Error compensation in machine tools - a review Part I: geometric, cutting-force induced and fixture-dependent errors

Accuracy of machined components is one of the most critical considerations for any manufacturer. Many key factors like cutting tools and machining conditions, resolution of the machine tool, the type of workpiece etc., play an important role, However, once these are decided upon, the consistent performance of the machine tool depends upon its ability to accurately position the tool tip vis-a-vis the required workpiece dimension. This task is greatly constrained by errors either built into the machine or occurring on a periodic basis on account of temperature changes or variation in cutting forces. The three major types of error are geometric, thermal and cutting-force induced errors. Geometric errors make up the major part of the inaccuracy of a machine tool, the error caused by cutting forces depending on the type of tool and workpiece and the cutting conditions adopted, This part of the paper attempts to review the work done in analysing the various sources of geometric errors that are usually encountered an machine tools and the methods of elimination or compensation employed in these machines. A brief study of cutting-force induced errors and other errors is also made towards the end of this paper. (C) 2000 Elsevier Science Ltd. All rights reserved.