Analysis of Geometrical Errors of XYZAC 5-Axis Milling Machine using BALLBAR Device

In this research, errors and accuracy of a 5-axis machine tools are investigated using a balbar device. The focus is on the measurement of positional errors and rotational errors related to rotational axes. Therefore, first, using homogeneous transformation matrices and based on the kinematic chain of machine axes, a mathematical error modeling is done for each axis in order to get an overview of the impact of errors on machine operation. In the following, a method to measure these errors is proposed, and to validate this proposed method, its results are compared with a valid method. Homogeneous transformation matrices (HTMs) are used to create a machine tool model and generate bearing error diagrams due to machine tool geometric errors based on the given experimental design. Simulated payload trajectory patterns can be used to evaluate unique fault effects for detected faults and to diagnose machine tool conditions.