Correction of the Control Program for End Milling on a CNC Machine

Authors

DOI:

https://doi.org/10.20535/2521-1943.2025.9.3(106).338080

Keywords:

a posteriori control method, end milling, correction of the CNC program

Abstract

The results of experimental testing of the correction of the CNC-programs for end milling on a CNC machine are presented. The correction is performed for serial and single-piece production conditions using the method of control using a posteriori information. A posteriori information is determined during measurements directly on the CNC machine with a three-coordinate probe from Renishaw. Moreover, for serial production, the pre-machined part is measured, and for single-piece production, the machining allowance is divided into two parts and the surface machined in the first pass is measured. The correction is performed using the experimentally determined transfer function of the machining system. The effectiveness of the developed methods has been experimentally proven: after milling the first part, the average error was 0.1 mm, and after machining the second part (and subsequent ones) using the corrected control program, the error decreased to 0.012 mm, i.e. the machining accuracy is increased by more than 8 times. In the conditions of single production, when dividing the allowance into two parts and determining the correction according to the calculated transfer function, the machining error decreased by more than 6 times. The time loss for performing two passes in the conditions of single production does not exceed the machining time according to traditional technology, when to ensure the specified accuracy it is necessary to perform several passes according to the same control program.

References

  1. Y. V. Petrakov, Control of cutting processes on CNC machines. Kyiv: Igor Sikorsky Kyiv Polytechnic Institute, 2025, 302 p. Available: https://ela.kpi.ua/handle/123456789/73431.
  2. Y. Petrakov and Y. Romanov, “Ensuring accuracy of contour milling on CNC machines”, Mechanics and Advanced Technologies, vol. 7, no. 1 (97), pp. 51-60, 2023. DOI: https://doi.org/10.20535/2521-1943.2023.7.1.276162.
  3. Y. Altintas, "Modeling approaches and software for predicting the performance of milling operations at MAL-UBC", Machining Science and Technology, vol. 4, no. 3, pp. 445-478, 2000. DOI: https://doi.org/10.1080/10940340008945718.
    |
  4. Z. Nie and Y. Zhao, “High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory”, Machines, vol. 13, no. 1, p. 69, 2025. DOI: https://doi.org/10.3390/machines13010069.
    |
  5. A. P. Kuznetsov and H.-J. Koriath, “Principles for numerical compensation of elastic deformations in computerized numerical control machine tools”, Academia Engineering, vol. 1, no. 3, 2024. DOI: https://doi.org/10.20935/AcadEng7278.
  6. T. C. Bera, K. A. Desai and P. V. M. Rao, “Error compensation in flexible end milling of tubular geometries”, Journal of Materials Processing Technology, vol. 211, no. 1, pp. 24-34, 2011. DOI: https://doi.org/10.1016/j.jmatprotec.2010.08.013.
    |
  7. M. Soori, “Deformation Error Compensation in 5-Axis Milling Operations of Turbine Blades”, Research Square, 2023. [Preprint]. DOI: https://doi.org/10.21203/rs.3.rs-1777472/v1.
  8. G. Bolar and S. N. Joshi, “Three-dimensional numerical modeling, simulation and experimental validation of milling of a thin-wall component”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 231, no. 5, pp. 792-804, 2017. DOI: https://doi.org/10.1177/0954405416685387.
    |
  9. W.-W. Huang, Y. Zhang, X.-Q. Zhang and L.-M. Zhu, “Wall thickness error prediction and compensation in end milling of thin-plate parts”, Precision Engineering, vol. 66, pp. 550-563, 2020. DOI: https://doi.org/10.1016/j.precisioneng.2020.09.003.
    |
  10. Y. Li and X. Cheng, “Micromilling of Ti-6Al-4V alloy for high-aspect-ratio thin walls and dimensional error compensation based on an online compensation system”, Mechanical Sciences, vol. 16, no. 2, pp. 403-415, 2025. DOI: https://doi.org/10.5194/ms-16-403-2025.
  11. K. Kuroda, H. Nakatsuji and I. Nishida, “Tool path generation in pocket machining considering workpiece deformation using Finite Element Method (FEM)”, Journal of Advanced Mechanical Design, Systems, and Manufacturing, vol. 18, no. 7, p. JAMDSM0089, 2024. DOI: https://doi.org/10.1299/jamdsm.2024jamdsm0089.
    |
  12. K. Kaneko, J. Shimizu and K. Shirase, “Voxel-based end milling simulation of machining error induced by elastic deformation of tool and workpiece”, Journal of Advanced Mechanical Design, Systems, and Manufacturing, vol. 18, no. 4, p. JAMDSM0042, 2024. DOI: https://doi.org/10.1299/jamdsm.2024jamdsm0042.
    |
  13. Y. Petrakov and D. Shuplietsov, “Accuracy control of contour milling on CNC machines”, Mechanics and Advanced Technologies, no. 2(83), pp. 51-56, 2018. DOI: https://doi.org/10.20535/2521-1943.2018.83.132223.
  14. Inspection Plus software for HAAS machining center. Programming manual H-2000-6222-0A-B. Haascnc.com. Available: https://www.haascnc.com/content/dam/haascnc/videos/bonus-content/macros-are-more-than-if-statements-they-are-lie-detectors!/Insp_Plus_Software_Mill_H-2000-6222-0A-B.pdf.
  15. Machine performance verification. Renishaw.com. Available: https://www.renishaw.com/api/redirector/renishaw.com/spr.

Downloads

Published

2025-09-26

How to Cite

[1]
Y. Petrakov and Y. Romanov, “Correction of the Control Program for End Milling on a CNC Machine”, Mech. Adv. Technol., vol. 9, no. 3(106), pp. 290–297, Sep. 2025.

Issue

Vol. 9 No. 3(106) (2025)

Section

Advanced Mechanical Engineering and Manufacturing Technologies

License

Copyright (c) 2025 Юрій Петраков, Ян Романов

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