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A novel method for machining accuracy reliability and failure sensitivity analysis for multi-axis machine tool

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Abstract

In the state of machining service, to evaluate the machining accuracy reliability of multi-axis CNC machine tools, analyze the accuracy failure mode and the reliability sensitivity under the failure mode, this paper proposes a research method by the cross-correlation studies of geometric error parameters to improve and promote the accuracy reliability of CNC machine tools. Firstly, by multi-body system theory, the homogeneous coordinate transformation matrix between each body of the machine tool is established, and the spatial machining accuracy model is constructed. At the same time, considering the time series problem in the measurement process of geometric error parameters, this paper studies the correlation between the error parameters for reliability analysis and proposes a novel reliability analysis index for each measurement point in the machine tool workspace. To validation of the method, the analysis results of this paper are compared with those by Monte Carlo simulation. In addition, the accuracy failure conditions of the machine tool are studied, the failure state function of machine tool accuracy is established, and the accuracy failure modes that may occur are analyzed from this, to carry out the accuracy failure sensitivity analysis under the failure mode, and to identify key geometric errors which have a great impact on the machining accuracy reliability of machine tool in the failure mode. Finally, taking a 3-axis machine tool as an example, according to the analysis results, this paper puts forward measures to improve the accuracy reliability and verifies the feasibility of the proposed method.

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Funding

The author(s) disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This work was supported by the National Natural Science Foundation of China (51975012) and Opening Project of the Key Laboratory of CNC Equipment Reliability, Ministry of Education, Jilin University.

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Authors and Affiliations

  1. Institute of Advanced Manufacturing and Intelligent Technology, Beijing University of Technology, Beijing, 100124, China

    Peng Niu, Qiang Cheng, Caixia Zhang, Xiaolong Hao & Congbin Yang

  2. Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology, Beijing, 100124, China

    Peng Niu, Qiang Cheng & Caixia Zhang

  3. Machinery Industry Key Laboratory of Heavy Machine Tool Digital Design and Testing Technology, Beijing University of Technology, Beijing, 100124, China

    Xiaolong Hao & Congbin Yang

  4. Key Laboratory of CNC Equipment Reliability, Ministry of Education, Jilin University, Changchun, China

    Chuanhai Chen

Authors
  1. Peng Niu
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  2. Qiang Cheng
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  3. Caixia Zhang
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  4. Xiaolong Hao
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  5. Congbin Yang
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  6. Chuanhai Chen
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Contributions

Qiang Cheng and Niu Peng is responsible for providing overall research ideas; Zhang Caixia, Hao Xiaolong, and Chuanhai Chen are responsible for the measurement of machine tool error data; Niu Peng and Congbin Yang are responsible for experimental data analysis.

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Correspondence to Qiang Cheng.

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Niu, P., Cheng, Q., Zhang, C. et al. A novel method for machining accuracy reliability and failure sensitivity analysis for multi-axis machine tool. Int J Adv Manuf Technol 124, 3823–3836 (2023). https://doi.org/10.1007/s00170-021-08003-4

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  • DOI: https://doi.org/10.1007/s00170-021-08003-4

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