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Thermal analysis and compensation of


a double-column machining centre
Cheng-Hsien Wu* and Yu-Tai Kung
Department of Mechanical and Automation Engineering, Da-Yeh University, Taiwan, People’s Republic of China
The manuscript was received on 17 May 2005 and was accepted after revision for publication on 3 October 2005.

DOI: 10.1243/095440506X77643

Abstract: The objective of this work is to enhance the accuracy of a double-column machining
centre by compensating thermal errors using software. Characteristics of the thermal errors
were analysed by carrying out a sequence of tests. Temperature measurements were carried
out with thermocouples. Capacitance probes were used to measure the thermal errors. A
multiple linear regression-based technique was applied to correlate the thermal errors to the
temperature distribution. The signals of the measured temperatures were sent to a central
processing unit board inside a computer numerical controller. The predicted thermal errors,
based on the regression model, were sent to the controller for real-time error compensation.
Test results show that a 90 per cent reduction in thermal errors has been achieved after
compensation.

Keywords: double-column machining centre, thermal error, thermocouple, compensation

1 INTRODUCTION compensation has received wide attention in order


to improve machine accuracy further. Some
Continuous operation of a machine tool generates research efforts have been dedicated to error com-
heat at the moving elements and causes thermal pensation for machine tools.
expansion, which in turn leads to inaccurate posi- Precise compensation requires an accurate thermal
tioning of machines. Among various error sources model which can predict the time-variant thermal
of a machine tool, thermally induced errors make errors during machining. Researchers have employed
up between 40 and 70 per cent [1]. Therefore, com- various techniques such as finite element methods,
pensation of thermal errors has received significant finite difference methods, and coordinate transforma-
attention over the past few years. tion methods, in modelling the thermal characteristics
Friction caused by spindle bearings is one of the [2–4]. However, boundary conditions and heat trans-
main heat sources in a machine tool. Such friction fer characteristics of a machine tool contain many
induces thermal errors as well as restricting the unknown parameters. It is difficult to predict the ther-
speed limits of the spindle. When the speed is high, mal errors by using the numerical approach only.
feed rates of the ball screw transmission increase. In contrast, empirical models developed by
Large amounts of heat are produced at the support experimental measurements have been demon-
bearings and the nut, because of a high rotational strated to show satisfactory prediction accuracy for
speed of the ball screw. Other heat sources include many applications [5–9]. Chen [5] studied the char-
gear and hydraulic oil, drives and clutches, pump acteristics of thermal errors based on a regression
and motors, guideways, cutting action and swarf, error model and an error model based on an artificial
and external heat sources. neural network. The results were compared for air
Recently, because of the development of sensing, cutting and real cutting conditions. Lee and Yang [6]
modelling, and computer techniques, real-time error modelled the thermal error for computer numerical
control (CNC) machine tools based on a correlation
*Corresponding author: Department of Mechanical and Auto- grouping and a successive linear regression analysis.
mation Engineering, Da-Yeh University, 112 Shan-Jiau Road, Pahk and Lee [7] considered both the thermal
Da Tsuen, Chang-Hua 515, Taiwan, Republic of China, spindle error and the thermal feed axis error. Multi-
email: chengwu@mail.dyu.edu.tw ple linear regression, neural network, and system

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110 Cheng-Hsien Wu and Yu-Tai Kung

identification methods were implemented for the


thermal error prediction. Yang and Ni [8] proposed
a new thermal error modelling methodology called
dynamic thermal error modelling. Their experiments
suggested that the thermal error dynamic model has
advantages over the conventional static model in
terms of model accuracy and robustness. Huang [9]
used the multiple-regression method to analyse the
thermal deformation of a ball-screw feed drive
system. Temperature increases in three elements,
namely the front bearing, the nut, and the back
bearing, were selected as independent variables of
the analysis model. The multiple-regression model
may therefore be used to predict the thermal defor-
mation of the ball screw.
Various methods have been implemented to model
the thermal errors of machine tools and most of the Fig. 1 Photograph of a double-column machining centre
results have shown that the proposed models can
accurately predict the thermal errors. However, little measure the temperature change at certain loca-
work has been carried out to investigate thoroughly tions. Initial tests were operated with a worktable
the thermal characteristics of a machine tool, espe- moving reciprocally along the x axis. The tempera-
cially at a double-column machining centre. ture of the ball screw on the x axis increased. The
The objective of this work has been to study the temperature change produced thermal errors and
temperature rise and the thermal deformation of a the thermal analysis for the feed drive system has
double-column machining centre. The temperature been reported by Wu and Kung [10]. The tempera-
rise was measured with thermocouples while capaci- tures of the two columns were found to be the
tance probes were applied to measure the thermal same as room temperature. Therefore, heat gener-
errors. The spindle and the feeding systems were ated by the x-axis feed drive system does not seem
operated in different combinations to study the ther- to transfer to the columns. Two main motions,
mal characteristics of the double-column machining namely the spindle rotation and the spindle
centre. The measured temperature rise and the ther- head moving along the bridge, were analysed in
mal errors were used to develop a compensation this study.
model, which was applied to compensate the ther- To improve the accuracy of the predicted model, it
mal error in real time. The thermal errors with is important to select the effective positions of tem-
compensation were compared with uncompensated perature measurements. From the related literature
thermal errors to verify the predicted thermal model. [8, 11] and the initial tests, temperatures at 11 points
were measured, as shown in Fig. 2(a). Three thermo-
couples (1–3) were used to measure the surface
2 EXPERIMENTAL SET-UP AND APPROACH temperatures of the spindle. A thermocouple (4)
was used to measure the temperature of coolant for
In this study, the object used to investigate the ther- the spindle. Four thermocouples (5–8) were used to
mal characteristics is a double-column machining measure the ball-screw temperatures of the bridge.
centre as shown in Fig. 1. The maximum speeds Two thermocouples (9 and 10) were used to measure
along the x axis, y axis, and z axis of the machining the surface temperatures of the bearings on both
centre are 20 m/min, 24 m/min, and 12 m/min, sides of the ball screw. The thermocouple (11) was
and the travels are 3.2 m, 1.2 m, and 0.8 m respec- used to indicate room temperature. The recorded
tively. The double-column machining centre has a room temperature was required to eliminate the
maximum spindle speed of 3000 r/min. effects of environmental variation.
As explained earlier, thermal errors are those Thermal errors were measured with a test bar and
that cause a relative displacement between the three capacitance probes. A test bar was attached to
workpiece and the tool on account of thermal defor- the spindle. Three capacitance probes, arranged in
mation of the machine elements. Some of the possi- orthogonal directions, were clamped with a jig on
ble heat sources are bearings, gear and hydraulic oil, the worktable. The relative positions of the test bar
pumps and motors, slideways, cutting action, and to these probes were collected with a data acquisi-
external environments. tion system.
In order to obtain the thermal field of the machin- To obtain the thermal errors, two measuring pro-
ing centre, K-type thermocouples were used to cedures are necessary for two different conditions.

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Thermal analysis and compensation of a double-column machining centre 111

position A). The relative positions cannot be col-


lected when the spindle is away from the probes.
Then, the spindle moves reciprocally at a 600 mm
stroke between B and C. The y-axis feed drive system
generates heat and produces thermal expansion.
After 5 min, the spindle stops at position B and
slowly moves to position A. Thermal errors are
recorded and the procedures are executed cyclically.

3 EXPERIMENTAL RESULTS AND DISCUSSION

To study the thermal characteristics, a set of experi-


ments are arranged. Detailed procedures and results
are as follows.

3.1 Case 1: with the spindle rotating


The spindle rotates at 1000 r/min for the first 2 h.
Fig. 2 Locations of the measured points for
The rotation speed is increased to 2000 r/min for
temperatures
another 2 h and to 3000 r/min for the last 2 h.
The temperature variation is measured with
thermocouples and the data are shown in Fig. 4(a).
Position B The temperature distribution of the ball screw on
Position C Position A the y axis changes little during the 6 h period. The
overall temperature of the spindle is increased from
about 30 to about 40  C. The spindle has two heat
sources. One is frictional heat. The other comes
from the motor located near the location of thermo-
couple 3 at temperature T3. Therefore, T3 is the high-
Z est temperature. The value of T1 is lower and the
value of T2 is the lowest because the relevant
Y
thermocouples are away from the motor.
The temperatures on the spindle drop abruptly
after operation for 310 min. Then the temperatures
600m increase again. To explain this phenomenon, the
20mm temperature T4 of the coolant for the spindle, is
recorded and analysed. The coolant temperature
drops sharply at the same time, as shown in
Capacitance Probe Jig
Fig. 4(a). When the coolant temperature exceeds
41  C, the refrigerator starts to work which reduces
Fig. 3 Procedures for measuring the thermal errors the coolant temperature. With decreasing tempera-
ture, the coolant cools the spindle. When the coolant
When the spindle rotates, it is assumed that the test temperature is lower than 38  C, the refrigerator
bar does not move and that the jig stays at the fixed stops working. The thermal energy, generated by
position. The thermal errors are continuously the spindle and the motor, continuously heats the
recorded. However, the approach has to be modified spindle and the temperatures increase again.
if the spindle moves along the y axis. The jig and the Thermal errors are measured simultaneously and
test bar have to be moved together to measure the the data are shown in Fig. 4(b). The thermal error
thermal errors continuously. As a result of this, it is on the z axis increases owing to the temperature
more difficult and unreliable. Therefore, intermittent rise of the spindle. The positive thermal error on
data recording is applied under this condition. The the z axis indicates that the test bar moves closer to
jig and the worktable are fixed while the spindle is the probe on the z axis. The thermal error drops after
moving. To prevent collision, a safe path is arranged, operation for 310 min because the refrigerator starts
as shown in Fig. 3. Firstly, the test bar is at the mea- to operate at that time.
suring position A. After the relative positions are The negative thermal error on the y axis means
recorded, the spindle moves to the starting point that the test bar moves away from the probe on the
of operating stroke, position B (20 mm away from y axis. There is a y-axis error as even the spindle

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112 Cheng-Hsien Wu and Yu-Tai Kung

Fig. 4 (a) Measured temperature and (b) thermal error versus time with the spindle rotating

does not move along the bridge. One possibility is The temperature variation is measured with the
that the spindle heat is conducted to the ball-screw thermocouples and the data are shown in Fig. 5(a).
feed drive system on the y axis. However, the ball- The heat sources on the ball screw are frictions
screw temperatures on the y axis have been almost caused by the nut and two support bearings of the
constant. There should be little thermal expansion y-axis feeding system. The temperatures at two
of the y-axis ball screw. Another possibility is that bearings reach 7.5  C and 12.3  C respectively. The
the y-axis error results from thermal distortion of temperature rise induces thermal expansion of the
the spindle. The motor is installed at the lower right feeding system. As the left-hand side of the ball
position of the spindle. Generated heat leads to a screw is fixed, the ball screw expands to the right.
non-uniform spindle temperature. The maximum This expansion causes a positive thermal error on
values of T1, T2, and T3 are 8.5  C, 8.8  C, and the y axis. On the other hand, a 17 mm thermal error
12.8  C respectively. A higher temperature on the on the z axis also exists. The z-axis thermal error
lower right distorts the spindle. As a result of arises in two possible ways.
this, the spindle may bend to the left and create a
1. The heat generated by the feeding system on the y
negative y-axis thermal error.
axis is conducted to the spindle and leads to spin-
dle expansion.
3.2 Case 2: with the spindle moving along the 2. The heat source inside the spindle causes the
y axis without rotation temperature rise and thermal expansion.
The spindle head reciprocates at a speed of 10 m/min Detailed analytical procedures are carried out as
for 2 h. The feed rate is increased to 20 m/min for follows. The spindle temperatures T1, T2, and T3
another 2 h and to 30 m/min for the last 2 h. approach 1.9  C, 0.8  C, and 2.1  C respectively.

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Thermal analysis and compensation of a double-column machining centre 113

Fig. 5 (a) Measured temperature and (b) thermal error versus time with the spindle moving along the y axis

The top of the spindle has a lower temperature than The temperature rise may have produced a 17 mm
the bottom of the spindle. Therefore, there must be a thermal expansion on the z axis. To verify the ther-
heat source inside the spindle. The ball-screw mal characteristics of the cooling system, a further
temperatures T5, T6, T7, and T8 are almost at the analysis follows in the next case.
same level as room temperature. Therefore, it is not
possible that the heat comes from the friction of
3.3 Case 3: with the machining centre turned on
the y-axis feeding system. However, the spindle
does not rotate in this case. To find the heat source, The machining centre is turned on and no further
a detailed study is conducted as follows. rotation or movement is executed. The coolant
There is a cooling system inside the machining temperature increases to as high as 5.8  C. The only
centre. When the power of the machining centre is heat source is the pump of the coolant system.
switched on, the coolant of the cooling system circu- When the machining centre is turned on, the coolant
lates in the spindle. The cooling system serves two circulates around the spindle and the spindle tem-
functions. One is as a pump to force the coolant to perature rises. The spindle temperatures T1, T2, and
flow. The pump works whenever the machining T3 are measured and the maximum values are
centre is in the ‘on’ condition. The other is as a 1.9  C, 0.8  C, and 2.1  C respectively. The z-axis
refrigerator. It works only when the coolant tem- thermal error reaches as high as 41 mm. This means
perature exceeds the upper limit. In this case, the that the thermal error is 7.1 mm when there is a 1  C
coolant temperature remains at the upper limit, rise in coolant temperature. The coolant tempera-
41  C. The refrigerator never works during the 6 h ture increases to 2.2  C in the previous case. To
period. The pump generates heat and causes simplify the analysis, the thermal expansion of the
a 2.2  C increase in the coolant temperature. spindle is assumed to be linear with the coolant

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114 Cheng-Hsien Wu and Yu-Tai Kung

Fig. 6 (a) Measured temperature and (b) thermal error versus time with the spindle reciprocating

temperature rise. Then an increase of 2.2  C in the 1000 r/min and 6 m/min respectively. The speed
temperature of the coolant is assumed to create a and feed rate are 2000 r/min and 8 m/min respec-
15.6 mm thermal error on the z axis (2.2  C · tively for the second 2 h, and 3000 r/min and
7.1 mm/ C). The result is close to the measured ther- 10 m/min respectively for the last 2 h. The tempera-
mal error on the z axis (17 mm). With these results, ture variation and thermal error are shown in Fig. 7.
the pump is believed to be the only source of the The temperatures of both spindle and feeding sys-
z-axis thermal error. The heat transfer from the feed- tem increase during this period. The spindle and the
ing system of the y axis to the spindle can therefore coolant are subjected to an abrupt temperature
be neglected. change at 300 min. Obviously, the refrigerator starts
to operate because the coolant temperature exceeds
3.4 Case 4: with the spindle rotating and the
the upper limit, 41  C. The thermal errors reach
y-axis feeding system running simultaneously
120 mm on the z axis and 6.5 mm on the y axis.
In this case, the spindle rotates and the y-axis Case 4 can be regarded as a combination of cases
feeding system runs simultaneously. One purpose 1 and 2. The spindle rotates at 1000, 2000, and
is to check whether these two thermal errors can 3000 r/min in case 1. The z-axis thermal error is
be superposed to obtain the total thermal error. 114 mm and the y axis thermal error is 28 mm. The
The other purpose is to develop a mathematical feed rates are 6, 8, and 10 m/min in case 2. The
model for the thermal error by implementing the thermal errors are 17 mm on the z axis and 25 mm
experimental data. The whole period lasts for 6 h on the y axis. The superposition of these two cases
and is equally divided into three stages. The rota- gives thermal errors of 131 mm on the z axis and
tional speed and y-axis feed rate for the first 2 h are 3 mm on the y axis. The measured thermal errors

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Thermal analysis and compensation of a double-column machining centre 115

Fig. 7 (a) Measured temperature and (b) thermal error versus time with the spindle rotating and the y-axis feeding system
running simultaneously

of case 4 are 120 mm and 5 mm on the z axis and equation that expresses the response as a linear
y axis respectively. They are in good agreement, function of the p predictors is estimated using the
which means that the thermal errors of spindle and measured data. The model is specified by a linear
feeding system can be superimposed on each other equation
in this study.
Y ¼ b0 þ b1 X1 þ    þ bp Xp þ e ð1Þ

4 ERROR COMPENSATION MODEL Matrix notation will simplify most of the results
used in the multiple-linear-regression analysis. Let
Thermal errors are time variant during machining. Y and e be n · 1 vectors whose elements are given
The machining centre can be compensated on the by the yi and the ei according to
basis of a pre-established empirical model which 2 3 2 3
correlates the thermal errors to the measured tem- y1 e1
6 y2 7 6 e2 7
perature. Various methods have been implemented 6 7 6 7
Y ¼ 6 . 7, e ¼ 6 .. 7 ð2Þ
to model the thermal errors of machine tools. 4 .. 5 4 . 5
A multiple-linear-regression analysis is applied to yn en
develop a thermal error model in this study.
In the multiple-regression analysis, several predic- Also, define b to be the vector parameter of length
tors are used to model a single response variable. For (p þ 1) · 1, including the intercept b0, according to
each of the n cases observed, values for the response 2
3
b1
and for each of the predictors are collected. If the 6 b2 7
response is called Y, and the predictors are called 6 7
b¼6 . 7 ð3Þ
X1, X2,. . ., Xp, then the data will form an n · (p þ 1) 4 .. 5
array. In the multiple-linear-regression analysis, an bn

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116 Cheng-Hsien Wu and Yu-Tai Kung

Next, define X to be an n · (p þ 1) matrix given by Ten running tests have been carried out and the
2 3 measured data collected. The tests include opera-
1 x11 x12 : x1p tions with various spindle speeds and feed rates.
6 1 x21 x22 : x2p 7
6 7 If three predictors are included in the multiple-
X ¼6
6: : : : : 77 ð4Þ
4: : : : : 5 linear-regression model, three temperatures T1, T2,
1 xn1 xn2 : xnp and T3 are found the best choice. The mathematical
equation can be expressed as
Using these quantities, the multiple-linear-
Ez ¼ 5:505 þ 3:388T1 þ 2:238T2 þ 3:97T3 ð7Þ
regression equation can be written in matrix terms
as The coefficient of determination is found to be
Y ¼ Xb þ e ð5Þ 0.997, which means the ability of prediction is
The regression model using the least-squares 99.7 per cent. Using this model gives a high
method is determined by minimizing the residual accuracy; however, it needs three thermal sensors
sum of squares. The coefficient of determination is to compensate errors on line. If fewer sensors are
defined as preferred, simpler models can be derived. If two
thermal sensors are installed in error compensation,
SYY  RSS T2 and T3 are the key temperatures to be measured.
R2 ¼ ð6Þ
SYY The coefficient of determination is found to be
0.996. If only one thermal sensor is set up in error
where SYY is the corrected sum of squares for the
compensation, measuring T2 is found to be the best
yi and RSS is the residual sum of squares. The
choice. The coefficient of determination is found to
coefficient gives the portion of variability in Y
be 0.994. If the number of sensors is larger, the
explained by regression on the X.
prediction ability becomes greater.
In this study, the thermal error modelling is based
on a multiple-linear-regression analysis. The res-
ponse is the thermal error Ez on the z axis, and the 5 REAL-TIME COMPENSATION SCHEME
predictors are the measured temperatures T1, T2,. . ., AND RESULTS
Tk. The procedures can be summarized as follows.
1. Determine the response (z-axis thermal error) In this study, the model in equation (7) is implemen-
and find the adequate predictors; then run the ted for compensating the thermal error on the z axis.
experiments and collect the data. The method used in this study is to shift the origins
2. Derive the multiple-regression equations and cal- of the axes. The compensation method utilizes a
culate the least-squares estimators. central processing unit board inside the computer
3. Validate the estimators. numerical controller. During operation processes,
4. Specify the probability distribution of the random the temperature signal is collected in real time and
error component e and estimate the variance. the errors are estimated with the regression model.
5. Check the estimators and verify the accuracy of Finally, the compensation signals are sent to the
the model. computer numerical controller to shift the origins
6. Apply the multiple-linear-regression model for of the slide axes to adjust the relative position
thermal error compensation. between the spindle tip and the working table.

Fig. 8 Measured thermal errors versus time with and without real-time compensation

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Thermal analysis and compensation of a double-column machining centre 117

Resultant z-axis thermal errors before and after in real time. Tests results show that the z-axis
compensation are shown in Fig. 8. The thermal thermal error of the machining centre has been
errors of the double-column machining centre are reduced from 120 to 12 mm.
reduced from 120 to 12 mm.
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