Thermal error modeling of CNC milling machine tool spindle system in load machining: based on optimal specific cutting e

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(2020) 42:456

TECHNICAL PAPER

Thermal error modeling of CNC milling machine tool spindle system in load machining: based on optimal specific cutting energy Hai‑tao Yue1 · Chen‑guang Guo1 · Qiang Li1 · Li‑juan Zhao1 · Guang‑bo Hao2 Received: 6 December 2019 / Accepted: 28 July 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020

Abstract The aim of this study is to reduce the influence of machine tools spindle thermal error on machining accuracy in load machining state. The temperature and thermal error measuring system and experiments of the 3-axis vertical milling machine tool spindle in idling and load machining state were established and carried out. The differences in temperature and thermal error between the idling and load machining states were analyzed. Upon combining the fuzzy clustering and gray correlation algorithm, the temperature-sensitive points were optimized. The thermal error prediction models of machine tool spindle system in load machining state with the optimal specific cutting energy were established based on the adaptive chaotic particle swarm optimization algorithm, and the model prediction effects were evaluated. The results showed that the spindle system temperature and thermal error in load machining were higher than the idle state. Two temperature-sensitive points were selected that not only reduced the redundancy of temperature measuring points but also ensured the model prediction accuracy. The thermal error models prediction accuracy was above 90%, and the root mean square error and residual error were better than PSO and regression. The experimental results showed that the thermal error prediction models have a high prediction accuracy and engineering application value. Keywords  Machine tool spindle system · Load machining · Specific cutting energy · Measuring points optimization · Thermal error modeling

1 Introduction Thermal error as the main error source accounts for 40–70% of the total machine tool errors [1–3]. As the main thermal influence area of machine tools [3], the variations in spindle system thermal error affect the machining accuracy seriously. With the enhancement of environmental protection awareness, as an important part of the machinery manufacturing industry, the key to green and sustainable development of manufacturing industry is to realize energy conservation and consumption reduction in machine tool processing [4–6]. The successful thermal error compensation Technical Editor: Lincoln Cardoso Brandao. * Chen‑guang Guo [email protected] 1



School of Mechanical Engineering, Liaoning Technical University, Fuxin, China



Department of Electrical and Electronic Engineering, University College Cork, Cork, Ireland

2

research on machine tool spindle system in load machining based on optimal processing energy consumption is of great significance to the realization of high precision, high energy efficiency and green sustainable machine tool processing technology. The traditional methods of thermal error compensation mainly include: (1) Instal