“Analysis of the topology and geometric accuracy of motions of a grinding machine during three-axis machining in an automatic cycle at the design stage”

Abstract

In order to increase the reliability of processing on a three-axis CNC flat grinding machine,
in accordance with the key issue of processing accuracy, this article proposes an analysis of
geometric accuracy and a design method for machines of this type. A geometric model of error
propagation was created based on the theory of multibody systems and the method of uniform
coordinate transformation. It is experimentally confirmed that the model has perfect prediction accuracy. Key geometric errors were analyzed using an orthogonal design and Design of
Experiments (DOE) parameter validation. DOE methods serve as a means to determine optimal
process settings with minimal research costs and maximum speed in obtaining results. During
process setup, technicians can proceed through trial and error. After cost analysis and error tracking,
a cost and quality model was established for key geometric error variables based on robust design
theory. Subsequently, the error tolerances of the key geometric variables were allocated according
to this model. The results indicate that the method enables a reasonable and optimal distribution of
geometric accuracy, thereby enhancing the accuracy of grinding processing and overall processing
reliability on grinding machines.