Construction of Online Identification and Compensation System for Ultra-precision Turning Tool-above-centre Error Based on Force Sensing

doi:10.3901/JME.2025.19.397

Abstract

Abstract: An online identification and compensation system for ultra-precision turning tool-above-centre error based on force sensing is proposed, aiming to solve the problems of machining continuity disruption and machining efficiency impact during offline identification of tool-above-centre error. Firstly, the surface morphology formed by the residual interference between the tool back face and the workpiece center when the tool-above-centre error exists, and its corresponding cutting force characteristics are studied, and the mapping relationship model between the tool-above-centre error and the cutting force is established. Secondly, the automatic identification algorithm of tool-above-centre error based on this mapping relationship is designed, and the execution program and interface are developed using LabVIEW software. Finally, the online recognition system is used in the machining experiments to identify the features of the force signals during the cutting process, output the tool-above-centre error, and compensate for the error online with the precision fine-tuning mechanism integrated into the experimental platform. Experimental results show the average difference between the tool-above-centre error identified by cutting force recognition and the machine tool feedback error is within 8 μm. The identified error is quickly compensated by a precision micro-adjustment mechanism, with a deviation within 1%. The entire identification and compensation process takes only about one minute, demonstrating the reliability and rapidity of the online tool- above-centre error identification and compensation system. This study will provide a new reference for the automatic identification and compensation of tool setting errors in ultra-precision machining.

Key words: ultra-precision turning, cutting force, tool-above-centre error, online recognition and compensation

CLC Number:

TH161

ZHANG Wenqi, ZHANG Guoqing, MA Shuai. Construction of Online Identification and Compensation System for Ultra-precision Turning Tool-above-centre Error Based on Force Sensing[J]. Journal of Mechanical Engineering, 2025, 61(19): 397-406.

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