Using a double ball bar to measure 10 position-dependent geometric errors for rotary axes on five-axis machine tools

Xiang, Sitong; Yang, Jing

doi:10.1007/s00170-014-6155-2

Cited by 44 publications

(11 citation statements)

References 22 publications

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“…The identified PDGEs can be compensated by generating new numerical control (NC) codes with inverse kinematic operation or post-processing software based on a well-defined compensation method, 3,31 and the same measurements were performed based on the five DBB setups. Then, the identified PDGEs were determined after compensation.…”

Section: Experimental Verificationmentioning

confidence: 99%

Highly efficient and accurate calibration method for the position-dependent geometric errors of the rotary axes of a five-axis machine tool

Guo

Tang

Jiang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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This paper proposes a calibration method for continuous measurements with a double ball bar (DBB) used to identify the position-dependent geometric errors (PDGEs) of the rotary axes of five-axis machine tools. The different DBB installation modes for the rotary axes of the spindle and workbench are established, and the same initial DBB installation position is used for multiple tests. This approach minimizes the number of required DBB installations, which increases the measurement efficiency of the PDGEs of the rotary axes and reduces installation errors. PDGEs identification based on the adaptive least absolute shrinkage and selection operator (LASSO) method is proposed. By assigning coefficients to the PDGEs polynomial, the ill-conditioned problem of the identification process can be effectively avoided, thereby improving the identification accuracy. The measurement and identification methods proposed in this paper are verified by experiments on a five-axis machine tool. After compensation, the PDGEs are obviously reduced and the accuracy indexes of the circular trajectory tests performed under multiaxis synchronous control are obviously improved.

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Section: Experimental Verificationmentioning

confidence: 99%

Highly efficient and accurate calibration method for the position-dependent geometric errors of the rotary axes of a five-axis machine tool

Guo

Tang

Jiang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…To date, this method is relatively advanced for geometric error modeling of a machine in the published work [ 19 ]. The main methods for calibrating a rotation axis are the reverse method [ 20 ], the three-point method [ 21 ], and the multi-point method [ 22 ]. In the error modeling of a measurement system with multiple degrees of freedom, Du proposed a self-calibration technique for a five-axis, laser-optical measurement system based on a ball bar [ 23 ].…”

Section: Introductionmentioning

confidence: 99%

Modeling and Analysis of System Error for Highly Curved Freeform Surface Measurement by Noncontact Dual-Axis Rotary Scanning

Zhu

Fang

et al. 2021

Sensors

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Profile measurement is a key technical enabler in the manufacturing of highly curved freeform surfaces due to their complex geometrical shape. A current optical probe was used to measure nearly rotary freeform surfaces with the help of one rotation axis, because the probe needs to measure along the normal vector of the surface under the limitation of the numerical aperture (NA). This kind of measuring system generally has a high cost due to the high-precision, multi-axis platform. In this paper, we propose a low-cost, dual-axis rotation scanning method for a highly curved freeform surface with an arbitrary shape. The optical probe can scan the surface profile while always keeping consistent with the normal vector of the measuring points with the help of the double rotation axis. This method can adapt to the changes in curvature in any direction for a highly curved freeform surface. In addition, the proposed method provides a system error calibration technique for the rotation axis errors. This technique can be used to avoid the dependence of the measuring system on the high-precision platform. The three key system errors that affect the measurement accuracy such as installation error of the B-axis, A-axis, and XZ perpendicularity error are first analyzed through establishing an error model. Then, the real error values are obtained by the optimal calculation in the calibration process. Finally, the feasibility of the measurement method is verified by measuring one cone mirror and an F-theta mirror and comparing the results to those obtained using commercial equipment. The maximum measurable angle of the system is ±90°, the maximum measurable diameter is 100 mm, and the measurement accuracy of the system reaches the micron level in this paper.

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“…Intra-axis errors of the rotary axes were estimated by running ball-bar tests on a five-axis machine tool with several circular patterns by Xiang and Yang [14]. They analyzed the effect of inter-axis and setup errors on measurement results.…”

Section: Introductionmentioning

confidence: 99%

An Integrated Geometric and Hysteretic Error Model of a Three Axis Machine Tool and Its Identification With a 3D Telescoping Ball-Bar

Esmaeili

Mayer

2020

JMMP

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The ball-bar instrument is used to estimate a maximum number of hysteretic error sources. Machine error parameters include inter- and intra-axis errors as well as hysteresis effects. An error model containing cubic polynomial functions and modified qualitative variables, for hysteresis modeling, is proposed to identify such errors of the three nominally orthogonal linear axes machine. Such model has a total of 90 coefficients, not all of which being necessary. A numerical analysis is conducted to select a minimal but complete non-confounded set of error coefficients. Four different ball-bar test strategies to estimate the model coefficients are simulated and compared. The first one consists of circular trajectories on the primary planes XY, YZ, and XZ and the others use the XY plane, as an equator, and either four, five, or nine meridians. It is concluded that the five-meridian strategy can estimate the additional eight error coefficients: ECZ1, ECZ2, ECZ3, ECZb, EZY3, EZX3, ECX3, and ECXb. The Jacobian condition number is improved by increasing the number of meridians to 5. Further increasing the number of meridians from five to nine improves neither the number of estimable coefficients nor the conditioning, and so as it increases, the test time it was dismissed.

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Using a double ball bar to measure 10 position-dependent geometric errors for rotary axes on five-axis machine tools

Cited by 44 publications

References 22 publications

Highly efficient and accurate calibration method for the position-dependent geometric errors of the rotary axes of a five-axis machine tool

Highly efficient and accurate calibration method for the position-dependent geometric errors of the rotary axes of a five-axis machine tool

Modeling and Analysis of System Error for Highly Curved Freeform Surface Measurement by Noncontact Dual-Axis Rotary Scanning

An Integrated Geometric and Hysteretic Error Model of a Three Axis Machine Tool and Its Identification With a 3D Telescoping Ball-Bar

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