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Critical geometric errors identification of a five-axis machine tool based on global quantitative sensitivity analysis

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Abstract

Rotation axes have been proven to be the greatest factor leading to machine tool errors, which seriously affect the machining accuracy. Therefore, it is imperative to identify the geometric errors of the rotation axes. This research focuses on how to identify the critical geometric errors of the rotation axes, so that the coupling effect of geometric errors which seriously affects the identification of geometric errors of the rotation axes can be examined. To achieve this goal, this paper proposes a global quantitative sensitivity analysis method based on homogeneous transformation matrix (HTM) theory and Sobol sensitivity analysis method. The size and randomness of geometric errors are taken into consideration and the specific indexing angles of the rotation axes are introduced to identify the critical geometric errors of the five-axis machine tool. Based on this analysis method, each geometric error components and the coupling effect between different error sources are evaluated under different indexing angles. The variation of the coupling effect of each error components within the traverse of the rotation axes is explored. The geometric error measurement experiment is established and the results are compared with the simulation results. The simulation results and experimental results reveal that the critical geometric errors that affect the machining accuracy and the variation of the geometric errors coupling effect, which provides useful guidance for the manufacturers and users of five-axis machine tools.

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Acknowledgements

Thanks goes to Mr. Wenguo Qi for his assistance in machine tool operation and test equipment calibration.

Funding

The work received financial support sponsored by the National Natural Science Foundation of China (51905377, 51705362) and Tianjin Natural Science Foundation (20JCQNJC00040, 20JCQNJC00050, 18JCQNJC75600).

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Authors and Affiliations

  1. Tianjin Key Laboratory of Advanced Mechatronics Equipment Technology, Tiangong University, Tianjin, China

    Xiaogeng Jiang, Zhiwei Cui, Liang Wang, Chang Liu & Yu Du

  2. School of Mechanical Engineering, Tiangong University, Tianjin, China

    Xiaogeng Jiang, Zhiwei Cui, Liang Wang, Chang Liu & Yu Du

  3. School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, UK

    Chang Liu

  4. State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha, 410082, Hunan, China

    Maojun Li

  5. School of Mechanical Engineering, Sichuan University, Chengdu, 610065, Sichuan, China

    Jian Liu

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  1. Xiaogeng Jiang
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  2. Zhiwei Cui
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  3. Liang Wang
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  4. Chang Liu
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  5. Maojun Li
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  6. Jian Liu
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  7. Yu Du
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Correspondence to Chang Liu or Yu Du.

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Jiang, X., Cui, Z., Wang, L. et al. Critical geometric errors identification of a five-axis machine tool based on global quantitative sensitivity analysis. Int J Adv Manuf Technol 119, 3717–3727 (2022). https://doi.org/10.1007/s00170-021-08188-8

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  • DOI: https://doi.org/10.1007/s00170-021-08188-8

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