞÞ qwx δx ðCÞ þ cosCðδx ðxÞ δx
>
>
>
>
> ðyÞ þ δx ðzÞÞ þ sin Cðδy ðxÞ δy ðyÞ þ δy ðzÞÞ þ cos B cos Cδx ðBÞ þ cos α cos B sin C
>
>
> 2
> y ðBÞ þ cosα sin B sin Cδx ðBÞ þ Lðcosα sin α sin C þ cos C sin α sin B þ cos αðεy
>
>
δ
>
> ðCÞ þ cos B sin Cε ðBÞ sin B sin Cε ðBÞ þ cosCðε ðCÞ ε ðxÞ þ ε ðyÞ ε ðzÞ
> x y x y y
> ε Þ þ sin Cðε ðxÞ ε ðyÞ þ ε ðzÞ ε ðCÞ þ ε þ ε ÞÞ þ sin2 αðsin Cε ðBÞ þ cos B
y
>
>
>
>
xz x x x y Bz yz x
> εy ðCÞ þ cos BcosCðεx ðCÞ εy ðxÞ þ εy ðyÞ εy ðzÞ εxz Þ þ cos B sin Cðεx ðxÞ εx ð
>
>
>
>
> yÞ þ εx ðzÞ εy ðCÞ þ εBz þ εyz ÞÞ cos α cos B cos Cεy ðBÞ cos α cos C sin Bεx ðBÞþ
>
>
>
> cos α cos C sin αðεz ðCÞ εz ðxÞ þ εz ðyÞ εz ðzÞ εxB εxy Þ þ cos BcosC sin αεz ðBÞ
>
>
>
> þcos α cos B sin α sin C sin α sin B sin Cðεz ðCÞ εz ðxÞ þ εz ðyÞ þ εz ðzÞ þ εxB þ εxy
>
>
>
> Þcos α cos BcosCðεz ðCÞ þ εz ðxÞ þ εz ðyÞ þ εz ðzÞ þ εxB þ εxy ÞÞ;
>
>
>
> uy ¼ q7x ðsin C cosCðεz ðCÞ εz ðxÞ þ εz ðyÞ εz ðzÞ εxy ÞÞ þ q7y ðcosC þ sin Cðεz ð
>
>
>
>
> xÞ þ εz ðzÞ þ εxy εxz Þ þ εx ðCÞÞ þ q7z ðcosCðεx ðyÞ εx ðxÞ εx ðzÞ þ εy ðCÞ þ εyz Þþ
>
>
> sin Cðεx ðCÞ εy ðCÞ εy ðyÞ εy ðzÞÞ qwx sin2 Cðεz ðCÞ þ εz ðyÞÞ qwy ð1 þ cos C
>
>
>
>
< sin Cðεz ðCÞ þ εz ðyÞÞÞ þ cosCδy ðxÞ δy ðCÞ cosCðδy ðyÞ δy ðzÞÞ sin Cðδx ðxÞ
δx ðyÞ þ δx ðzÞÞ cos B sin Cδx ðBÞ cos C sin αδz ðBÞ þ sin B sin Cδy ðBÞ þ cosα (C2)
>
>
> cos B cos Cδy ðBÞ þ cosα sin B cos Cδx ðBÞ þ Lðþcosα sin α cos C sin α sin B sin
>
>
> 2
> C þ cos αðcos Cðεx ðxÞ εx ðyÞ þ εx ðzÞ εy ðCÞ þ εBz þ εyz Þ sin Cðεx ðCÞ 2εy ðxÞ
>
>
>
> þεy ðyÞ εy ðzÞ εxz Þ þ cos B cos Cεx ðBÞ εx ðCÞ sin B cos Cεy ðBÞÞ þ sin αðcos
>
>
>
> Cεx ðBÞ cos B cos Cðεx ðyÞ εx ðzÞ þ εy ðCÞ εBz εyz Þ cos B sin Cðεx ðCÞ εy ðx
>
>
>
> Þ þ εy ðyÞ εy ðzÞ εxz Þ cos Bεx ðCÞÞ þ cosα sin α cos B cos C þ cosα cos B sin Cεy
>
>
>
>
> ðBÞ þ cosα sin B sin Cεx ðBÞ cos B sin α sin Cεz ðBÞ sin α sin B cos Cðεz ðCÞ εz
>
>
> ðxÞ þ εz ðyÞ εz ðzÞ εxB εxy Þ þ ðcosα sin α sin C cosα sin α cos B sin CÞðεz ðxÞ
>
>
>
> þεz ðzÞ þ εxB þ εxy ÞÞ;
>
>
>
>
> uz ¼ q7x ðcosCεy ðCÞ þ sin Cεx ðCÞ þ εx ðCÞ εy ðxÞ þ εy ðyÞ εy ðzÞ εxz Þ þ q7y ðsin Cεy
>
>
>
> ðCÞ cosCεx ðCÞ þ εx ðxÞ εx ðyÞ þ εx ðzÞ εy ðCÞ þ εyz Þ þ q7z qwz þ δz ðxÞ δz ðC
>
>
>
> Þ δz ðyÞ þ δz ðzÞ þ cosαδz ðBÞ þ sinαsinBδx ðBÞ þ cos B sin αδy ðBÞ Lðcos2 αþ
>
>
> sin2 αcosB þ cos α sin αðεx ðBÞ εx ðxÞ þ εx ðyÞ εx ðzÞ þ εy ðCÞÞ þ sin αsinBðεy ð
>
>
>
>
> xÞ εx ðCÞ εy ðyÞ þ εy ðzÞÞ cos α sin αsin2 CðεBz þ εyz Þ sin αsinBsin2 Cεxz þ
>
>
>
> cos α sin αcosCεx ðCÞ ðcos α sin α sin C þ cos C sin α sin BÞεy ðCÞ ðsin α sin B
>
>
>
>
: sin C cos α sin α cos BcosCÞεx ðCÞ cos α sin α cos B sin Cεy ðCÞ þ cos α sin α
>
cos Bðεx ðxÞ εx ðBÞ þ εx ðyÞ þ εx ðzÞ þ εy ðCÞ þ εBz þ εyz Þ þ cos α sin α sin Bεy ðBÞÞ:
97
C. Wu et al. International Journal of Machine Tools and Manufacture 124 (2018) 80–98
Appendix D
2 sin Cðεx ðyÞ þ εy ðCÞ
3
cos C sin Cðεz ðCÞ sin C cos C εx ðxÞ εyz Þ cosC
6 þε 07
6 z ðyÞ εxy Þ ðεz ðCÞ þ εz ðyÞÞ ðεx ðCÞ þ εy ðyÞ þ εy ðxÞ 7
6 þεxz Þ εy ðCÞ 7
6 cosCðεx ðyÞ þ εy ðCÞ 7
Tw ¼ 6 sin C cos Cðεz ðCÞ 7
6 þε ðyÞ ε Þ cos C þ sin C εx ðxÞ εyz Þ þ sin C
07
6 z ðεz ðCÞ þ εz ðyÞÞ ðεx ðCÞ þ εy ðyÞ þ εy ðxÞ 7
6 7
xy
þεxz Þ þ εx ðCÞ
4 εx ðCÞ þ εy ðyÞ þ cos C εy ðCÞ þ εx ðyÞ þ cos C 5
1 0
εy ðCÞ þ sin Cεx ðCÞ εx ðCÞ sin Cεy ðCÞ
2 0 0 0 3 1
u1 sinα cos αεx ðBÞ u2 u3
6 u4 u5 0 ðεx ðCÞ þ εy ðyÞÞ 7
Tv1 ¼ 6
4 cos α sin αεx ðCÞ
7
sin αεy ðCÞ sin αεx ðCÞ cos α sin αεy ðCÞ 5
2 0 0 0 3 0
v1 v2 sin2 αεy ðCÞ 0
6 v3 v4 εx ðCÞ 07
Tv2 ¼ 6
4 cos α sin αεx ðCÞ cos α sin αεy ðCÞ
7
v5 v6 5
0 0 0 0
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