A geometric AccurAcy design method of multi-Axis nc mAchine tool for improving mAchining AccurAcy reliAbility metodA projektowAniA i poprAwy niezAwodności dokłAdności obróbczej wieloosiowej obrAbiArki nc wykorzystującA pojęcie dokłAdności geometrycznej

The reliability of machining accuracy is of great significance to performance evaluation and optimization design of the machine tools. Different geometric errors have various influences on the machining accuracy of the machine tools. The main emphasis of this paper is to propose a generalized method to distribute geometric accuracy of component for improving machining accuracy reliability under certain design requirements. By applying MBS theory, a comprehensive volumetric model explaining how individual errors in the components of a machine affect its volumetric accuracy (the coupling relationship) was established. In order to reflect the ability to reach the required machining accuracy, the concept of machining accuracy reliability is proposed in this paper. Based on advanced first order and second moment (AFOSM) theory, reliability and sensitivity with single failure modes were obtained and the model of machining accuracy reliability and the model of machining accuracy sensitivity with multiple failure modes were developed. By taking machining accuracy reliability as a measure of the ability of machine tool and taking machining accuracy sensitivity as a reference of optimizing the basic parameters of machine tools to design a machine tool, an accuracy distribution method of machine tools for improving machining accuracy reliability with multiple failure modes was developed and a case study example for a five-axis NC machine tool was used to demonstrate the effectiveness of this method. It is identified that each improvement of the geometric errors leads to a decrease in the maximum values and mean values of possibility of failure, and the gaps among reliability sensitivity of geometric parameter errors improved also decreased. This study suggests that it is possible to obtain the relationships between geometric errors and specify the accuracy grades of main feeding components of mechanical assemblies for improving machining accuracy reliability.