Reduction of errors and improvement of accuracy in 5-axis/5-face machining through ball (reference sphere) measurement.
To ensure accuracy in a 5-axis machining center equipped with two rotary axes such as the AC axis in addition to the orthogonal XYZ axes, it is necessary to minimize errors such as deviations and tilts at the center of the rotary axes. The precision adjustment of the 5-axis machining center, which is said to be complex and difficult, can be performed automatically using a ball (reference sphere) measurement macro. By employing a "database-type error correction" method, it is possible to correct error factors that were difficult to eliminate with conventional correction methods.
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basic information
The ball (reference sphere) measurement macro is a macro program that measures the position of a reference sphere with a diameter of approximately 25mm using a touch probe to measure and correct the errors of a 5-axis table. The error correction is divided into the following two stages. 【First Stage】 Measurement of the Rotation Center This is a macro program that measures the trajectory of the ball (reference sphere) mounted on the 5-axis table with a touch probe and automatically aligns the rotation center coordinates. The traditional method using a test bar and dial gauge, which made aligning the rotation center complicated and difficult, can now be done in a short time through ball (reference sphere) measurement. 【Second Stage】 Database Error Correction This is a macro program that corrects the machining origin based on an error database for each tilt axis angle. Even after performing the first stage of rotation center measurement, various other errors accumulate, causing the actual position of the ball (reference sphere) when the 5-axis table is indexed to deviate from the theoretical position. The amount of this deviation is measured and recorded with a touch probe for every 15° of tilt axis angle to build the error database. Based on this error database, the correction amount corresponding to the tilt axis angle during machining is added to the machining origin, allowing for the correction of errors that could not be eliminated in the first stage.
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Price range
P4
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Applications/Examples of results
<Significant Reduction in Initial Product Defects> As a result of introducing the ball (reference sphere) measurement macro, the defect rate in 5-axis machining, particularly initial product defects, has been reduced. During the startup of new workpieces, it often takes multiple iterations of error correction processes to finally achieve the first good product. With the introduction of the ball (reference sphere) measurement macro, we have significantly reduced the time required for the dimensional adjustment process of these initial products. <Operation Possible Even with Machines Having Accuracy Issues> There were machines with a history of accidents and poor accuracy that implemented the ball (reference sphere) measurement macro. By introducing a database-type error correction macro, we were able to secure the necessary accuracy. This has allowed us to maintain production and ensure machining accuracy without spending time and costs on repairing the 5-axis table.
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Company information
Listener Engineering is an expert in macro programming. We create macros for 5-axis machine alignment measurement, work measurement, tool measurement, etc., tailored to your needs.