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Trajectory-Based Identification of Rotary-Axis Position-Independent Geometric Errors Considering Excitation

Songtao He1, Seth Osei1, Wei Wang1

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|February 27, 2026
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Summary

This study introduces a new method to identify geometric errors in five-axis machine tools. The research highlights how excitation projection, not just the test path, impacts accuracy for rotary axes position-independent geometric errors (PIGEs).

Keywords:
PIGEsfive-axis machine toolidentification accuracyrotary axistrajectory

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Area of Science:

  • Manufacturing Engineering
  • Mechanical Engineering
  • Metrology

Background:

  • Rotary axes in five-axis machine tools increase flexibility but introduce significant geometric errors, particularly position-independent geometric errors (PIGEs).
  • PIGEs are a major cause of accuracy degradation in advanced manufacturing processes.
  • Limited research has explored the impact of test trajectory characteristics, specifically excitation projection, on PIGE identification accuracy.

Purpose of the Study:

  • To propose and validate a trajectory-based method for identifying rotary-axis PIGEs in five-axis machine tools using a single setup.
  • To systematically investigate the influence of excitation projection on the accuracy of PIGE identification.
  • To compare the identification performance for different machine tool kinematic configurations (AC-type vs. BC-type).

Main Methods:

  • Development of a comprehensive error model for rotary axes.
  • Implementation of a double differential identification scheme to analyze error components.
  • Validation through both simulation studies and experimental tests on AC-type and BC-type machine tools.

Main Results:

  • Accurate identification of all rotary-axis PIGEs was achieved for an AC-type machine tool after the second differential under favorable excitation projection.
  • Optimal excitation projection varies depending on the machine tool's kinematic configuration, as shown in simulations for a BC-type machine tool.
  • Compensation using identified PIGEs significantly reduced trajectory errors, confirming the method's effectiveness.

Conclusions:

  • Identification accuracy of rotary-axis PIGEs is critically dependent on the interplay between excitation projection and the machine tool's structural configuration.
  • The proposed single-setup method offers a practical and effective approach for enhancing the identification accuracy of PIGEs in five-axis machine tools.
  • Future research should consider the specific kinematic structure when designing test trajectories for optimal PIGE identification.