In-Process Compensating for the Body Deformation by Image-Processing for High-Accuracy Processing of Small Desktop Machine Tool

Abstract

The dimensions of machine tools are often larger than necessary for production needs. By miniaturizing these machines, companies can reduce energy consumption and costs by scaling down manufacturing lines. Smaller machines are also easier to transport and install, enabling more flexible manufacturing setups. However, smaller machine tools have lower rigidity, which can cause significant deformation during machining and lead to greater machining errors compared to larger tools. This study focuses on achieving high-precision machining by compensating for tool displacement caused by machine deformation. The proposed method estimates actual cutting amount by measuring tool displacement in real-time using image processing. Additionally, the study introduces a method for compensating machining errors during multi-process machining by tracking tool tip displacement with image processing. Cutting tests confirmed that the method accurately estimates the actual cutting amount using both fixed cameras and robotic systems that maintain the tool-camera position. Furthermore, results comparing uncorrected and compensation-controlled machining demonstrate the method's effectiveness for achieving highly accurate machining.