Thin-walled parts are widely applied in the automotive and aerospace industry for their superior properties. However, severe machining error may occur due to their low rigidity under the effects of multiple error sources in the machining process. Solutions based on mechanism analysis and finite element method have been developed while most of them are not robust under the complex machining conditions. Aiming to solve this problem, a comprehensive error compensation method that includes three major error sources, which are geometric error, thermal error, and force-induced error, is proposed. The geometric error and thermal-induced error of the machining center are firstly modeled and compensated to provide a high precision movement system for the on-machine measurement inspection. The force-induced error model is then established based on the probing data. Finally, the comprehensive error model is obtained through the transformation of the coordinate systems. Besides, a real-time compensation system is developed based on the specific functions of the NC system. To validate the proposed method, two sets of compensation cases are conducted, the objects of which are a thin web workpiece and a valve body part, respectively. The experiment results reveal that the machining errors of both experiment sets are decreased by more than 60.7% and the machining productivity is improved by more than 41.9%.

薄壁零件以其优越的性能被广泛应用于汽车和航空航天工业。然而，在加工过程中，在多种误差源的影响下，由于其刚性低，可能会出现严重的加工误差。已经开发了基于机构分析和有限元方法的解决方案，但大多数解决方案在复杂的加工条件下并不稳健。针对这一问题，提出了一种包含几何误差、热误差和力致误差三大误差源的综合误差补偿方法。首先对加工中心的几何误差和热致误差进行建模和补偿，为在机测量检测提供高精度的运动系统。然后基于探测数据建立力引起的误差模型。最后通过坐标系的变换得到综合误差模型。此外，还根据数控系统的具体功能开发了实时补偿系统。为了验证所提出的方法，进行了两组补偿案例，其对象分别是薄腹板工件和阀体零件。实验结果表明，两组实验组的加工误差均降低了60.7%以上，加工生产率提高了41.9%以上。为了验证所提出的方法，进行了两组补偿案例，其对象分别是薄腹板工件和阀体零件。实验结果表明，两组实验组的加工误差均降低了60.7%以上，加工生产率提高了41.9%以上。为了验证所提出的方法，进行了两组补偿案例，其对象分别是薄腹板工件和阀体零件。实验结果表明，两组实验装置的加工误差均降低了60.7%以上，加工生产率提高了41.9%以上。