Dimensional and geometrical errors of three-axis CNC milling machines in a virtual machining system

• A virtual machining system is presented in order to create machined parts.
• Geometrical errors of three-axis milling machine tools were modeled.
• The real errors are enforced to the nominal machining G-codes by developed software.
• To validate the system, surfaces of virtual and real machined parts are compared.

Virtual machining systems are applying computers and different types of software in manufacturing and production in order to simulate and model errors of real environment in virtual reality systems. Many errors of CNC machine tools have an effect on the accuracy and repeatability of part manufacturing. Some of these errors can be reduced by controlling the machining process and environmental parameters. However geometrical errors which have a big portion of total error need more attention. In this paper a virtual machining system which simulates the dimensional and geometrical errors of real three-axis milling machining operations is described. The system can read the machining codes of parts and enforce 21 errors associated with linear and rotational motion axes in order to generate new codes to represent the actual machining operation. In order to validate the system free form profiles and surfaces of virtual and real machined parts are compared in order to present the reliability and accuracy of the software.