Machining Error Compensation Based on the Reconstructed Free-Form Surfaces of CAD Models

To reduce the machining errors as much as possible is a goal for many machine shops. After a part is machined and measured, the errors are known but how to reduce them is still an issue. The objective of this research was to develop an automatic system, which can adopt the measured data to modify the original CAD model of the machined part so that the cutting tool paths can be regenerated based on the reconstruction of the CAD model. Then we can perform finish machining on the part by using the new tool paths to remove much of the remaining errors. We already completed the two-dimensional profile machining and found promising. The errors of three squares with different orientations can be controlled within 0.0065 mm. We are continuing to work on the three-dimensional free-form surfaces.