A kinematic model to compensate the structural deformations in machine tools using fiber Bragg grating (FBG) sensors

Structural deformations are one of the most significant factors that affects machine tool (MT) positioning accuracy. These induced errors are complex for accurate representation by a model, nevertheless they need to be evaluated and predicted in order to increase the machining performance. This paper presents a novel approach to calibrate a machine tool in real-time, analyzing the thermo-mechanical errors through fiber Bragg grating (FBG) sensors embedded in the MT frame. The proposed configuration consists of an adaptronic structure of passive materials, Carbon Fiber Reinforced Polymers (CFRP), equipped with FBG sensors that are able to measure in real-time the deformed conditions of the frame. By using a proper thermo-mechanical kinematic model, the displacement of the end effector may be predicted and corrected when it is subjected to external undesired factors. By starting from a set of Finite Element (FE) simulations to develop a model able to describe the MT structure stresses, a prototype has been fabricated and tested. The aim of this study was to compare the numerical model with the experimental tests using FBG sensors. The experimental campaign has been performed by varying the structure temperature over time and measuring the tool tip point (TTP) positions. The obtained results showed a substantial matching between the real and the predicted position of the TTP, thereby confirming the effectiveness of the proposed system.