Multi-stage error compensation with closed-loop quality control in five-axis flank milling of sculptured surface

Machining efficiency and accuracy are subjected to higher requirements due to the increasingly widespread application of sculptured surface parts in the fields of aerospace, transportation, and energy. However, the influence of geometric error, tool deflection, and other factors decreases the quality and reliability of CNC machined workpiece. Error compensation is a popular and effective way to improve the machining accuracy of the workpiece. A novel multi-stage error compensation methodology that combines model-based and data-driven approaches is proposed, which realizes the closed-loop quality control process of the sculptured surface by five-axis flank milling. The global process consists of two special stages. First, the compensated machining of stage I is completed by a flexible mirror compensation method after establishing the tool deflection prediction model, which is the major factor causing the geometric error of the machined part. Subsequently, based on the on-machine measurement (OMM) data, the surface is automatically reconstructed by mirror points in 3D software and the toolpath for stage II compensated machining is generated. Finally, the verification experiment on the five-axis machine tool demonstrates that the methodology introduced in this research can effectively enhance the machining accuracy of the workpiece.