A comprehensive error compensation approach considering machining process for complex thin-wall parts machining

Based on statistical analysis, the paper viewed the process of NC machining as a mathematical function with the reference model as an independent variable and the machining result as the dependent variable. Then the whole error compensation process is divided into three typical states whose process functions are built separately. With the help of the removal amount coefficient, the mathematical model of comprehensive error compensation is constructed. And the model is resolved by Taylor expansion to calculate the error compensation amount which is used to reconstruct the geometric model of the part and regenerate a new NC program. The approach is verified with a milling experiment of thin-wall blades. The maximum error was 0.031 mm after machining at the error compensation machining amount, which is 32.9% of the maximum error of 0.094 mm after machining at the normal machining amount. The result shows that the approach is efficient in improving machining quality.