An investigation into fixture error compensation in micromilling using tool-based conductive touch-off

Jacob A. Kunz, Angela Sodemann, J. Rhett Mayor

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Citation (Scopus)

Abstract

In micro-milling, decreased tool size leads to a need for tighter tolerances for fixture error in order to avoid excessive tool load and maintain machining accuracy. In 4-axis machining on a curved surface, fixture errors propagate cumulatively leading to a significant error at the tool tip. As a result a compensation approach is essential to successful micro-feature production on curved surfaces. Tool stresses are shown to be highly dependent on the amount of fixture error. The scaling down of tool sizes is shown to result in an exponential increase in tool stresses. This paper proposes the use of a conductive touch-off method that utilizes the milling tool in its spindle to perform an in-situ registration mapping of positional errors. The fixturing errors are characterized using the Denavit-Hartenberg robotic linkage convention. A forward kinematic solution uses homogeneous transformation matrices to investigate the effects of fixturing errors on milling tool path errors in 4-axis micro-milling on curved surfaces. The touch-off registration measures the positional error in the tool axis direction allowing for axial tool position compensation. This results in decreased tool stresses and increased channel depth accuracy which is necessary for successful milling. A preliminary implementation of the conductive touch-off registration approach has demonstrated the efficacy of the technique when applied to production of micro-features on concave surfaces.

Original languageEnglish (US)
Title of host publicationASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010
Pages381-389
Number of pages9
Volume2
DOIs
StatePublished - 2010
Externally publishedYes
EventASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010 - Erie, PA, United States
Duration: Oct 12 2010Oct 15 2010

Other

OtherASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010
CountryUnited States
CityErie, PA
Period10/12/1010/15/10

Fingerprint

Error compensation
Machining
Kinematics
Robotics

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

Cite this

Kunz, J. A., Sodemann, A., & Mayor, J. R. (2010). An investigation into fixture error compensation in micromilling using tool-based conductive touch-off. In ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010 (Vol. 2, pp. 381-389) https://doi.org/10.1115/MSEC2010-34273

An investigation into fixture error compensation in micromilling using tool-based conductive touch-off. / Kunz, Jacob A.; Sodemann, Angela; Mayor, J. Rhett.

ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. Vol. 2 2010. p. 381-389.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Kunz, JA, Sodemann, A & Mayor, JR 2010, An investigation into fixture error compensation in micromilling using tool-based conductive touch-off. in ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. vol. 2, pp. 381-389, ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010, Erie, PA, United States, 10/12/10. https://doi.org/10.1115/MSEC2010-34273
Kunz JA, Sodemann A, Mayor JR. An investigation into fixture error compensation in micromilling using tool-based conductive touch-off. In ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. Vol. 2. 2010. p. 381-389 https://doi.org/10.1115/MSEC2010-34273
Kunz, Jacob A. ; Sodemann, Angela ; Mayor, J. Rhett. / An investigation into fixture error compensation in micromilling using tool-based conductive touch-off. ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. Vol. 2 2010. pp. 381-389
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