Accuracy Analysis of Machining Trajectory Contemplating Workpiece Dislocation on a Six Degree of Freedom Machining Bed

Abstract

Machining is material removal from a workpiece. Current spindle technologies allow the material to be removed very quickly but unfortunately this compromises the accuracy of the desired machined trajectory on the workpiece. Proposed solution to the problem is restricting motion of the tool and giving rotation to the workpiece. This paper presents analysis of the accuracy of trajectory of material removal from a workpiece, such that the workpiece rotates with six degrees of freedom, in the presence of error generated due to an offset of the workpiece from centre of the moving platform of the machining bed. The kinematics of the machining bed is, therefore, modeled using as inverse kinematic formulation applying geometric and vector addition method. The mechanism outputs three rotational and three translational motions. The leg length for each of six legs of the bed is computed individually. Moreover, workpiece position offset error is modelled to find actual leg lengths of the bed. Finally accuracy computation model is proposed to analyse the accuracy of the final trajectory of the motion of the workpiece. The models are verified in simulation for a trajectory and validated experimentally on a six degree of freedom (6DOF) machining bed. The results reveal maximum inaccuracy in machining trajectory to be 1% in experiments while less than 1% in simulation. This verifies quality of the mechanism and efficacy of the proposed 6DOF machining bed in machining accuracy.