Geometric error compensation through position feedback modification and comparison of correction strategies in 3- axis machine-tool

In machine-tools, geometrical defects are unavoidable. They can greatly affect the dimensional accuracy of the final workpiece if not corrected. Software compensation strategies are less expensive than mechanical adjustments and they provide great improvement in volumetric accuracy. In this study, different compensation methods are compared in a 3-axis milling applications: Numerical Controller (NC) internal compensation tables, modification of the programmed tool-path (G-code) and modification of position feedback signals. The latter is the main purpose of this work, because it shows great potential and is not linked to one particular type of NC. It communicates with a custom software application that processes the position data and generates corrected signals according to a geometric model based on the rigid body assumption. The NC is then induced to perform volumetric error correction based on its default programming. The compensation methods are compared based on their ability to bring out or correct imposed geometric errors. The highlighted solution shows performances comparable to the G-code modification by correcting more than 96% of the imposed geometric errors without affecting the numerical chain from the program generation to its execution on the machine. It is also independent of the NC or the motors control cards.