Ballbar dynamic tests for rotary axes of five-axis CNC machine tools

•Dynamic errors of rotary axes in a five-axis machine tool are measured.•The method does not need complicated calibration works.•The circle center and the radius determine the characteristics of the test path.•A synchronously tuning of servo control gains for all linear and rotary axes.

This paper proposes a new ball bar test method for the inspection of dynamic errors of rotary axes in five-axis CNC machine tools. The test circle is defined in a workpiece coordinate system and the ball bar test is performed by simultaneously driving of linear–rotary axis couple. The effects of the center position and the radius on the setting values, rotational range and measurement sensitivity of the rotary axis were investigated. The proposed ball bar test is performed in two steps: the circular positioning and the circular tracking with a continuous feed. Axial dynamic errors are obtained by subtracting the measured tracking errors from the positioning errors. A ball bar test system (BBTS) was developed to plan the tool path and the tool orientation, to communicate with the five-axis CNC controller and to process the measured data. Error patterns were simulated regarding the gain mismatch, backlash and tracking direction to help a fast diagnosis of the error sources. Simulations and experimental results prove the effectiveness of the new test method.