Influence of resistant forces on the positioning precision of kinematic

feed chains used on CNC machine tools

FUNARU Marian1, a, STAN Gheorghe1,b
1

Vasile Alecsandri University of Bacau, Department of Industrial Engineering, Calea Marasesti

Street, No. 157, 600115 Bacau, Romania
a

marian_funaru@yahoo.com, bghstan@ub.ro

Keywords: kinematic feed chain, resistance forces, dead zone, backlash, positioning precision

Abstract. Many researches from the international literature and also those of the specialised
companies from the machine tools domain, have focused in the past years on increasing the
positioning precision and implicitly, the manufacturing precision of the numerically controlled
machine tools. The results of these efforts have led to the elimination or compensation of different
factors which affect the positioning precision of the kinematic feed chains. Nevertheless, the effects
of some factors still find themselves in the positioning error of the kinematic feed chains, an
important component of this error being represented by the cutting and friction force induced error
(resistant errors). This paper presents a new method of experimental analysis for establishing the
influence of resistant forces on the positioning precision of the kinematic feed axis. Due to the fact
that measuring the positioning precision during the cutting process is difficult to achieve, the
experiments were carried out using a simulated force. In order to simulate an axial force, a
hydraulic system was adopted, composed of a hydraulic cylinder, a distributor valve and a check
valve.
Introduction
Recent researches from the international literature and specialised companies from the machine
tools domain have concentrated on increasing the manufacturing precision of the numerically
controlled machine tools, which cannot be achieved without increased the positioning precision of
the kinematic feed chains which represent a very important part of the machine tools structure [1].
The results of these efforts have led to the elimination or compensation of different factors which
affect the positioning precision of the kinematic feed chains. Nevertheless, the effects of some
factors still find themselves in the positioning error of the kinematic feed chains, an important
component of this error being represented by the cutting and friction force induced error (resistant
errors) [2].
Increasing the positioning precision with regard to the errors induced by the resistant forces is
mainly based on using two methods: eliminating/minimising the error or compensating it [3]. The
first method represents a structural approach and regards the error minimisation from the machine
tool design stage and the second method uses the software compensation of these errors as they
appear [4].
This paper presents a new method of experimental analysis for establishing the influence of
resistant forces on the positioning precision of the kinematic feed axis. Experiments were carried
out on a kinematic feed chain, which uses a ballscrew-nut mechanism as the motion transmission
system.
Due to the fact that measuring the positioning precision during the cutting process is difficult to
achieve, the cutting force components values being difficult to measure as well, the experiments
were carried out using a simulated force, which was achieved by means of a hydraulic circuit,
formed mainly from a hydraulic cylinder, a distributor valve and a check valve. Measurements of

the values of the resistant force were achieved using a force transducer, as a part of the
experimental setup.
Experimental design and setup
Experimental researches have been conducted on a test stand, having the structure presented in
figure 1. The kinematic feed chain is mainly composed of the electromechanical actuator 1, having
the rod 5 fixed against the moving element 8. The table has the dimensions of 250x400mm and the
axial guiding is achieved using two linear rolling cylindrical guiderails 4, with the dimensions of
20x1000mm, provided with several supporting elements 3, with the purpose of assuring a high
stiffness of the table-guideway assembly.
The structure of the electromechanical actuator is mainly composed of a precision ballscrew
(precision class 7, in conformity with ISO 3408), having the diameter of 20mm and a 5mm pitch.
The ballscrew is supported by two sets of angular contact ball bearings on the motor side. Using
this type of bearing allows the development of high axial forces, reaching a maximum of 9300N, in
both moving ways and also leads to obtaining a minimum backlash when reversing the moving
direction. On the side opposite to the motor, the ballscrew is supported by a polymer sliding
bearing, which has the advantages of a high service life and a vibration free functioning.

Fig.1. General view of the experimental test stand

The ballscrew mechanism is actuated by an AC servomotor, having a rated torque of 1.4Nm and
which is electrically controlled by a servodrive. The servomotor and the ballscrew are coupled
directly using an elastic coupling.

Fig. 2. Hydraulic system adopted for simulating the resistant force

Given the difficulties of measuring the position of the moving table during the manufacturing
process and also of placing the elements of the measuring system on the table, the experiments were
carried out using a simulated force. In order to achieve this simulated force, a hydraulic system was
adopted, being presented in figure 2, mainly composed of the hydraulic cylinder 3, the distributor
valve 4 and the check valve 5. By pushing the cylinder rod 1, the pressure inside the circuit will
grow, until the check valve opens, the value of the pressure being controlled. The presence of the
distributor valve enables the restarting of the cycle. The force transducer incorporated in the
experimental setup and the interface of the electromechanical actuator allow real-time readings of
the resistant force values.
Description of the experimental method
Several international standards are used for determining the positioning precision of the
numerically controlled axes from CNC machine tools, from which the most commonly used in the
present time are VDI/DGQ 3441 and ISO 230:2. These standards establish the methodology
regarding the testing, testing conditions and evaluation procedure for processing the measuring
results. Testing procedure is based on repeated measurements of the effective position of the tested
feed axis, discreted in several points (target positions), placed at equal distances along the table
stroke.
For measuring the positioning precision of the researched feed axis, a calibrated measuring
system consisting of a Renishaw ML 10 laser interferometer was used, having the measuring
accuracy of 0.1 m. The evaluation of the positioning precision of the moving table, in conformity
with VDI/DGQ 3441, is done through the following main parameters: positioning inaccuracy P,
mean repeatability Ps and mean reversal error U. It is necessary for the precision parameters to be
determined using statistical methods, because of the large number of measuring points and
measuring runs which are done for each point. This is required in order to evaluate the evolution of
the position deviations with high accuracy [5].
Experimental results and discussion
Experimental data was aquired in order to determine the positioning precision of the moving
table, for two directions of the resistant force in relation to the ballscrew position: centered and
asymmetric. The method of placing the rod of the hydraulic cylinder on the moving table in both
cases, is graphically represented in figure 3. In order to determine the positioning precision in the
case of the asymmetrical resistant force, the cylinder rod was placed at a distance l=100mm in
relation to the ballscrew symmetry axis. The static parameters of the positioning precision were
measured and calculated for several values of the resistant force: 530, 1239 and 1547N for the
centered resistant force and 579, 755 and 1284N for the asymmetrical resistant force.

Fig. 3. Emplacement of the resistant force on the moving table in relation to the ballscrew symmetry axis

Working parameters for the experiments which were carried out using a centered resistant force
are given in table 1, for a feed rate of 6m/min and in table 2 are presented the parameters of the

kinematic feed chain used for the experimental test carried out using an asymmetrical resistant
force. From the obtained experimental data, several positioning precision diagrams were drawn,
being given in figure 4 for the centered resistant force. Due to the fact that the curves of the other
diagrams for the asymmetrical resistant force present the same trend, they were not included in the
paper.
Table 1. Kinematic feed chain parameters used for different values of the centered resistant force

Setul
nr.
1
2
3

Mm
[Nm]
0.462
1.080
1.348

Fa
[N]
530
1239
1547

I
[A]
0.364
0.842
1.052

a
[mm/s2
]
100
100
100

V
[m/min]

Ps

[m]

[m]

[m]

6
6
6

19.499
24.018
25.709

3.671
4.822
4.415

4.704
5.640
6.332

Table 2. Kinematic feed chain parameters used for different values of the asymmetric resistant force
Ps
Setul
Mm
Fa
I
a
V
U
P

nr.
1
2
3

[Nm]
0.504
0.658
1.119

[N]
579
755
1284

[A]
0.393
0.513
0.873

[mm/s2
]
100
100
100

a.

b.

[m/min]

[m]

[m]

[m]

6
6
6

26.417
26.628
27.295

2.819
2.652
2.545

7.132
8.584
10.164

c.
Fig. 4. Positioning precision diagrams, for the centered resistant force: a. Fr=530N, b. Fr=1239N, c. Fr=1544N

Conclusions
Analysis of the obtained experimental data and diagrams shows that the size of the resistant force
placed on the center of the moving table has a relatively small influence on the static parameters of
the positioning precision, a higher impact being found in the value of the positioning inaccuracy,
which ranges between 19 and 25m. The mean repeatability value maintains quasi-constant, at
about 4m and the mean reversal error varies very little, from 5 to 7m.
When placing the resistant force asymmetrically on the moving table, although the values of the
resistant force are very close to the ones used in the case of the centered force, the values of the
positioning precision parameters are slightly modified, particularily in the case of the reversal error,
its value ranging from 7 to 10m, for a resistant force of 579 and 1284N, respectively. This is due
to the fact that the moving table rotates when the direction of the resistant force is assymetrical in
relation to the ballscrew symmetry axis. The small rotation values are translated into a deadzone,
which has a direct impact on the positioning precision, especially when using the indirect position
measuring system.
From the obtained results, an experimental database is formed, which is useful for the designers
and builders of CNC machine tools when establishing the maximum values of the axial force
available at the moving table. Also, the experimental results represent a guide for selecting the type
of guideways which are to be used and the rolling element type, in order to obtain a high ridigity of
the moving table-guideway assembly.
References
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H. Wu, G. Turyagyenda, J.G. Yang, Modeling and real-time compensation of cutting forceinduced errors on NC turning center, Key Engineering Materials 315-316 (2006), 274-278.
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geometric, cutting-force induced and fixture-dependent errors, International Journal of Machine
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M. Samir, O. Tunde, A review of machine tool accuracy enhancement through error
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[5]
VDI/DGQ 3441, Statistical Testing of the Operational and Positional Accuracy of Machine
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