A spatial error modeling method under the influence of multiple error factors

At present, the deviation caused by the weight of the machine tool at the tool tip is rarely considered in the spatial error model of machine tools, which leads to a deviance between the prediction accuracy of the spatial error model and the actual results. To address the issues, a synthesis modeling method for geometric errors and the deviation at the tool tip caused by the machine tool’s self-weight is introduced in this paper. In the initial phase, the spatial error model of machine tools is established based on multi-body system theory and the homogeneous coordinate transformation matrix. Subsequently 25 machining points are selected for analysis, which employ orthogonal design. The simulation analysis is conducted to ascertain the deviation caused by the weight of the machine tool tip for the 25 machining points. A tooltip deviation model is formulated using polynomial fitting, elucidating the variation of tooltip deviation in the machine operation. Consequently, a synthesis modeling method for geometric errors and the deviation at the tool tip caused by the machine tool’s self-weight is devised. In the final stage, the S-shaped test piece is selected as the research object, Simulation analysis and experimental verification show that the contour error trend of the obtained S-shaped specimen is basically the same, and the residual value is small and less than 10% of the measurement result, which verifies the correctness of the method proposed in this article. The core idea of this approach applies to all types of multi-axis machines.