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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| Format: | Article |
| Language: | English |
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Nature Portfolio
2025-05-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-02047-2 |
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| author | Liuquan Wang Ruijie Yang Shisheng Lv Zhiqi Yang Shuwei Xin Yanqiang Liu Qiang Liu |
| author_facet | Liuquan Wang Ruijie Yang Shisheng Lv Zhiqi Yang Shuwei Xin Yanqiang Liu Qiang Liu |
| author_sort | Liuquan Wang |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-dcd84bc0ed064cffbd99fc0f7360bcdf |
| institution | OA Journals |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-dcd84bc0ed064cffbd99fc0f7360bcdf2025-08-20T02:29:26ZengNature PortfolioScientific Reports2045-23222025-05-0115112210.1038/s41598-025-02047-2Combined contour error control method for five-axis machine tools based on digital twinLiuquan Wang0Ruijie Yang1Shisheng Lv2Zhiqi Yang3Shuwei Xin4Yanqiang Liu5Qiang Liu6School of Mechanical Engineering and Automation, Beihang UniversitySchool of Mechanical Engineering and Automation, Beihang UniversitySchool of Mechanical Engineering and Automation, Beihang UniversitySchool of Mechanical Engineering and Automation, Beihang UniversitySchool of Mechanical Engineering and Automation, Beihang UniversitySchool of Mechanical Engineering and Automation, Beihang UniversitySchool of Mechanical Engineering and Automation, Beihang UniversityAbstract 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.https://doi.org/10.1038/s41598-025-02047-2Contour error controlDigital twinModel predictive pre-compensation controlFive-axis machine tool |
| spellingShingle | Liuquan Wang Ruijie Yang Shisheng Lv Zhiqi Yang Shuwei Xin Yanqiang Liu Qiang Liu Combined contour error control method for five-axis machine tools based on digital twin Scientific Reports Contour error control Digital twin Model predictive pre-compensation control Five-axis machine tool |
| title | Combined contour error control method for five-axis machine tools based on digital twin |
| title_full | Combined contour error control method for five-axis machine tools based on digital twin |
| title_fullStr | Combined contour error control method for five-axis machine tools based on digital twin |
| title_full_unstemmed | Combined contour error control method for five-axis machine tools based on digital twin |
| title_short | Combined contour error control method for five-axis machine tools based on digital twin |
| title_sort | combined contour error control method for five axis machine tools based on digital twin |
| topic | Contour error control Digital twin Model predictive pre-compensation control Five-axis machine tool |
| url | https://doi.org/10.1038/s41598-025-02047-2 |
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