A 3-D Machine Tool Error Modeling System

In response to the increasing demand for better understanding of the manufacturing processes and the machining systems, a new testing standard--ASME B5.54 and a family of new testing instruments have been developed for evaluating the performances of a variety of CNC machining centers. Because of the advancement and versatility of the new instruments, test data are being collected at a much higher rate and complexity than with the conventional dial- gage or straight-edge techniques. This calls for a more intelligent way to present the potential machine errors and the part errors than the conventional X-Y plots of errors versus machine axis travel. A means of presenting the potential machine and part errors proposed in here is to use computer emulation. This proposal describes a plan to develop a 3-D Machine Error Modeling System which can emulate the part cutting process on a machine and eventually display the part errors a 3-D solid model fashion. The work plan will begin with a detail analysis of some 200+ machine measurement data files to identify the machine error sources and the type of instruments used to perform the measurements. A 2-D machine error modeling system will first be developed and then expanded to a 3-D modeling capability. In Phase II, the work will be expanded to include developing advanced machine and part error modeling techniques which can then be used to develop corrective actions for the entire manufacturing process. It is anticipated that this technology can be assessed through the Internet or the information superhighway for many manufacturing companies, large or small.