Machining error compensation of free-form surfaces by combination of ordinary kriging method and mirror compensation method

Improving the accuracy and efficiency of free-form surface machining is a common goal of modern manufacturing. In this study, a compensation method combining the ordinary kriging method based on sequential quadratic programming method optimization (SQP-OK) and the mirror compensation method for machining errors of free-form workpieces was applied, with the aim of significantly improving the workpiece machining accuracy. Machining errors on the surface of the workpiece were predicted utilizing the SQP-OK after the workpieces were completed with semi-finishing machining based on the on-machine measurement (OMM) results of the workpiece. Based on the prediction result, the mirror compensation method was applied to calculate the compensation points. Free-form workpieces were compensated for by modifying the NC code for semi-finishing. To verify the effectiveness of the proposed method, two free-form workpieces were machined with computer numerical control (CNC) compensation, applying the proposed method and the method modifying the overall machining allowance. The experimental results revealed that the compensation method proposed in this paper reduced the average value of the machining errors decreased by 28.6% in absolute value, 31.1% in maximum undercut, and 28.8% in maximum overcut for the free-form workpiece, respectively, compared with the compensation method of modifying the overall machining allowance.