System and method for correcting machining error during a precision jig grinding process

An error compensation method for a Computer Numerical Controller (CNC) machine tool system, the CNC machine tool system including a CNC machine tool having (a) two or more linear machine axes or (b) two or more linear machine axes and one or more rotational machine axes, the CNC machine tool further including a spindle configured to hold a rotary tool having at least one cutting edge for removing the material from the workpiece such that at least one of the linear axes reciprocates while the other axes are utilized to traverse a contour on the workpiece, the CNC machine tool system further including one or more processors, the error compensation method comprising:

• receiving, with the CNC machine tool system, instructions for a workpiece;
• interpreting, with the CNC machine tool system, the received instructions to translate the received instructions into linear and/or rotational axis servo commands for a toolpath trajectory;
• removing, with the CNC machine tool system, material from the workpiece using the linear and/or rotational axis servo commands for the toolpath trajectory to create a first machined workpiece;
• measuring, with the CNC machine tool system, the first machined workpiece for geometric accuracy in comparison to a desired geometry to determine one or more errors;
• mirroring, with the CNC machine tool system, the one or more errors with respect to the desired geometry to create a correction point template;
• superimposing, with the CNC machine tool system, the plurality of correction points onto the linear and/or rotational axis servo commands to modify the linear and/or rotational axis servo commands to create a corrected toolpath trajectory temporally after normal trajectory generation and prior to execution of the linear and/or rotational axis servo commands;
• and
• removing, with the CNC machine tool system, material from the first machined workpiece or a second workpiece using the modified linear and/or rotational axis servo commands for the corrected toolpath trajectory to create a second machined workpiece with an improved geometry accuracy in comparison to the desired geometry.

A Computer Numerical Controller (CNC) machine tool system, comprising:

• a CNC machine tool comprising:
• (a) two or more linear machine axes or (b) two or more linear machine axes and one or more rotational machine axes;
• and
• a spindle configured to hold a rotary tool having at least one cutting edge for removing material from a workpiece;
• and
• one or more processors configured to:
• receive instructions for a workpiece;
• interpret the received instructions to translate the received instructions into linear and/or rotational axis servo commands for a toolpath trajectory;
• utilize the linear and/or rotational axis servo commands for the tool path trajectory to cause the CNC machine tool to remove material from the workpiece to create a first machined workpiece;
• receive one or more errors in the first machined workpiece in comparison to a desired geometry;
• mirror the one or more errors with respect to the desired geometry to create a correction point template;
• superimpose the plurality of correction points onto the linear and/or rotational axis servo commands to modify the linear and/or rotational axis servo commands to create a corrected toolpath trajectory temporally after normal trajectory generation and prior to execution of the linear and/or rotational axis servo commands;
• and
• utilize the modified linear and/or rotational axis servo commands for the corrected toolpath trajectory to cause the CNC machine tool to remove material from the workpiece or a second workpiece to create a second machined workpiece with an improved geometry accuracy of better than 2 micrometers in comparison to the desired geometry.

A Computer Numerical Controller (CNC) machine tool system, comprising:

• a CNC machine tool comprising:
• (a) two or more linear machine axes or (b) two or more linear machine axes and one or more rotational machine axes;
• and
• a spindle configured to hold a rotary tool having at least one cutting edge for removing material from a workpiece, wherein the CNC machine tool is configured to reciprocate at least one of the linear machine axes while the other axes are utilized to traverse a contour on the workpiece;
• and
• one or more processors configured to:
• receive instructions for a workpiece;
• interpret the received instructions to translate the received instructions into linear and/or rotational axis servo commands for a toolpath trajectory;
• utilize the linear and/or rotational axis servo commands for the tool path trajectory to cause the CNC machine tool to remove material from the workpiece to create a first machined workpiece;
• receive one or more errors in the first machined workpiece in comparison to a desired geometry;
• mirror the one or more errors with respect to the desired geometry to create a correction point template;
• superimpose the plurality of correction points onto the linear and/or rotational axis servo commands to modify the linear and/or rotational axis servo commands to create a corrected toolpath trajectory temporally after normal trajectory generation and prior to execution of the linear and/or rotational axis servo commands;
• and
• utilize the modified linear and/or rotational axis servo commands for the corrected toolpath trajectory to cause the CNC machine tool to remove material from the workpiece or a second workpiece to create a second machined workpiece with an improved geometry accuracy of better than 2 micrometers in comparison to the desired geometry.