Combined contour error control method for five-axis machine tools based on digital twin
Abstract Contour error is a critical factor influencing machining quality. This paper proposes a combined contour error control method for five-axis machine tools based on digital twin. The proposed method combines pre-compensation implemented in digital twin with feedback control in the real-time c...
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| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Nature Portfolio
2025-05-01
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| Series: | Scientific Reports |
| Subjects: | |
| Online Access: | https://doi.org/10.1038/s41598-025-02047-2 |
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| Summary: | Abstract Contour error is a critical factor influencing machining quality. This paper proposes a combined contour error control method for five-axis machine tools based on digital twin. The proposed method combines pre-compensation implemented in digital twin with feedback control in the real-time controller. After obtaining the tool path input, the digital twin performs interpolation and applies model predictive pre-compensation control to the interpolated commands to control modeled errors. The pre-compensated commands and interpolation data are sent to the real-time controller where contour error is estimated and controlled in each control cycle through feedback control to control unmodeled errors. Using the S-shaped curve as the test case, the maximum tool tip position contour error is reduced by 77.78%, with an average reduction of 83.90%. The maximum tool orientation contour error decreased by 79.05%, with an average reduction of 86.66%. The experimental results demonstrate that the proposed method significantly reduces tool contour error. |
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| ISSN: | 2045-2322 |