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<p>Aspheric surface grinding is a critical process for processing large aspheric components, where the precision and surface quality directly influence the efficiency of the entire machining process. In this process, the comprehensive volumetric error of the machine tool significantly impacts the precision of the workpiece’s shape. This paper first examines the mechanism of volumetric error transmission in optical plane grinding machine, and utilizing screw theory and incorporating the machine tool’s topological structure, we derived a volumetric error model suitable for XYZ three-axis machine tools. Additionally, this study elucidated the impact of Abbe error on the machine’s spatial precision and revised the model based on the Abbe principle. The model’s effectiveness was validated by measuring the body diagonal error of the machine. Lastly, we proposed an advanced optimization strategy for machining point positions based on the genetic adaptive particle swarm optimization (GA-APSO) algorithm. Further, based on the theory of arc enveloping grinding and the established volumetric error model of the machine tool, we developed specialized computer-aided manufacturing (CAM) software suitable for aspheric surface grinding and conducted aspheric surface machining test. The results show that the optimized screw theory model can compensate the machine tool volumetric error to about 6&#xa0;µm, increasing the compensation rate from 60% before the correction to 81% after the correction, and reducing the PV value of a 200-mm diameter aspherical surface from 14.8 to 9.2&#xa0;µm, effectively improving the machining accuracy.</p>

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A novel method of volumetric error compensation for aspherical grinding machine considering error coupling effect and compensation strategy

  • 期刊论文

  • 发表日期：

    2025年3月17日

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  • Kai Zhang,
  • Xiangbo He,
  • Ruirui Li,
  • Peizhi Huang,
  • Bingjia Feng,
  • Huiming Feng,
  • Linbin Huang,
  • Yunfeng Peng

摘要

Aspheric surface grinding is a critical process for processing large aspheric components, where the precision and surface quality directly influence the efficiency of the entire machining process. In this process, the comprehensive volumetric error of the machine tool significantly impacts the precision of the workpiece’s shape. This paper first examines the mechanism of volumetric error transmission in optical plane grinding machine, and utilizing screw theory and incorporating the machine tool’s topological structure, we derived a volumetric error model suitable for XYZ three-axis machine tools. Additionally, this study elucidated the impact of Abbe error on the machine’s spatial precision and revised the model based on the Abbe principle. The model’s effectiveness was validated by measuring the body diagonal error of the machine. Lastly, we proposed an advanced optimization strategy for machining point positions based on the genetic adaptive particle swarm optimization (GA-APSO) algorithm. Further, based on the theory of arc enveloping grinding and the established volumetric error model of the machine tool, we developed specialized computer-aided manufacturing (CAM) software suitable for aspheric surface grinding and conducted aspheric surface machining test. The results show that the optimized screw theory model can compensate the machine tool volumetric error to about 6 µm, increasing the compensation rate from 60% before the correction to 81% after the correction, and reducing the PV value of a 200-mm diameter aspherical surface from 14.8 to 9.2 µm, effectively improving the machining accuracy.