AN ADAPTIVE ERROR-CORRECTION METHOD USING FEATURE-BASED ANALYSIS TECHNIQUES FOR MACHINE PERFORMANCE IMPROVEMENT .2. EXPERIMENTAL-VERIFICATION

The development and derivation of an adaptive error correction method using an interactive inspection system and feature-based analysis tech nique for machine performance improvement were presented in Part 1 of this paper. Here, in Part 2, the experimental verification of the deri ved feature-based residual error models and analysis technique is desc ribed in derail. The experimental procedure and results of both the pr ocess-intermittent and the post-process gauging are presented. A polyn omial regression method is used to derive the parametric functions tha t represent the deviation of imperfect features from nominal. The outp ut of these polynomial functions is compared with process-intermittent inspection data to determine the machine errors and then to identify the residual systematic errors. Feature-based residual error models ar e used to correlate the residual errors to the systematic residual err or components. Inverse kinematics technique and multiple regression me thods are used to identify and characterize the contribution of each e rror component as a function of the machine's temperature profile and nominal position. The residual error components are then combined with the error components identified through the pre-process characterizat ion process to refine the geometric-thermal error model. After the err or model is adaptively fine tuned, it can be used more effectively to compensate the machine tool error for more precise manufacturing.