Accuracy design of high precision machine tools using error sensitivity analysis methodology

Geometric accuracy is a crucially important performance factor for machine tools. Theoretically, the effects of source errors on pose accuracy (positional and angular accuracy) of 3-, 4- or 5-axis machine tools cannot fully be compensated by software, and only those pose errors associated with the permission motions are compensatable by means of error compensation. Therefore, the uncompensatable pose errors should be strictly guaranteed in the processes of design and manufacture. In this paper, after the geometric error model is established, the source errors affecting the uncompensatable pose accuracy are identified out of all the source errors. In order to enhance the understanding of which source errors have more influences on the pose accuracy, a probabilistic sensitivity analysis method is proposed, and the global sensitivity index is defined to evaluate the influence in the overall workspace. According to the sensitivity analysis results, the uncompensatable pose accuracy index is allocated to each source error. And then, assembly accuracy acceptance criteria are proposed as a guideline for machine assemblers. As an application example, the presented approaches are applied to the accuracy design and manufacture of a 4-axis machine tool, and double ball bar measurement and machining test are carried out to check the accuracy of the designed machine tool.