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A new method for characterizing spindle radial error motion a two-dimensional point of view

A new method for characterizing spindle radial error motion a two-dimensional point of view. Xiaodong Lu Special presentation at noon of Aug 25, 2009 Organized by James Bryan. Background. J. Tlusty , “System and Methods of Testing Machine Tools”, Microtecnic , 13(4):162-178, 1959.

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A new method for characterizing spindle radial error motion a two-dimensional point of view

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  1. A new method for characterizing spindle radial errormotiona two-dimensional point of view Xiaodong Lu Special presentation at noon of Aug 25, 2009 Organized by James Bryan

  2. Background • J. Tlusty, “System and Methods of Testing Machine Tools”, Microtecnic, 13(4):162-178, 1959. • J. Bryan, R. Clouser, and E. Holland. “Spindle Accuracy”, American Machinist, 111(25):149-164, 1967 • R. Donaldson, A Simple Method for Separating Spindle Error from Test Ball Roundness Error, CIRP Annals, Vol. 21/1, 1972 • J. Peters, P. Vanherck, An Axis of Rotation Analyser, Proc. Of 14th International MTDR Conference, 1973. • ANSI/ASME B89.3.4M – 1985, Axes of Rotation: Methods for specifying and testing, 1985. • ISO 230-7:2006, Test code for machine tools—Part 7: Geometric accuracy of axes of rotation, 2006 • J. B. Bryan, The History of Axes of Rotation and my Recollections, Proceedings of ASPE Summer Topical Meeting on Precision Bearings and Spindles, 2007. • E. R. Marsh, Precision Spindle Metrology, DEStech Publications, 2008.

  3. Something is wrong! • Darcy Montgomery of Kodak Graphics (Vancouver) sent Email to Prof. Yusuf Altintas (UBC), questioning about ASNI B89.3.4, what if the amplitudes of once-per-revolution components in X and Y are not equal to each other? The removal of once-per-revolution component is questionable. • Darcy’s question motivated me and my students (UBC) to develop a new method for a more rigorous treatment of the spindle radial error motion.

  4. Motivation: axis-asymmetric turning Y X

  5. Face turning as well

  6. Spindle motion analysis framework Layer 1: Test Point Motion Layer 2: Spindle Motion Layer 3: Predict Application Error: effect of spindle radial error motion on a specific application

  7. 1: Test point motion: Point Tagging

  8. 1: Test point vector motion V[-2] V[0] V[1] V[-1] V[2] V[-2] Error Motion 2ω V[2] V[2] 2ω 2ω V[-1] V[-1] V[-1] ω ω ω ω ω ω ω V[1] V[1] V[1] V[1] V[0] V[0] V[0] V[0] V[0]

  9. 1: Test point vector motion 2ω 2ω ω ω

  10. 1: Test point vector motion Spindle rotation average point: the intersection between the spindle axis average line and the radial plane at the specified axial location Spindle rotation center: the intersection between the spindle axis of rotation and the radial plane at the specified axial location

  11. 2: Spindle Error Motion

  12. 3: Spindle error motion effect on applications Applications with two sensitive directions: Applications with single fixed sensitive direction: Applications with single rotating sensitive direction:

  13. Once-per-revolution radial motion Y Y X X A spindle with once-pre-revolution radial error motion The perfect spindle

  14. Once-per-revolution radial motion Y Y X X A spindle with once-pre-revolution radial error motion The perfect spindle

  15. E-beam rotary writing machine A spindle with once-pre-revolution radial error motion

  16. E-beam rotary writing machine A spindle with once-pre-revolution radial error motion

  17. E-beam rotary writing machine A spindle with once-pre-revolution radial error motion

  18. E-beam rotary writing machine A spindle with once-pre-revolution radial error motion

  19. E-beam machine with multi-tools A spindle with once-pre-revolution radial error motion Produced pattern on a once-per-rev error spindle

  20. Mutli-tool boring with k=2 error A spindle with K=2 radial error motion: Produced holes

  21. Mutli-tool boring with k=2 error A spindle with K=2 radial error motion: Produced holes

  22. Another example Spindle Error Motion: ANSI/ASME B89.3.4M

  23. Applications with 2 sensitive directions • Machining/measuring axis-asymmetric patterns • Machining/measuring axis symmetric pattern with multiple tools installed at different radial directions

  24. Experiment 1

  25. ball motion measurement, 4000 rpm

  26. Error motion across speeds

  27. Structure stiffness

  28. Experiment 2

  29. Ball motion measurement at 500 rpm

  30. Error motion along X at 500 rpm

  31. V(-1) error motion across speeds

  32. Conclusions

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