A vector error gradient compensation method for geometric error of boring deep holes on thin-walled boxes.

The final machining process, high-precision boring, can significantly affect the geometric error index of deep holes in gearboxes with thin-walled features. However, traditional mirror and mean compensation strategies are inadequate in compensating for the complex spatial and vector geometric errors, resulting in machining problems when boring deep holes in thin-walled boxes. This paper proposed a gradient compensation method that considered the geometric error and boring process characteristics to improve the current machining accuracy. The disadvantages of the classical compensation methods were analyzed in detail based on the error characteristics in boring deep holes. A gradient compensation was proposed and derived to improve the machining precision for boring deep holes on thin-walled boxes. On the other hand, a cutting test was designed and implemented using a control variable method in industrial cutting environment. Two different codes were programmed for boring process to validate the advantages of the proposed compensation method than the common. With the proposed compensation method, the geometric accuracy was improved by 86.12%, indicating that the proposed model was efficient for boring deep holes in thin-walled boxes. As a result, the proposed gradient compensation method successfully reduces the machining error of actual boring deep holes in thin-walled boxes. [ABSTRACT FROM AUTHOR]