Online machining error estimation method of numerical control gear grinding machine tool based on data analysis of internal sensors

This paper presents an online estimation method of cutting error by analyzing of internal sensor readings. The internal sensors of numerical control (NC) machine tool are selected to avoid installation problem. The estimation mathematic model of cutting error was proposed to compute the relative position of cutting point and tool center point (TCP) from internal sensor readings based on cutting theory of gear. In order to verify the effectiveness of the proposed model, it was simulated and experimented in gear generating grinding process. The cutting error of gear was estimated and the factors which induce cutting error were analyzed. The simulation and experiments verify that the proposed approach is an efficient way to estimate the cutting error of work-piece during machining process.