Identification of 11 position-independent geometric errors of a five-axis machine tool using 3D geometric sensitivity analysis

In this paper, a method is proposed for identification of 11 position-independent geometric errors (PIGEs) of five-axis machine tools with a tilting/rotary table via single-ball measurements and three-dimensional (3D) geometric sensitivity analysis. Eleven PIGEs were identified, including three squareness errors between three linear axes, two offset errors, and two squareness errors for the tilting/rotary axis. The approach uses a set-up of a ball and three circular measurements involving simultaneous control of two linear axes and a tilting/rotary axis. A 3D geometric sensitivity analysis is carried out to investigate the effects of the 11 PIGEs on each of the measurement’s paths and between the measurement paths. The particular measurement paths used allow the radius of the circular path at the first measurement, and the distance between the circular paths of the second and third measurements, to be increased for accurate identification of the 11 PIGEs. The proposed method was also used to derive root-sum-square values of sensitivity coefficients, and then applied to a commercial five-axis machine tool for experimental verification. It calculates the peak-to-valley values of the positional deviations in the x-, y-, and z-directions along the test paths as 152.1, 118.2, and 47.1 μm, respectively, without compensation for the identified PIGEs, and as 17.6, 15.0, and 11.4 μm, respectively, with compensation. The results confirm the validity of our proposed method.