A geometric error measurement method for five-axis ultra-precision machine tools

Song, Luqi; Zhao, Xueshen; Zhang, Qiang; Shi, Daming; Sun, Tao

doi:10.1007/s00170-023-11181-y

Cited by 6 publications

(2 citation statements)

References 27 publications

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“…To identify the dominant errors affecting machining accuracy, a common approach involved removing the workpiece for offline measurement [27][28][29][30]. In this context, a measurement technique based on the double ball bar (DBB) was proposed to address geometric error measurement challenges for five-axis ultra-precision machine tools operating with interpolated five-axis motion [31]. Their suggested method was less constrained by the machine tool's configuration and could measure the geometric errors of a five-axis ultra-precision machine tool with a single setup.…”

Section: Introductionmentioning

confidence: 99%

Development of Theoretical and Numerical Framework for Selecting the Cutting Process Parameters for Turned Slender Parts

Ezugwu,

Fayomi,

Onifade

et al. 2023

JESA

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Metal cutting productivity or material removal rate is a constrained objective. Higher productivity, which is guaranteed by higher cutting process parameters (feed, speed, and depth of cut), is accompanied by higher constraining and unwanted factors like higher cutting forces, higher power demand, higher machine tool and workpiece deflections (in other words, form error), higher waste heat generation and coolant demand, faster tool wear rate, higher predisposition to periodic and regenerative chatter, compromised surface quality, etc. The research focused on the development of theoretical and numerical framework for selecting the cutting process parameters to enhance the productivity, integrity, and accuracy of turned slender parts. The method involved theoretical modelling that expresses material removal rate and form error in terms of cutting process parameters, workpiece flexibility parameters, workpiece geometrical parameters, and kinematic parameters. Cutting tests were carried out in validation of the arising theoretical and numerical results. Parametric studies were carried out using the developed computational model to understand the trend of accuracy and productivity with variation of cutting process parameter. As expected, the parametric study shows that flexibility of the slender workpiece reduced MRR. The results showed that deviation of predicted values of MRR from the desired values rises with rise of all the cutting process parameters; feed, depth of cut and spindle speed. The findings also indicate that as the feed rate and depth of cut increase, the variance between the predicted diameter and the target values also increases. However, there is a fluctuating pattern with a gradual decrease in variance as the spindle speed rises. Based on the results of the parametric studies, specified tolerance ranges could be met by choosing parameter sets that meet the specifications. If the numerical model relies on FEA, it might require extensive computational resources and expertise, limiting its practicality. Overcoming these limitations often involves continuous research and development efforts, incorporating real-world data, and improving the accuracy and adaptability of the framework for specific machining scenarios. The parametric study results can be used as a framework for the selection of cutting process parameter to enhance the productivity, integrity, and accuracy of turned slender parts.

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Section: Introductionmentioning

confidence: 99%

Development of Theoretical and Numerical Framework for Selecting the Cutting Process Parameters for Turned Slender Parts

Ezugwu,

Fayomi,

Onifade

et al. 2023

JESA

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show abstract

“…Further, Jiang et al [14] established a new testing procedure to identify and characterize the PIGEs of the rotary axes in a five-axis machine, through a four-step process with double ball bars. Song et al [21] carried out measurement experiments with double ball bars to extract seven PIGEs for the geometric errors of a five-axis UPM machine. It is, thus, clear that these proposed methods were carried out only to identify PIGEs, but the machining form errors would not be fully considered with crucial PIGEs under the machining process.…”

Section: Introductionmentioning

confidence: 99%

A Theoretical and Experimental Identification with Featured Structures for Crucial Position-Independent Geometric Errors in Ultra-Precision Machining

Zhang,

Zhang

2023

Machines

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In ultra-precision machining (UPM), position-independent geometric errors (PIGEs), i.e., squareness errors, have a crucial impact upon the form accuracy of a machined surface. Accordingly, more research work has been conducted in PIGE identification, to improve the form accuracy. However, the general identification methods were developed without consideration of the specific squareness errors for crucial PIGEs under the form errors of the machining process. Therefore, a new method with featured structures was proposed, to identify crucial PIGEs in UPM. Firstly, a volumetric error model was developed for PIGEs, to discuss the relationship between squareness errors and their resulting machining form errors. Secondly, following the developed model, some featured structures have been proposed with their machining form errors, to significantly indicate crucial PIGEs. Finally, a series of UPM and measuring experiments were conducted for the featured structures, and then their machining form errors were measured and extracted with specific squareness errors for the identification of crucial PIGEs. The theoretical and experimental results revealed that the proposed method is simple and efficient with the featured structures to accurately identify crucial PIGEs in UPM. Significantly, the study offers a deep insight into high-quality fabrication in UPM.

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An error allocation method for five-axis ultra-precision machine tools

Song,

Sun,

Jia

et al. 2023

Int J Adv Manuf Technol

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A geometric error measurement method for five-axis ultra-precision machine tools

Cited by 6 publications

References 27 publications

Development of Theoretical and Numerical Framework for Selecting the Cutting Process Parameters for Turned Slender Parts

Development of Theoretical and Numerical Framework for Selecting the Cutting Process Parameters for Turned Slender Parts

A Theoretical and Experimental Identification with Featured Structures for Crucial Position-Independent Geometric Errors in Ultra-Precision Machining

An error allocation method for five-axis ultra-precision machine tools

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