Simulation, Modeling and Experimental Research on the Thermal Effect of the Motion Error of Hydrostatic Guideways

Lei, Penghui; Wang, Zhenzhong; Shi, Chen; Peng, Yunfeng; Lü, Feng

doi:10.3390/mi12121445

Cited by 5 publications

(3 citation statements)

References 24 publications

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“…However, FEA is one of the effective methods to study the profile function of guide rail incorporating the thermal effect. Indeed, our research group have established the dynamic profile function of guide rail incorporating the thermal effect using FEA, which was published in Lei et al, 34 and it provides the direct reference for developing the improved model of motion accuracy for hydrostatic guideways with the consideration of the thermal effect from the oil temperature fluctuation. Also, Refs.…”

Section: Discussionmentioning

confidence: 99%

Modeling and analysis on motion accuracy of hydrostatic guideways incorporating the manual lapping effect

Shi

Wang

Lei

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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As one of the crucial functional units in ultra-precision machines, the hydrostatic guideways have been commonly adopted due to their own superiority. Although the existed analysis approaches can enable researchers to understand the influence of various design parameters on motion accuracy of hydrostatic guideways, the corresponding imperfections remain to be captured easily. In this paper, targeted at avoiding those defectiveness as much as possible, the kinematic theory based quasi-static analysis model with less simplification is developed directly, wherein the profile pattern difference between main and vice guide rails induced by the manual lapping technology is taken into consideration, and the general structure of hydrostatic guideways extracted from Z axis of the ultra-precision grinding machine UPG80 is determined as the research object. Three CASE studies are proposed orderly to verify the correctness and effectiveness of the established analytical model, and the results demonstrate that the variation trends of the theoretically calculated vertical straightness errors are in good accordance with those of the experimentally measured. Furthermore, the fluctuation amplitude deviation between the predicted and the measured motion accuracy does occur in CASE 3, which should be attributed to the accumulated thermal effect revealed via an experimental platform of hydrostatic guideways with similar structure type to the research object. It also is figured out that, the variation of three components of guide rails’ profile errors caused by the thermal accumulation leads to the fluctuation amplitude deviation reflected in CASE 3, and the level of influence can be known as Amplitude component ( E) > Phase component ( φ) Upside wavelength component ( λup) > Downside wavelength component ( λdown). This study can serve as a valuable foundation for improving the motion accuracy of hydrostatic guideways and is also confirmed to be valuable to the peer designers.

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Section: Discussionmentioning

confidence: 99%

Modeling and analysis on motion accuracy of hydrostatic guideways incorporating the manual lapping effect

Shi

Wang

Lei

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…Shamoto et al (2001) used finite element method (FEM) to elucidate the interaction between oil film reaction forces and geometric errors on the oil film contact surface. Their findings revealed that thermal elevation can lead to significant deformations, further compounding surface errors, as highlighted by subsequent studies conducted by Li et al (2018) and Lei et al (2021). Furthermore, the structural integrity of hydrostatic guideway can be compromised by localized deformations resulting from screw preload, manifesting as contour errors on the oil film contact surface, which can be considered as assembly errors (Song et al, 2023).…”

Section: Introductionmentioning

confidence: 99%

Influence of multisource errors of oil film contact surface on motion accuracy of hydrostatic guideway

He,

Liang,

et al. 2024

ILT

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Purpose This study aims to explore the impact of multisource deformation errors on the oil film contact surface, which arise from manufacturing, assembly, oil pressure and thermal influences, on the motion accuracy of hydrostatic guideway. Design/methodology/approach Using thermal-structural coupling simulations, this research investigates the effects of assembly, oil pressure and thermal factors on deformation errors of the oil film contact surface. By integrating these with manufacturing errors, a profile error model for the oil film contact surface is developed, characterizing the cumulative effect of these errors. Using kinematic theory and progressive Mengen flow controller characteristics, the motion error at any position of the hydrostatic guideway is quantified, examining how surface error traits impact motion accuracy. Findings The error averaging effect is affected by the profile error of oil film contact surface. Meanwhile, the motion accuracy of hydrostatic guideway is highly sensitive to the oil film contact surface error amplitude. Originality/value This approach allows for precise prediction and analysis of motion accuracy in hydrostatic guideways during the design and manufacturing stages. It also provides guidance for planning process tolerances. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2024-0063/

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“…The straightness error is one of the most important geometric errors of the guideway, which not only affects the machining accuracy, but also the reliability and stability of the equipment during long-term operation [ 3 ]. In the process of equipment manufacturing, there are many methods which can effectively reduce the straightness error of the guideway, such as improving the flatness of the guideway working surface [ 4 ], optimizing the fluid parameters in the slider [ 5 ] and reducing hydraulic oil temperature fluctuations [ 6 ]. During the equipment debugging stage, by accurately measuring the straightness error of the guideway and compensating it in the CNC system, the straightness error of the guideway can be further reduced [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

Splicing Measurement and Compensation of Straightness Errors for Ultra-Precision Guideways

Zhou,

Zheng,

et al. 2023

Micromachines

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The straightness error of guideways is one of the key indicators of an ultra-precision machine, which plays an important role in the machining accuracy of a workpiece. In order to measure the straightness error of a long-distance ultra-precision guideway accurately, a splicing measurement for the straightness error of a guideway using a high-precision flat mirror and displacement sensor was proposed in this paper, and the data splicing processing algorithm based on coordinate transformation was studied. Then, comparative experiments on a splicing measurement and direct measurement of the straightness error were carried out on a hydrostatic guideway grinder. The maximum difference between the two measurements was 0.3 μm, which was far less than the straightness error of 5.8 μm. The experiment demonstrated the correctness of the proposed splicing measurement method and data processing algorithm. To suppress the influence of the straightness error on machining accuracy, a straightness error compensation algorithm based on error rotation transformation and vertical axis position correction was proposed, and the grinding experiment of a plane optics with a size of 1400 mm × 500 mm was carried out. Without error compensation grinding, the flatness error of the element was 7.54 μm. After error compensation grinding, the flatness error was significantly reduced to 2.98 μm, which was less than the straightness errors of the guideways. These results demonstrated that the straightness error of the grinding machine had been well suppressed.

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Simulation, Modeling and Experimental Research on the Thermal Effect of the Motion Error of Hydrostatic Guideways

Cited by 5 publications

References 24 publications

Modeling and analysis on motion accuracy of hydrostatic guideways incorporating the manual lapping effect

Modeling and analysis on motion accuracy of hydrostatic guideways incorporating the manual lapping effect

Influence of multisource errors of oil film contact surface on motion accuracy of hydrostatic guideway

Splicing Measurement and Compensation of Straightness Errors for Ultra-Precision Guideways

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