Total differential methods based universal post processing algorithm considering geometric error for multi-axis NC machine tool

Multi-axis numerical control machining for free-form surfaces needs CAD/CAM system for the cutter location and orientation data. Since these data are defined with respect to the coordinate of workpiece, they need converting for machine control commands in machine coordinate system, through a processing procedure called post processing. In this work, a new universal post processing algorithm considering geometric error for multi-axis machine tool with arbitrary configuration. Firstly, ideal kinematic model and real kinematic model of the multi-axis NC machine tool are built respectively. Difference between the two kinematic models is only whether to consider the machine tool's geometric error or not. Secondly, a universal generalized post processing algorithm containing forward and inverse kinematics solution is designed to solve kinematic models of multi-axis machine tool. Specially, the inverse kinematics solution is used for the ideal kinematic model, while the forward kinematics solution is used for the real kinematic model. Then, a total differential algorithm is applied to improve the calculation speed and reduce the difficulty of inverse kinematics solution. Realization principle of the total differential algorithm is to transform the inverse kinematics solution problem into that one of solving linear equations based on spatial relationship of adjacent cutter locations. Thirdly, to reduce the complexity of geometric error calibration experiment, effect weight of geometric error components is determined by the sensitivity analysis based on orthogonal method, and then the real kinematic model considering geometric error is established. Finally, the universal post processing algorithm based on total differential methods is implemented and demonstrated experimentally in a five-axis machine tool. The results show that the maximum error value can be decreased to one-fifth using the proposed method in this paper. •It proposed a universal post-processing algorithm considering geometric error for multi-axis machine tool with arbitrary configuration.•Based on ideal and real kinematic models of the machine tool, a universal generalized post-processing algorithm containing forward kinematics solution and inverse kinematics solution is designed.•Total differential algorithm is applied to improve the calculation speed and reduce the difficulty of inverse kinematics solution.•Effect weight of factors of each axis geometric error component and distribution rules of