Abstract
Geometric errors are caused due to the inaccuracy of machine components’ manufacturing and assembling, and significantly impact the dimensional precision of workpieces. Many researches have researched the methods of inversely identifying geometric errors of multi-axis milling machines from the workpiece profile, but those methods are inapplicable to identify geometric errors of ultra-precision lathe. This paper presents a new approach to research the inverse identification of geometric errors from the surface topography of workpiece for an ultra-precision lathe. First, a volumetric error model is built to analyze tool position errors caused by geometric errors. Next, a matrix decomposition method is put forward to simplify the calculation of tool position errors and describe the propagation process of geometric errors during the manufacturing process. This method decomposes final tool position errors into a sum of three components, and each has a definite geometric meaning. Then, an equivalent machining model is constructed to identify crucial geometric errors from the surface topography of workpiece. Geometric errors in this model can be worked out precisely through topography data sampled along a radial path on workpiece surface. Finally, some simulation experiments are implemented to verify the precision of matrix decomposition method and one plane surface is machined to validate the effectiveness of equivalent machining model.
Similar content being viewed by others
References
Min W, Jiafu L, Tao Z (2017) Identification of CNC machine tools’ geometric errors based on circular tests. J Beijing Univ Technol 42(02):171–177
Slamani M, Mayer R, Balazinski M (2013) Concept for the integration of geometric and servo dynamic errors for predicting volumetric errors in five-axis high-speed machine tools: an application on a XYC three-axis motion trajectory using programmed end point constraint measurements. Int J Adv Manuf Technol 65(9–12):1669–1679
Aguado S, Samper D, Santolaria J (2012) Identification strategy of error parameter in volumetric error compensation of machine tool based on laser tracker measurements. Int J Mach Tool Manu 53(1):160–169
Cheng Q, Zhao H, Zhang G, Gu P, Cai L (2014) An analytical approach for crucial geometric errors identification of multi-axis machine tool based on global sensitivity analysis. Int J Adv Manuf Technol 75(1–4):107–121
Erkan T, Mayer R, Wozniak A (2011) Surface probing simulator for the evaluation of CMM probe radius correction software. Int J Adv Manuf Technol 55(1–4):307–315
Cheng Q, Feng Q, Liu Z (2016) Sensitivity analysis of machining accuracy of multi-axis machine tool based on POE screw theory and Morris method. Int J Adv Manuf Technol 84(9–12):2301–2318
Chen G, Liang Y, Sun Y (2013) Volumetric error modeling and sensitivity analysis for designing a five-axis ultra-precision machine tool. Int J Adv Manuf Technol 68(9–12):2525–2534
Ibaraki S, Ota Y (2014) A machining test to calibrate rotary axis error motions of five-axis machine tools and its application to thermal deformation test. Int J Mach Tools Manuf 86:81–88
Pezeshki M, Arezoo B (2016) Kinematic errors identification of three-axis machine tools based on machined work pieces. Precis Eng 43:493–504
Jiang Z, Tang X, Zhou X, Zheng S (2015) Machining tests for identification of location errors on five-axis machine tools with a tilting head. Int J Adv Manuf Technol 79(1–4):245–254
Gao H, Fang F, Zhang X (2014) Reverse analysis on the geometric errors of ultra-precision machine. Int J Adv Manuf Technol 73(9–12):1615–1624
Slamani M, Mayer R, Balazinski M, Seyedhossein H (2010) Dynamic and geometric error assessment of an XYC axis subset on five-axis high-speed machine tools using programmed end point constraint measurements. Int J Adv Manuf Technol 50(9–12):1063–1073
Wu Q, Sun Y, Chen W, Chen G (2017) Theoretical and experimental investigation of spindle axial drift and its effect on surface topography in ultra-precision diamond turning. Int J Mach Tools Manuf 116:107–113
Chen G, Liang Y, Sun Y (2014) Frequency domain error analysis in turning. Int J Adv Manuf Technol 73(5–8):929–940
Huang P, Lee W, Chan C (2015) Investigation of the effects of spindle unbalance induced error motion on machining accuracy in ultra-precision diamond turning. Int J Mach Tools Manuf 94:48–56
Yang D, Liu Z (2015) Surface plastic deformation and surface topography prediction in peripheral milling with variable pitch end mill. Int J Mach Tools Manuf 91:43–53
Cao Y, Liu T, Ye X et al (2016) Lathe errors identification based on surface topography analysis after turning. Precis Eng 46:243–253
Dong Z, Zhang S, Xiong Z, Rao X (2018) A generalized dynamic model for spindle vibration influencing surface topography in different ultra-precision machining processes. Int J Adv Manuf Technol 96(5–8):2471–2478
Yu D, Gan S, Wong YS (2012) Optimized tool path generation for fast tool servo diamond turning of micro-structured surfaces. Int J Adv Manuf Technol 63(9–12):1137–1152
Yang X, An C, Wang Z, Wang Q, Peng Y (2016) Research on surface topography in ultra-precision fly cutting based on the dynamic performance of machine tool spindle. Int J Adv Manuf Technol 87(5–8):1957–1965
Jiang X, Cripps R (2016) Geometric characterization and simulation of position independent geometric errors of five-axis machine tools using a double ball bar. Int J Adv Manuf Technol 83(9–12):1905–1915
He Z, Fu J, Xu Y (2015) New method to measure angular position errors of rotational axis of CNC machine tool. J Zhejiang Univ (Engineering Science) 49(05):835–840
Chen JX, Lin S, Zhou X (2016) A comprehensive error analysis method for the geometric error of multi-axis machine tool. Int J Mach Tools Manuf 106:56–66
Ding S, Huang X, Yu C, Liu X (2016) Identification of different geometric error models and definitions for the rotary axis of five-axis machine tools. Int J Mach Tools Manuf 100:1–6
Liu X, Zhang X, Fang F (2016) Identification and compensation of main machining errors on surface form accuracy in ultra-precision diamond turning. Int J Mach Tool Manu 105:45–57
Liu XL, Zhang XD, Fang FZ, Zeng Z, Gao HM, Hu XT (2015) Influence of machining errors on form errors of microlens arrays in ultra-precision turning. Int J Mach Tool Manu 96:80–93
Acknowledgments
The authors are grateful to Dr. Duan Jie and Dr. Xiong Shoucong for the academic discussion and their valuable comments on this work.
Funding
This work was funded by the Science Challenge Project (Grant no. TZ2018006-0102-01).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Tao, H., Chen, R., Xuan, J. et al. A new approach to identify geometric errors directly from the surface topography of workpiece in ultra-precision machining. Int J Adv Manuf Technol 106, 5159–5173 (2020). https://doi.org/10.1007/s00170-019-04661-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-04661-7