System and method for virtually calibrating a computer numeric controlled machine to compensate for surface distortions

A method for virtually calibrating a CNC machine to compensate for surface distortions on an object to be machined, said method comprising:

• providing g-code instructions representing movement of a toolhead of the CNC machine for machining an object free of surface distortions;
• selecting a linear axis of movement of the toolhead from one of x, y and z
• linear axes of movement prior to machining the object to be machined;
• instructing the toolhead to travel on the object to be machined along the selected linear axis of movement, but where the toolhead actually travels along an actual axis that is deviated from the linear axis as a result of the surface distortions on the object to be machined;
• selecting multiple points along the actual axis;
• measuring the surface distortions particular to the object to be machined by comparing a distance between each of the multiple points along the actual axis and the selected linear axis to determine an offset amount of each of the multiple points;
• and
• modifying the g-code instructions for machining the object to be machined based on the determined offset amounts to compensate for surface distortions particular to the object to be machined before uploading the g-codes to a CNC controller.

A system for virtually calibrating a computer numeric controlled (CNC) machine to compensate for surface distortions on an object to be machined, said system comprising:

• means for providing g-code instructions for machining a surface of a distortion-free object;
• means for selecting a true axis of movement of a toolhead of the CNC machine prior to machining the object to be machined using the g-code instructions, where the true axis is a straight line;
• means for instructing the toolhead to travel on the object to be machined along the true axis, but where the toolhead actually travels along an actual axis that is deviated from the true axis as a result of the surface distortions on the object to be machined;
• means for selecting multiple points along the actual axis;
• means for measuring the surface distortions particular to the object to be machined by comparing a distance between each of the multiple points along the actual axis and the true axis to determine an offset amount of each of the multiple points to determine a lack of straightness of the object to be machined;
• and
• means for modifying the g-code instructions for machining the object to be machined based on the determined offset amounts to correct for the measured surface distortions particular to the object to be machined before uploading the g-codes to a CNC controller.