An Efficient Ultraprecision Machining System Automating Setting Operations of Roughly Machined Workpiece

Abstract

Ultraprecision machining is required in many advanced fields. To create precise parts for realizing their high performance, the whole machining process is usually conducted on the same ultraprecision machine tool to avoid setting errors by reducing setting operations. However, feed rate is relatively slow and machining efficiency is not so high compared to ordinary machine tools. Thus, the study aims to develop an efficient ultraprecision machining system including an industrial robot to avoid manual setting and to automate the setting operations. In this system, ultraprecision machining is conducted for the workpiece having a shape near the target shape, which is beforehand prepared by ordinary machine tools and is located on the machine table by means of an industrial robot. Since the setting errors of the roughly machined workpiece deteriorate machining accuracy, the differences from the ideal position and attitude are detected with a contact type of on-machine measurement device. Numerical control (NC) data is finally modified to compensate the identified workpiece setting errors to machine the target shape on an ultraprecision machine tool. From the experimental results, it is confirmed that the proposed system has the possibility to reduce time required in ultraprecision machining to create precise parts with high efficiency.