Temperature compensation in ball screws of CNC machines

Authors

DOI:

https://doi.org/10.20535/2521-1943.2025.9.2(105).327901

Keywords:

CNC machine tools, ball screw, thermal error compensation, temperature sensing, accuracy measurement

Abstract

Thermal deformation of ball screw feed drives is a major source of positioning error in high-speed CNC machine tools. Frictional heat generated during rapid screw motion causes expansion and leads to significant deviations at the tool center point. This literature review compiles recent advances in temperature compensation techniques for ball screws, focusing on approaches to model and compensate thermal errors, methods for measuring temperature on moving feed axes, and techniques for evaluating positioning accuracy. A wide range of compensation methods are examined, from physics-based thermal models and empirical regression models to modern machine learning and hybrid approaches. Various sensor strategies for capturing temperature—contact thermistors, wireless embedded sensors, and infrared thermography—are compared in terms of responsiveness and practicality. Methods for quantifying thermal elongation and positioning error, such as laser interferometry and other high-precision measurement systems, are also reviewed. The review finds that data-driven (empirical) modeling techniques, non-contact temperature sensing, and laser-based accuracy measurements have shown particular promise.

References

  1. Z. Z. Xu, X. J. Liu, H. K. Kim, J. H. Shin, and S. K. Lyu, “Thermal error forecast and performance evaluation for an air-cooling ball screw system,” International Journal of Machine Tools and Manufacture, vol. 51, no. 7–8, pp. 605–611, Apr. 2011, doi: https://doi.org/10.1016/j.ijmachtools.2011.04.001.
  2. Y. Li, M. Yu, Y. Bai, Z. Hou, and W. Wu, “A review of thermal error modeling methods for machine tools,” Applied Scienc-es, vol. 11, no. 11, p. 5216, Jun. 2021, doi: https://doi.org/10.3390/app11115216.
  3. H. Liu, Z. Rao, R. Pang, and Y. Zhang, “Research on thermal Characteristics of Ball screw feed System considering nut Movement,” Machines, vol. 9, no. 11, p. 249, Oct. 2021, doi: https://doi.org/10.3390/machines9110249 .
  4. R. Rong, H. Zhou, Y. Huang, J. Yang, and H. Xiang, “Novel Real-Time Compensation Method for machine tool’s ball screw thermal error,” Applied Sciences, vol. 13, no. 5, p. 2833, Feb. 2023, doi: https://doi.org/10.3390/app13052833.
  5. E. Miao, Y. Liu, H. Liu, Z. Gao, and W. Li, “Study on the effects of changes in temperature-sensitive points on thermal error compensation model for CNC machine tool,” International Journal of Machine Tools and Manufacture, vol. 97, pp. 50–59, Jul. 2015, doi: https://doi.org/10.1016/j.ijmachtools.2015.07.004 .
  6. H. Liu, E. M. Miao, X. Y. Wei, and X. D. Zhuang, “Robust modeling method for thermal error of CNC machine tools based on ridge regression algorithm,” International Journal of Machine Tools and Manufacture, vol. 113, pp. 35–48, Nov. 2016, doi: https://doi.org/10.1016/j.ijmachtools.2016.11.001.
  7. Y. Zhang, J. Yang, and H. Jiang, “Machine tool thermal error modeling and prediction by grey neural network,” The Interna-tional Journal of Advanced Manufacturing Technology, vol. 59, no. 9–12, pp. 1065–1072, Aug. 2011, doi: https://doi.org/10.1007/s00170-011-3564-3 .
  8. M. Pajor and J. Zapłata, “Intelligent Machine Tool – a thermal diagnostic system for a CNC pretensioned ball screw,” Diffu-sion and Defect Data, Solid State Data. Part B, Solid State Phenomena/Solid State Phenomena, vol. 220–221, pp. 491–496, Dec. 2014, doi: https://doi.org/10.4028/www.scientific.net/ssp.220-221.491 .
  9. H. Zhou, P. Hu, H. Tan, J. Chen, and G. Liu, “Modelling and compensation of thermal deformation for machine tool based on the real-time data of the CNC system,” Procedia Manufacturing, vol. 26, pp. 1137–1146, Jan. 2018, doi: https://doi.org/10.1016/j.promfg.2018.07.150.
  10. S. Tanaka, T. Kizaki, K. Tomita, S. Tsujimura, H. Kobayashi, and N. Sugita, “Robust thermal error estimation for machine tools based on in-process multi-point temperature measurement of a single axis actuated by a ball screw feed drive system,” Journal of Manufacturing Processes, vol. 85, pp. 262–271, Dec. 2022, doi: https://doi.org/10.1016/j.jmapro.2022.11.037.
  11. Z.-Z. Xu, C. Choi, L.-J. Liang, D.-Y. Li, and S.-K. Lyu, “Study on a novel thermal error compensation system for high-precision ball screw feed drive (1st report: Model, calculation and simulation),” International Journal of Precision Engineering and Manufacturing, vol. 16, no. 9, pp. 2005–2011, Aug. 2015, doi: https://doi.org/10.1007/s12541-015-0261-4.
  12. J. Zhang, B. Li, C. Zhou, and W. Zhao, “Positioning error prediction and compensation of ball screw feed drive system with different mounting conditions,” Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manu-facture, vol. 230, no. 12, pp. 2307–2311, Dec. 2016, doi: https://doi.org/10.1177/0954405416679444.
  13. A. Verl and S. Frey, “Correlation between feed velocity and preloading in ball screw drives,” CIRP Annals, vol. 59, no. 1, pp. 429–432, Jan. 2010, doi: https://doi.org/10.1016/j.cirp.2010.03.136.
  14. Y.-L. Qiu, C.-G. Zhou, Y. Ou, and F.-T. Feng, “Theoretical and experimental analysis of the temperature rise of a ball screw,” The International Journal of Advanced Manufacturing Technology, vol. 127, no. 1–2, pp. 703–715, May 2023, doi: https://doi.org/10.1007/s00170-023-11550-7 .
  15. J. Jedrzejewski, Z. Kowal, W. Kwasny, and Z. Winiarski, “Ball screw unit precise modelling with dynamics of loads and moving heat sources taken into account,” Journal of Machine Engineering, vol. 19, no. 4, pp. 27–41, Dec. 2019, doi: https://doi.org/10.5604/01.3001.0013.6228.
  16. A. Geist, M. F. Yaqoob, C. Friedrich, C. Naumann, and S. Ihlenfeldt, “Concept of integrating a hybrid thermal error compen-sation into an existing machine tool control architecture,” Journal of Machine Engineering, Sep. 2024, doi: https://doi.org/10.36897/jme/192866.
  17. Y.-L. Qiu, C.-G. Zhou, Y. Ou, and F.-T. Feng, “Theoretical and experimental analysis of the temperature rise of a ball screw,” The International Journal of Advanced Manufacturing Technology, vol. 127, no. 1–2, pp. 703–715, May 2023, doi: 10.1007/s00170-023-11550-7.
  18. E.-M. Miao, Y.-Y. Gong, P.-C. Niu, C.-Z. Ji, and H.-D. Chen, “Robustness of thermal error compensation modeling models of CNC machine tools,” The International Journal of Advanced Manufacturing Technology, vol. 69, no. 9–12, pp. 2593–2603, Aug. 2013, doi: https://doi.org/10.1007/s00170-013-5229-x.
  19. B. Zhou, G.-H. Chen, J. Mao, Y. Li, and S.-W. Zhang, “A ball screw all-round error compensation technology based on nov-el hybrid deep learning for CNC machine tool,” Journal of Vibroengineering, vol. 26, no. 5, pp. 1216–1236, Apr. 2024, doi: https://doi.org/10.21595/jve.2024.23841.
  20. N. Zimmermann, T. Büchi, J. Mayr, and K. Wegener, “Self-optimizing thermal error compensation models with adaptive in-puts using Group-LASSO for ARX-models,” Journal of Manufacturing Systems, vol. 64, pp. 615–625, May 2022, doi: https://doi.org/10.1016/j.jmsy.2022.04.015.
  21. L. Yu, Q. Li, J. Li, L. Shang, and G. Chen, “Research on thermal compensation of X-Axis partition of drilling and tapping center machine tools,” IEEE Access, vol. 11, pp. 10751–10761, Jan. 2023, doi: https://doi.org/10.1109/access.2023.3240770.
  22. J. Mayr et al., “Thermal issues in machine tools,” CIRP Annals, vol. 61, no. 2, pp. 771–791, Jan. 2012, doi: https://doi.org/10.1016/j.cirp.2012.05.008.
  23. J. Zapłata, “Measurements of temperature of CNC machine tool ball screw utilising IR method,” International Journal of Ap-plied Mechanics and Engineering, vol. 22, no. 3, pp. 769–777, Aug. 2017, doi: https://doi.org/10.1515/ijame-2017-0049.
  24. Test code for machine tools – Part 2: Determination of accuracy and repeatability of positioning of numerically controlled ax-es, ISO 230-2:2014, International Organization for Standardization, Switzerland, 2014

Downloads

Published

2025-06-26

How to Cite

[1]
T. Skrypnyk and V. Korenkov, “Temperature compensation in ball screws of CNC machines”, Mech. Adv. Technol., vol. 9, no. 2(105), pp. 157–165, Jun. 2025.

Issue

Vol. 9 No. 2(105) (2025)

Section

Advanced Mechanical Engineering and Manufacturing Technologies

License

Copyright (c) 2025 Taras Skrypnyk, Volodymyr Korenkov

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

The ownership of copyright remains with the Authors.
 
Authors may use their own material in other publications provided that the Journal is acknowledged as the original place of publication and National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” as the Publisher.

Authors who publish with this journal agree to the following terms:

  1. Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under CC BY 4.0 that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.

  2. Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.

  3. Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work