Manhart How to reduce the sources of errors and error compensation to improve machining accuracy?

To reduce the sources of errors and perform error compensation to improve machining accuracy, the following measures can be taken:
I. Reduce the sources of errors
1. **Improve equipment accuracy**:
– Select higher-precision measuring equipment and machine tools to ensure the accuracy and reliability of the equipment.
– Calibrate and maintain the equipment regularly to eliminate potential errors.
2. **Optimize the process system**:
– Eliminate potential positioning errors by adjusting the process system, such as adjusting the relative positions of machine tools, fixtures, workpieces and tools.
– Use appropriate processing methods, such as the average original error method, to group parts with large dimensional errors and reduce the errors of each group.
3. **Select suitable tools and materials**:
– Select tools and raw materials that meet the processing requirements to avoid errors caused by tool wear or uneven materials.
4. **Improve experimental design and measurement methods**:
– Design a good experimental plan, introduce control groups, randomization methods and blind experiments, etc. to control the influence of various factors on the experimental results.
– Select high-precision measuring tools and optimize the measurement methods to ensure the accuracy of the measurement.
5. **Reduce the force deformation of the process system**:
– Improve the rigidity of the system, especially the rigidity of the weak links in the process system, to reduce the error caused by deformation.
– Reduce the load and its changes to avoid errors caused by excessive cutting force.
2. Error compensation
1. **Error compensation method**:
– When it is impossible to directly reduce or eliminate the original error in the processing system, the original error can be artificially created to offset the original error inherent in the processing system.
– For example, in the guide rail processing of the grinder, the guide rail is precisely processed using the pre-loading method, that is, the “counterweight” is used instead of the weight of the component, or the guide rail surface is finely processed after the component is assembled.
2. **CNC system parameter compensation**:
– For CNC machine tools, CNC system parameters can be used for error compensation, especially for systematic errors in feed motion, such as pitch accumulation error, backlash error, etc.
– Using software compensation, the compensation value is input into the CNC system through pre-measurement and calculation to eliminate these errors.
3. **Multiple measurements to take the average value**:
– During the measurement process, multiple independent measurements are taken and the average value is calculated to reduce the impact of errors on the results.
– This method has been statistically proven to be an effective way to reduce errors.
Through the above measures, the sources of errors can be effectively reduced and errors can be compensated, thereby significantly improving the processing accuracy. In actual operation, it is necessary to select appropriate measures and use them in combination according to specific processing requirements and conditions to achieve the best results.