A new active error compensatory method of machinery accuracy†

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Abstract
A new active error compensatory method for on-line cutting control has been developed for reduction of the form errors in machining. This approach is a combination of in-process gauging and model active compensatory control. In this approach, there are two features of substantial importance: stochastic modelling and optimum forecasting. Through stochastic modelling, the cutting tool error motions can be represented by a simple model without the necessity of obtaining the complex cause-and-effect relationships between various errors and error sources, and more importantly, it is possible to account for both repeatable and non-repeatable parts of errors. Optimum forecasting is an important prerequisite for a rational control strategy, considering the inevitable time delay associate with sensing, computation and actuation. The proposed control method was implemented for the control of cylindricity in boring operations. Through the controller simulation based on experimental measurements, the improvement in cylindricity accuracy confirms the effectiveness of this proposed strategy