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A Ball Bar Measurement Scheme with Single-Axis Rotation Modes for Position-Independent Geometric Error Identification

Jinlong Zhang1,2, Hongtao Yang2, Zhaoyao Shi1

  • 1Beijing Engineering Research Center of Precision Measurement Technology and Instruments, Beijing University of Technology, Beijing 100124, China.

Sensors (Basel, Switzerland)
|June 26, 2026
PubMed
Summary
This summary is machine-generated.

This study introduces an improved double ball bar method to precisely identify geometric errors in five-axis machine tools. The technique significantly enhances machining accuracy by decoupling and pinpointing rotary axis errors.

Keywords:
PIGEsball barerror identificationfive-axis machine toolrotating axes

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Area of Science:

  • Manufacturing Engineering
  • Metrology
  • Mechanical Engineering

Background:

  • Position-independent geometric errors (PIGEs) of rotary axes are primary limitations in five-axis machine tool accuracy.
  • Accurate identification of these errors is crucial for high-precision manufacturing.

Purpose of the Study:

  • To propose an improved double ball bar (BB) measurement scheme for accurate identification of rotary-axis PIGEs in dual rotary table five-axis machine tools.
  • To achieve complete error decoupling and efficient geometric error identification.

Main Methods:

  • An improved double ball bar (BB) measurement scheme with independent single-axis rotary measurement for error decoupling.
  • Utilizing a standard fixed-length ball bar without auxiliary fixtures to minimize setup errors.
  • Developing a non-iterative analytical algorithm based on circular eccentricity fitting for geometric error identification.

Main Results:

  • Mathematical models correlating rotary-axis PIGEs with BB length deviations were established.
  • Numerical simulations quantified the relationship between PIGEs and BB length variations.
  • Successful identification and compensation of all eight rotary-axis PIGEs on a BC-type dual rotary table five-axis machine tool.

Conclusions:

  • The proposed method enables high-precision PIGE decoupling and identification, significantly improving machining accuracy.
  • Experimental results showed a reduction in maximum positional error from 144.53 μm to 7.72 μm (79.48% improvement).
  • The method offers a reliable alternative for geometric error identification in five-axis machining systems, particularly for dual rotary table configurations.