Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracer...Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracers to enable the rapid and high-precision measurement of geometric errors for gantry-type computer numerical control(CNC)machine tools.This method also improves on the existing measurement efficiency issues in the single-base station measurement method and multi-base station time-sharing measurement method.We consider a three-axis gantry-type CNC machine tool,and the geometric error mathematical model is derived and established based on the combination of screw theory and a topological analysis of the machine kinematic chain.The four-station laser tracers position and measurement points are realized based on the multi-point positioning principle.A self-calibration algorithm is proposed for the coordinate calibration process of a laser tracer using the Levenberg-Marquardt nonlinear least squares method,and the geometric error is solved using Taylor’s first-order linearization iteration.The experimental results show that the geometric error calculated based on this modeling method is comparable to the results from the Etalon laser tracer.For a volume of 800 mm×1000 mm×350 mm,the maximum differences of the linear,angular,and spatial position errors were 2.0μm,2.7μrad,and 12.0μm,respectively,which verifies the accuracy of the proposed algorithm.This research proposes a modeling method for the precise measurement of errors in machine tools,and the applied nature of this study also makes it relevant both to researchers and those in the industrial sector.展开更多
Assembly geometric error as a part of the machine tool system errors has a significant influence on the machining accuracy of the multi-axis machine tool.And it cannot be eliminated due to the error propagation of com...Assembly geometric error as a part of the machine tool system errors has a significant influence on the machining accuracy of the multi-axis machine tool.And it cannot be eliminated due to the error propagation of components in the assembly process,which is generally non-uniformly distributed in the whole working space.A comprehensive expression model for assembly geometric error is greatly helpful for machining quality control of machine tools to meet the demand for machining accuracy in practice.However,the expression ranges based on the standard quasistatic expression model for assembly geometric errors are far less than those needed in the whole working space of the multi-axis machine tool.To address this issue,a modeling methodology based on the Jacobian-Torsor model is proposed to describe the spatially distributed geometric errors.Firstly,an improved kinematic Jacobian-Torsor model is developed to describe the relative movements such as translation and rotation motion between assembly bodies,respectively.Furthermore,based on the proposed kinematic Jacobian-Torsor model,a spatial expression of geometric errors for the multi-axis machine tool is given.And simulation and experimental verification are taken with the investigation of the spatial distribution of geometric errors on five four-axis machine tools.The results validate the effectiveness of the proposed kinematic Jacobian-Torsor model in dealing with the spatial expression of assembly geometric errors.展开更多
In heavy duty machine tools, hydrostatic turntable is often used as a means for providing rotational motion and supporting workpiece, so the accuracy of turntable is crucial for part machining. In order to analyze the...In heavy duty machine tools, hydrostatic turntable is often used as a means for providing rotational motion and supporting workpiece, so the accuracy of turntable is crucial for part machining. In order to analyze the influence of load-indcued errors on machining accuracy, an identification model of load-induced errors based on the deformation caused by applied load of hydrostatic turntable of computerized numerical control(CNC) gantry milling heavy machine is proposed. Based on multi-body system theory and screw theory, the space machining accuracy model of heavy duty machine tool is established with consideration of identified load-induced errors. And then, the influence of load-induced errors on space machining accuracy and the roundness error of a milled hole is analyzed. The analysis results show that load-induced errors have a big influence on the roundness error of machined hole, especially when the center of the milled hole is far from that of hydrostatic turntable.展开更多
The methods of identifying geometric error parameters for NC machine tools are introduced. According to analyzing and comparing the different methods, a new method-displacement method with 9 lines is developed based o...The methods of identifying geometric error parameters for NC machine tools are introduced. According to analyzing and comparing the different methods, a new method-displacement method with 9 lines is developed based on the theories of the movement errors of multibody system (MBS). A lot of experiments are also made to obtain 21 terms geometric error parameters by using the error identification software based on the new method.展开更多
Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining qualit...Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.展开更多
In order to improve the low output accuracy caused by the elastic deformations of the branch chains,a finite element-based dynamic accuracy analysis method for parallel mechanisms is proposed in this paper.First,takin...In order to improve the low output accuracy caused by the elastic deformations of the branch chains,a finite element-based dynamic accuracy analysis method for parallel mechanisms is proposed in this paper.First,taking a 5-prismatic-spherical-spherical(PSS)/universal-prismatic-universal(UPU)parallel mechanism as an example,the error model is established by a closed vector chain method,while its influence on the dynamic accuracy of the parallel mechanism is analyzed through numerical simulation.According to the structural and error characteristics of the parallel mechanism,a vector calibration algorithm is proposed to reduce the position and pose errors along the whole motion trajectory.Then,considering the elastic deformation of the rod,the rigid-flexible coupling dynamic equations of each component are established by combining the finite element method with the Lagrange method.The elastodynamic model of the whole machine is obtained based on the constraint condition of each moving part,and the correctness of the model is verified by simulation.Moreover,the effect of component flexibility on the dimensionless root mean square error of the displacement,velocity and acceleration of the moving platform is investigated by using a Newmark method,and the mapping relationship of these dimensionless root mean square errors to dynamic accuracy is further studied.The research work provides a theoretical basis for the design of the parameter size of the prototype.展开更多
A systematic geometric model has been presented for calibration of a newly designed 5-axis turbine blade grinding machine. This machine is designed to serve a specific purpose to attain high accuracy and high efficien...A systematic geometric model has been presented for calibration of a newly designed 5-axis turbine blade grinding machine. This machine is designed to serve a specific purpose to attain high accuracy and high efficiency grinding of turbine blades by eliminating the hand grinding process. Although its topology is RPPPR (P: prismatic; R: rotary), its design is quite distinct from the competitive machine tools. As error quantification is the only way to investigate, maintain and improve its accuracy, calibra- tion is recommended for its performance assessment and acceptance testing. Systematic geometric error modeling technique is implemented and 52 position dependent and position independent errors are identified while considering the machine as five rigid bodies by eliminating the set-up errors of workpiece and cutting tool. 39 of them are found to have influential errors and are accommodated for finding the resultant effect between the cutting tool and the workpiece in workspace volume. Rigid body kinematics techniques and homogenous transformation matrices are used for error synthesis.展开更多
We propose a novel spatial phase-shifting interferometry that exploits a genetic algorithm to compensate for geometric errors. Spatial phase-shifting interferometry is more suitable for measuring objects with properti...We propose a novel spatial phase-shifting interferometry that exploits a genetic algorithm to compensate for geometric errors. Spatial phase-shifting interferometry is more suitable for measuring objects with properties that change rapidly in time than the temporal phase-shifting interferometry. However, it is more susceptible to the geometric errors since the positions at which interferograms are collected are different. In this letter, we propose a spatial phase-shifting interferometry with separate paths for object and reference waves. Also, the object wave estimate is parameterized in terms of geometric errors, and the error is compensated by using a genetic algorithm.展开更多
Many factors affect the integrity of precision ball bearings.In this study,the multi-dimensional controllability of precision ball bearings produced in different company brands(bearing A and bearing B)were studied and...Many factors affect the integrity of precision ball bearings.In this study,the multi-dimensional controllability of precision ball bearings produced in different company brands(bearing A and bearing B)were studied and compared.The geometric errors(flatness,parallelism,roundness and cylindricity of inner and outer rings,roundness,groove and roughness of inner and outer rings)and vibration errors of bearings were analyzed.Concurrently,the residual stress,residual austenite content,element content ratio,metamorphic layer and temperature-vibration displacement coupling test were also analyzed.Based on the above analysis conclusion,the bearing fatigue life test was carried out for 2150 h.The reliability of the conclusion is proved again as follows.When the residual austenite content in the raceway of precision ball bearing is 10%,the axial residual stress is 877.4 MPa;the tangential residual stress is 488.1 MPa;the carbon content is 6%;the test temperature of bearing is the lowest;and the service life is prolonged.展开更多
Motivated by the definition of the machining errors induced by tool path planning methods, a mapping curve of the tool axis of a cylindrical cutter is constructed on the tool surface. The mapping curve is a typical on...Motivated by the definition of the machining errors induced by tool path planning methods, a mapping curve of the tool axis of a cylindrical cutter is constructed on the tool surface. The mapping curve is a typical one that can be used to express the closeness between the tool surface and the surface to be machined. A novel tool path planning method is proposed for flank or plunge milling ruled surfaces based on the minimization of the one-sided Hausdorff distance (HD) from the mapping curve to the surface to be machined. It is a nonlinear optimization problem in best uniform approximation (BUA) or Chebyshev sense. A mathematical programming model for computing the minimum one-sided HD is proposed. The linearization method of the programming model is provided and the final optimal solutions are obtained by simplex method. The effectiveness of the proposed BUA method is verified by two numerical examples and compared with the least squares (LS) and double point offset (DPO) methods. The variation in tool orientation induced by the optimization of the tool positions is also evaluated.展开更多
The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface qu...The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.展开更多
基金Supported by Natural Science Foundation of Shaanxi Province of China(Grant No.2021JM010)Suzhou Municipal Natural Science Foundation of China(Grant Nos.SYG202018,SYG202134).
文摘Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracers to enable the rapid and high-precision measurement of geometric errors for gantry-type computer numerical control(CNC)machine tools.This method also improves on the existing measurement efficiency issues in the single-base station measurement method and multi-base station time-sharing measurement method.We consider a three-axis gantry-type CNC machine tool,and the geometric error mathematical model is derived and established based on the combination of screw theory and a topological analysis of the machine kinematic chain.The four-station laser tracers position and measurement points are realized based on the multi-point positioning principle.A self-calibration algorithm is proposed for the coordinate calibration process of a laser tracer using the Levenberg-Marquardt nonlinear least squares method,and the geometric error is solved using Taylor’s first-order linearization iteration.The experimental results show that the geometric error calculated based on this modeling method is comparable to the results from the Etalon laser tracer.For a volume of 800 mm×1000 mm×350 mm,the maximum differences of the linear,angular,and spatial position errors were 2.0μm,2.7μrad,and 12.0μm,respectively,which verifies the accuracy of the proposed algorithm.This research proposes a modeling method for the precise measurement of errors in machine tools,and the applied nature of this study also makes it relevant both to researchers and those in the industrial sector.
基金Supported by National Natural Science Foundation of China (Grant No.51975369)National Key Science and Technology Research Program of China (Grant No.2019ZX04027001)。
文摘Assembly geometric error as a part of the machine tool system errors has a significant influence on the machining accuracy of the multi-axis machine tool.And it cannot be eliminated due to the error propagation of components in the assembly process,which is generally non-uniformly distributed in the whole working space.A comprehensive expression model for assembly geometric error is greatly helpful for machining quality control of machine tools to meet the demand for machining accuracy in practice.However,the expression ranges based on the standard quasistatic expression model for assembly geometric errors are far less than those needed in the whole working space of the multi-axis machine tool.To address this issue,a modeling methodology based on the Jacobian-Torsor model is proposed to describe the spatially distributed geometric errors.Firstly,an improved kinematic Jacobian-Torsor model is developed to describe the relative movements such as translation and rotation motion between assembly bodies,respectively.Furthermore,based on the proposed kinematic Jacobian-Torsor model,a spatial expression of geometric errors for the multi-axis machine tool is given.And simulation and experimental verification are taken with the investigation of the spatial distribution of geometric errors on five four-axis machine tools.The results validate the effectiveness of the proposed kinematic Jacobian-Torsor model in dealing with the spatial expression of assembly geometric errors.
基金Projects(51575010,51575009)supported by the National Natural Science Foundations of ChinaProject(Z1511000003150138)supported by Beijing Nova Program,China
文摘In heavy duty machine tools, hydrostatic turntable is often used as a means for providing rotational motion and supporting workpiece, so the accuracy of turntable is crucial for part machining. In order to analyze the influence of load-indcued errors on machining accuracy, an identification model of load-induced errors based on the deformation caused by applied load of hydrostatic turntable of computerized numerical control(CNC) gantry milling heavy machine is proposed. Based on multi-body system theory and screw theory, the space machining accuracy model of heavy duty machine tool is established with consideration of identified load-induced errors. And then, the influence of load-induced errors on space machining accuracy and the roundness error of a milled hole is analyzed. The analysis results show that load-induced errors have a big influence on the roundness error of machined hole, especially when the center of the milled hole is far from that of hydrostatic turntable.
基金This project is supported by National Advanced ResearchFoundation (No.PD521910) and National Natural ScienceFoundation of Ch
文摘The methods of identifying geometric error parameters for NC machine tools are introduced. According to analyzing and comparing the different methods, a new method-displacement method with 9 lines is developed based on the theories of the movement errors of multibody system (MBS). A lot of experiments are also made to obtain 21 terms geometric error parameters by using the error identification software based on the new method.
基金supported by the National Natural Science Foundation of China(Nos.52005413,52022082)Natural Science Basic Research Plan in Shaanxi Province of China(No.2021JM-054)the Fundamental Research Funds for the Central Universities(No.D5000220135)。
文摘Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.
基金Supported by the National Natural Science Foundation of China(Grant Nos.U21A20122,51975523 and 51905481)the Natural Science Foundation of Zhejiang Province(Grant No.LY22E050012)the Students in Zhejiang Province Science and technology Innovation Plan(Grant No.2020R403054).
文摘In order to improve the low output accuracy caused by the elastic deformations of the branch chains,a finite element-based dynamic accuracy analysis method for parallel mechanisms is proposed in this paper.First,taking a 5-prismatic-spherical-spherical(PSS)/universal-prismatic-universal(UPU)parallel mechanism as an example,the error model is established by a closed vector chain method,while its influence on the dynamic accuracy of the parallel mechanism is analyzed through numerical simulation.According to the structural and error characteristics of the parallel mechanism,a vector calibration algorithm is proposed to reduce the position and pose errors along the whole motion trajectory.Then,considering the elastic deformation of the rod,the rigid-flexible coupling dynamic equations of each component are established by combining the finite element method with the Lagrange method.The elastodynamic model of the whole machine is obtained based on the constraint condition of each moving part,and the correctness of the model is verified by simulation.Moreover,the effect of component flexibility on the dimensionless root mean square error of the displacement,velocity and acceleration of the moving platform is investigated by using a Newmark method,and the mapping relationship of these dimensionless root mean square errors to dynamic accuracy is further studied.The research work provides a theoretical basis for the design of the parameter size of the prototype.
文摘A systematic geometric model has been presented for calibration of a newly designed 5-axis turbine blade grinding machine. This machine is designed to serve a specific purpose to attain high accuracy and high efficiency grinding of turbine blades by eliminating the hand grinding process. Although its topology is RPPPR (P: prismatic; R: rotary), its design is quite distinct from the competitive machine tools. As error quantification is the only way to investigate, maintain and improve its accuracy, calibra- tion is recommended for its performance assessment and acceptance testing. Systematic geometric error modeling technique is implemented and 52 position dependent and position independent errors are identified while considering the machine as five rigid bodies by eliminating the set-up errors of workpiece and cutting tool. 39 of them are found to have influential errors and are accommodated for finding the resultant effect between the cutting tool and the workpiece in workspace volume. Rigid body kinematics techniques and homogenous transformation matrices are used for error synthesis.
基金supported by the National Research Foundation and the Ministry of Education, Science and Engineering of Korea through the National Creative Re-search Initiative Program (R16-2007-030-01001-0)
文摘We propose a novel spatial phase-shifting interferometry that exploits a genetic algorithm to compensate for geometric errors. Spatial phase-shifting interferometry is more suitable for measuring objects with properties that change rapidly in time than the temporal phase-shifting interferometry. However, it is more susceptible to the geometric errors since the positions at which interferograms are collected are different. In this letter, we propose a spatial phase-shifting interferometry with separate paths for object and reference waves. Also, the object wave estimate is parameterized in terms of geometric errors, and the error is compensated by using a genetic algorithm.
基金funded by the National Key R&D Program of Manufacturing Basic Technology and Key Components(Grant Nos.2020YFB2009604 and 2018YFB2000502).
文摘Many factors affect the integrity of precision ball bearings.In this study,the multi-dimensional controllability of precision ball bearings produced in different company brands(bearing A and bearing B)were studied and compared.The geometric errors(flatness,parallelism,roundness and cylindricity of inner and outer rings,roundness,groove and roughness of inner and outer rings)and vibration errors of bearings were analyzed.Concurrently,the residual stress,residual austenite content,element content ratio,metamorphic layer and temperature-vibration displacement coupling test were also analyzed.Based on the above analysis conclusion,the bearing fatigue life test was carried out for 2150 h.The reliability of the conclusion is proved again as follows.When the residual austenite content in the raceway of precision ball bearing is 10%,the axial residual stress is 877.4 MPa;the tangential residual stress is 488.1 MPa;the carbon content is 6%;the test temperature of bearing is the lowest;and the service life is prolonged.
基金supported by the National Natural Science Foundation of China (51175065)
文摘Motivated by the definition of the machining errors induced by tool path planning methods, a mapping curve of the tool axis of a cylindrical cutter is constructed on the tool surface. The mapping curve is a typical one that can be used to express the closeness between the tool surface and the surface to be machined. A novel tool path planning method is proposed for flank or plunge milling ruled surfaces based on the minimization of the one-sided Hausdorff distance (HD) from the mapping curve to the surface to be machined. It is a nonlinear optimization problem in best uniform approximation (BUA) or Chebyshev sense. A mathematical programming model for computing the minimum one-sided HD is proposed. The linearization method of the programming model is provided and the final optimal solutions are obtained by simplex method. The effectiveness of the proposed BUA method is verified by two numerical examples and compared with the least squares (LS) and double point offset (DPO) methods. The variation in tool orientation induced by the optimization of the tool positions is also evaluated.
基金support from the National Natural Science Foundation of China(51575028)National Natural Science Foundation of China(51605258)the Fundamental Research Funds for the Central Universities of China(YWF-18-BJ-J-75)。
文摘The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.