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A proposal of models for thermal compensation in machine tools based on a formulation for in-series heat transfer

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Abstract

Machine tools need to possess excellent positioning accuracy to meet increasingly stringent dimensional tolerances and geometric specifications for producing parts. The accuracy is significantly affected by distortions caused by irregular thermal distribution throughout the machine’s structure, with the motorized spindle being a major source of heat. In this study, through finite element analysis, the influence of the spindle’s heating on other machine components is examined, revealing that the air inside the protection cover acts as one of the main mediums for heat transfer from the spindle to other components far from the spindle. A thermal error compensation model is proposed, considering the in-series heat transfer through the air inside the protection cover, leading to a higher-order thermal expansion curve. Additionally, the thermal errors caused by ball screws are addressed using a first-order exponential model. Testing the two models on a CNC turning center shows a considerable reduction in radial thermal error when combined with inputs from the CNC and temperature sensors strategically placed on the machine.

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Authors and Affiliations

  1. Department of Product Engineering, ROMI SA, Rod. SP304 Km141.5, Santa Bárbara D’Oeste, 13450-000, São Paulo, Brazil

    Alexandre B. Zoppellari

  2. Department of Production Engineering, School of Engineering at São Carlos, University of São Paulo -USP, Av. Trabalhador São-carlense 400, São Carlos, 13566-590, São Paulo, Brazil

    Reginaldo T. Coelho

Authors
  1. Alexandre B. Zoppellari
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  2. Reginaldo T. Coelho
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by ABZ and RTC. The first draft of the manuscript was written by ABZ, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Alexandre B. Zoppellari.

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Zoppellari, A.B., Coelho, R.T. A proposal of models for thermal compensation in machine tools based on a formulation for in-series heat transfer. Int J Adv Manuf Technol 130, 2635–2647 (2024). https://doi.org/10.1007/s00170-023-12810-2

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  • DOI: https://doi.org/10.1007/s00170-023-12810-2

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