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Error modeling and accuracy optimization of rotating ultrasonic vibration assisted EDM machine tool

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Abstract

Rotating ultrasonic vibration assisted EDM is a composite machining method that uses EDM to etch a metal surface and adds rotating and ultrasonic vibration. It has high efficiency and a wide range of workpiece materials. Aiming at the structural characteristics of rotary ultrasonic vibration assisted EDM machine tool, the errors caused by the main moving parts of the machine tool were analyzed. The structure relationship is described by multi-body system theory, and the geometric error model is deduced by homogeneous coordinate transformation method. The aim was to improve the overall accuracy, reduce the cost, trace the error source, and get the corresponding relationship between the basic geometric errors and the precision parameters of the related parts. Under the requirement of ensuring the overall accuracy, an optimization function was established that minimizes the cost and relaxes all accuracy parameters to the greatest extent. Finally, MATLAB and its genetic algorithm toolbox was used for analysis. Verification shows that this model can properly reduce the cost on the premise of ensuring the accuracy.

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Abbreviations

ΔX x :

Positioning error

ΔY x :

Y direction of straightness error

Δz x :

Z direction of straightness error

Δα x :

Rolling error

Δβ x :

Britain swing error

Δγ x :

Deflection error

ΔX y :

X direction of straightness error

Δy y :

Positioning error

Δz y :

Z direction of straightness error

Δα y :

Britain swing error

Δβ y :

Rolling error

Δγ y :

Deflection error

ΔX z :

X direction of straightness error

Δy z :

Y direction of straightness error

Δz z :

Positioning error

Δα z :

Britain swing error

Δβ z :

Deflection error

Δγ z :

Rolling error

ΔX c :

X direction runout error

Δy c :

Y direction runout error

Δz c :

Axial runout error

Δα c :

Rotation error around X-axis

Δβ c :

Rotation error around Y-axis

Δγ c :

Turning error

Δα yz :

X, Z axis perpendicularity error

Δβ xz :

X, Z axis perpendicularity error

Δγ xy :

X, Y axis perpendicularity error

Δγ xC :

C, X axis perpendicularity error

Δβ yC :

C, Y axis perpendicularity error

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Acknowledgments

This work was accomplished at the North China University of Technology, Beijing, China. This topic is derived from the Beijing Municipal Natural Science Foundation (No. 3162011).

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Authors and Affiliations

  1. School of Mechanical and Material Engineering, North China University of Technology, Beijing, 100144, China

    Minggang Xu, Zhiwei Wu, Feng Gao, Linlin Liu & Enyu Song

Authors
  1. Minggang Xu
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  2. Zhiwei Wu
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  3. Feng Gao
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  4. Linlin Liu
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  5. Enyu Song
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Corresponding author

Correspondence to Zhiwei Wu.

Additional information

Recommended by Editor Chongdu Cho

Zhiwei Wu is a Master’s candidate in the School of Mechanical and Material Engineering, North China University of Technology, Beijing, China.

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Xu, M., Wu, Z., Gao, F. et al. Error modeling and accuracy optimization of rotating ultrasonic vibration assisted EDM machine tool. J Mech Sci Technol 34, 2751–2760 (2020). https://doi.org/10.1007/s12206-020-0607-4

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  • DOI: https://doi.org/10.1007/s12206-020-0607-4

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