Influence of Motion Error of Translational and Rotary Axes onto Machined Surface Generated by Simultaneous Five-axis Motion

In the machining process the dynamic behaviors of machine tools, such as tool vibration, vibration of mechanical structure, and motion error of feed drive systems, influence the machined surface. However, the influence of dynamic behaviors onto the machined surface generated by simultaneous five-axis motion has not been investigated up to now. This study focuses on the influence of motion error of translational and rotary axes onto the machined surface generated by a simultaneous five-axis motion. The geometry used for the tests is the cone frustum, which is typically used for evaluating machining accuracy of five-axis controlled machine tool. A method to simulate the tool motion trajectory and tool orientation for a five-axis machine has been developed based on the modeling of the feed drive systems considering their dynamic characteristic. The machined surface of cone frustum is predicted based on the simulated results. In order to verify the validity of simulation result and the influence of motion error in each axis on the finished surface, cutting tests have been carried out. The tests have proven that the proposed simulation method can predict the machined surface. The influence of motion error in each axis on finished surface is also discussed based on the results of cutting tests and simulations.