Closed Force Loop Evaluation of Machining Systems

Machine tools accuracy has been a cornerstone in defining machining system capability and directly affecting dimensional and geometrical tolerance of machined parts. The effort for achieving higher precision and accuracy can be distinguished in two general ideas. One is to improve performance of machine tools by designing better, stiffer and more accurate machine tools. The other is to develop tools and methods for evaluating and measuring their behaviour and gain knowledge of their performance. In order to properly control the machine tool characteristics that can affect and improve their accuracy such as static stiffness and static accuracy.This thesis is aiming at establishing and further advancing the idea of loaded testing of machining systems and the concept of Elastically Linked Systems as a framework for measuring, identifying and characterising quasi-static stiffness of machine tools under loaded conditions. This will allow the creation of an improved capability profile of machining system accuracy. The focus is on the implementation of Elastically Linked Systems concept (ELS) through the Loaded Double Bar system, a measurement method that can partly simulate the process-machine interaction by reproducing forces exerted on the machine tool structure for the evaluation of system characteristics under loaded condition. This allows the qualitative and quantitative evaluation and comparison of machine tools for the purpose of accuracy enhancement, identification of weak directions with potential utilization in process planning, machine procurement and maintenance.Through two case studies, the capability to identify the effect of machine components and structure behaviour is shown.QC 20180514