This paper presents a novel modeling and compensation method for the volumetric errors of a six-axis gantry automated fiber placement (AFP) machine. Based on the screw theory, the forward and inverse kinematics models of the AFP machine are established. In order to improve the accuracy of the inverse kinematics solution, the Paden-Kahan sub-problem method is used to perform the inverse kinematics solution for the simplified topology of the rotary axes. Using error motion twist to establish a volumetric error transfer model for 54 geometric errors. According to the measurement data of a laser tracker and the Levenberg-Marquardt method to identify the geometric error parameters. The explicit formula of the inverse kinematics solution is used to obtain the error compensation of each motion axis, and the G code of the laying path is modified by the iterative method to realize the compensation of the volumetric errors. By comparing the positions of the tool center point before and after the error compensation, the practicability of the volumetric error modeling and iterative compensation methods are verified, and the geometric accuracy of the AFP machine can be effectively improved.
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