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12–2 Prediction of Machining Accuracy of 5-Axis Machine Tools with Kinematic Errors
M. Sharif Uddin1, S. Ibaraki2, A. Matsubara3, and T. Matsushita4
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Kyoto University, Kyoto, Japan, 606-8501,ms_uddin@preceng.mbox.media.kyoto-u.ac.jp Kyoto University, Kyoto, Japan, 606-8501, ibaraki@prec.kyoto-u.ac.jp 3 Kyoto University, Kyoto, Japan, 606-8501, matsubara@prec.kyoto-u.ac.jp 4 Okuma Corp.,Aichi, Japan 480-0193, te-matsushita@gmx.okuma.co.jp Abstract. Kinematic errors due to geometric inaccuracies in 5axis machine tools cause deviations in tool positions and orientation from commandedvalues, which consequently affect geometric accuracy of the machined surface. The present research work studies the prediction of machining accuracy of a 5-axis machine tool with its kinematic errors.First, kinematic errors associated with linear and rotary axes of a 5-axis machine tool with tilting rotary table types, are identified by a DBB method. By using an error model of the machine tool,erroneous tool position and orientations are computed. Then, machining error with respect to the nominal geometry is predicted and evaluated. With the aim to improve the geometric accuracy of a machinedsurface, an error compensation for tool position and orientation is also presented. As an example, the machining of a tilted taper cone by using a straight end mill, as described in the standardNAS979, is considered in a case study to experimentally verify the prediction and the compensation of machining errors in 5-axis machining. Keywords: 5-axis machining, kinematic errors, geometricinaccuracy, DBB, error compensation

1. Introduction
With a tremendously increasing need for machined components with geometric complexity and high dimensional accuracy, 5-axis machine tools areextensively used in the manufacturing of dies and molds, and aerospace parts. Because of having its versatile functionalities, a 5-axis mache tool offers notable benefits including increased material removal...