Research On Dynamic Contour Error Compensation Technology Of Ultra-precision Machine Tool By FTS

Fast tool serve(FTS)ultra-precision turning technology is very promising in the manufacture of micro-nano structured functional surfaces and free-form surfaces.In this paper,the main goal is to compensate the dynamic contour error triggered by the inertial vibration of the Z-axis motion platform in the ultra-precision machine tool processing.A set of high-frequency and high-precision FTS device is developed,and an experimental system is set up to extract the error caused by the inertial vibration.The device performs ultraprecision real-time amplitude control to compensate for dynamic contour errors and improve the quality of the processed surface.The main research content of this article is summarized as follows:(1)A high-performance FTS device was designed,the mechanical characteristics of the flexible tool holder were comprehensively modeled and analyzed,and the BP neural network algorithm optimized by genetic algorithm(GA)was used to perform multiobjective optimization design on the tool holder.The finite element analysis of the optimized structure through Ansys software verified the correctness of the design process.(2)The FTS prototype was manufactured and assembled,a test experiment system was built,and a series of necessary performance tests were carried out.The test results showed that the device met the design requirements and proved the correctness of the theoretical design work.For red copper rods,the prototype machine was used to carry out the processing experiment of the typical sinusoidal microstructure surface.The experimental results show that the manufactured FTS device has stable and good actual processing ability.(3)The measurement principle of the Z-axis high-precision grating system of ultraprecision machine tools is studied,a signal extraction scheme is designed,and a control system is set up to read and extract the Z-axis grating signal in real time.Based on the LABVIEW programming language,the host computer software design is carried out,and the development of various functions is completed to realize the real-time monitoring of the position of the Z-axis motion axis and the extraction and conversion of the position error,and output as the amplitude control signal of the FTS.(4)The design experiment studied the inertial vibration and the dynamic contour error caused by the machine tool Z axis during the movement process,verified the correctness of the signal extraction scheme,and verified the contour error easily caused by the inertial vibration of the Z axis,Make the processing accuracy worse.In order to compensate this contour error,a method of real-time amplitude control of FTS to compensate the error was proposed,and an experimental system was built.Using the proposed method,a compensation processing experiment was carried out,which verified the feasibility and correctness of the proposed compensation method,and provided a new optimization idea for the creation of high-quality surfaces and the control of manufacturing errors.