ELSEVIER

Design of a kinematic coupling

for precision applications
C. H. Schouten, P. C. J. N. Rosielle, and P. H. J. Schellekens
Department of Mechanical Engineering, Precision Engineering, Eindhoven
University of Technology, Eindhoven, The Netherlands

To m a c h i n e a complex precision product, several tools are n e e d e d . These

tools are placed on a tool turret. A tool must r e t u r n several times to its
original position. To attain a very high repeatability between the u p p e r part
a n d the base o f the tool turret m o u n t e d on a precision lathe, it is preferable
that the parts of the tool turret are statically d e t e r m i n e d in their contacts.
This is attained by using a kinematic coupling. To attain the r e q u i r e d
stiffness this coupling is provided with a preload o f 1.5 • 103 N. The ma-
chining forces are typically less than 1 Newton. A special kinematic cou-
pling, consisting o f grooves a n d balls, was designed, made, and tested. By
providing the grooves with self-adjusting surfaces, hysteresis is r e d u c e d to
less than one-tenth o f a micrometer. M a x i m u m stiffness is a i m e d at by using
c e m e n t e d carbide, a material with a high admissible stress, at the contact
points. Experiments show that this kinematic coupling, u n d e r a preload o f
1.5 • 10 3 N, has a static stiffness o f m o r e than 1 • 10 8 N / m in every direction
and a repeatability better than one-tenth o f a m i c r o m e t e r . © Elsevier
Science Inc., 1997

Keywords: kinematic coupling; repeatability; static stiffness; hysteresis;

self-adjusting surfaces; elastic hinges

Introduction "Kelvin clamps. ''6 A kinematic coupling consists of

The position o f a r/g/d body is fully d e f i n e d if all six
degrees of f r e e d o m are constrained; t h e n the
body is said to be "statically d e t e r m i n e d . " Con-
straining a d e g r e e of f r e e d o m m o r e than once
requires elasticity (so the body c a n n o t be r/g/d any
m o r e ) , which introduces difficulties in the design.
It is, therefore, preferable to design statically de-
termined, especially for precision machines, a,2
With such a statically d e t e r m i n e d body, it is possi-
ble to replace that body to the original position,
with respect to the rest of the machine, with high
repeatability. T h e r e are no r e d u n d a n t elements
that constrain the same d e g r e e o f freedom. Re-
peatability of such a m a c h i n e can be m u c h better
than the m a n u f a c t u r i n g accuracy.
In the literature, such statically d e t e r m i n e d
bodies are known as "kinematic couplings "3-5 or
Address reprint requests to Ir. C. H. Schouten, Tinelstract 166,
5654 LX, Eindhoven, The Netherlands.
two parts. The n u m b e r of contact points between
these two parts equals the n u m b e r of degrees of
f r e e d o m that must be constrained. O n e of the
possibilities is a kinematic coupling consisting of
three radial V-grooves in one part and three balls
(or segments of balls) on the o t h e r part, as shown
in Figure 1. Every ball has two contact points with a
V-groove. This design consists o f similar parts, and
it shows predictable thermal behavior, with the
thermal c e n t e r located in the middle o f the cou-
pling. A high stiffness is obtained if the coupling is
provided with a preload. T h e value of the maxi-
m u m static stiffness that will be attained d e p e n d s
u p o n such parameters as the admissible stress of
the material and the dimensions of the balls and
grooves. If these parameters are known, the value
o f the static stiffness is highly predictable. 7 Be-
cause o f the symmetry of the coupling, a central
preload in the vertical direction causes a similar
deflection o f every contact.
Calculations are often based on the assump-

Precision Engineering 20:46-52, 1997

© Elsevier Science Inc., 1997 0141-6359/97/$17.00
655 Avenue of the Americas, New York, NY 10010 PII S0141-6359(97)00002-0
 S c h o u t e n et al.: Kinematic coupling for precision applications
Figure 1 A kinematic coupling with three
V-grooves and three balls
tion of ideal Hertzian contacts 3,5 between the bod-
ies. In this context, "ideal" m e a n s no friction be-
tween the bodies in contact and no surface
roughness. In this frictionless situation, contact
stresses do not c h a n g e if there is a relative move-
m e n t between surfaces. However, in real contacts,
every relative m o v e m e n t between surfaces intro-
duces a friction force Fp in the direction opposite
to the m o v e m e n t . This friction force is tangential
to the surface a n d causes a tangential deflection 8t.
Expressions for the tangential displacement have
b e e n f o u n d by Mindlin for the case of no-slip a n d
by Deresiewicz for partial slip ( r e p o r t e d in J o h n -
sonS). In the first instance there is no slip at the
interfaces. T h e tangential deflection 8 t is a func-
tion of the tangential friction force Ff, the radius
o f the contact area a, the shear modules G, a n d the
Poisson ratio v of the contact material, a T h e tan-
gential stiffness is:
F~ 4aG E f" F0 • tano~
ct- ~t - 2 - v with G- 2(1 + v) (1)
With a "local" n o r m a l stiffness c n =- d F n / ~ , , o f E e • a
(Hertzian theory) a n d an equivalent elastic
Young's m o d u l e s E e = E / ( 1 - v ~) Equation (1)
becomes:
Ct 2(1 - v)
- (2)
Cn 2 -- V
Contact between a ball and a conventional
V-groove is shown schematically in F i g u r e 2. Varia-
tion of the preload causes a variation in (elastic)
d e f o r m a t i o n (symbolized by an elastic spring) in
the contact. It is also possible that there is a move-
m e n t between the surfaces (symbolized by fric-
tion). W h e n the preload varies so m u c h that there
is a relative m o v e m e n t between ball a n d V-groove,
PRECISION ENGINEERING
Inthedirection
ofthepreload
,.sioo:r 2sin2aC
Figure 2 Schematic diagram of a ball in a conven-
tional V-groove
/~2cosZa Cn
it is almost certain that the original position will
n o t be regained once this variation no l o n g e r ex-
ists. This uncertainty of position is t e r m e d hyster-
esis s,,1 a n d can be described as:
2. IF, I
Sv - (3)
C
In this equation, F f is the friction force and c the
stiffness in the same direction. If the preload on
the ball in the V-groove varies, the m a x i m u m fric-
tion force that will a p p e a r is Ft. = f " F,, (with coef-
ficient of friction f and reactive force F,, in the
contacts n o r m a l to the surfaces of the V-groove).
By using this relationship for ~ in Equation (3),
m a x i m u m hysteresis in the direction of the pre-
load is given by:
2" [ F,,~I 2 " 12" f" Fn" sine[
sv - - (4)
cn,~ 2 • cos2cx • cn
In this equation, Ff, is the friction force in the
direction of the pre~'oad and %/, the n o r m a l stiff-
ness in the same direction, Figure 2. With F,, =
F p / 2 c o s e ~ , Equation (4) becomes:
(5)
Sv- COS20~" C n
For o u r application, repeatability needs to be bet-
ter than one-tenth of a m i c r o m e t e r . Hysteresis is
very undesirable w h e n such a high repeatability is
required. Equation (b) shows that hysteresis is
small if the angle of inclination c~ is small a n d / o r
the coefficient of friction f is small a n d / o r the
n o r m a l stiffness c,, is large for a certain preload FF
Hysteresis is theoretically zero if there is no rela-
tive m o v e m e n t between the ball and the surfaces
of the V-groove.
Minimizing hysteresis
Repeatability improves w h e n hysteresis decreases,
because t h e n the indefiniteness o f position is less
after a force or t e m p e r a t u r e variation. According
47
S c h o u t e n et al.: Kinematic coupling for precision applications
I
hin~
lastic
saw-cut~
Z•x
Y
Figure 3 Elastic hinge principle
to Equation (5), this can be realized by, for exam-
ple, the choice of a suitable material for the con-
tacts: (1) with a low coefficient of friction f; a n d
(2) with a high admissible (Hertzian) stress (for a
high feasible stiffness %).
A high value of the normal static stiffness
leads n o t only to m i n i m u m hysteresis, b u t also to a
high total stiffness of the coupling. That is why
c e m e n t e d carbide, a material with a very high
admissible stress ( ~ 5 • 103 N / m m 2 ) , is used at the
contacts. Because this c e m e n t e d carbide is used,
instead of steel, the m a x i m u m contact stiffness
that will be attained with the same contact geom-
etry and p r e l o a d /~ is approximately twice as
high. 7 Unfortunately, the coefficient o f friction of
c e m e n t e d carbide (~-- 0.2) is similar to the coeffi-
cient of friction of steel. So hysteresis decreases,
b u t if the p r e l o a d varies so m u c h that there is a
relative m o v e m e n t b e t w e e n ball and surface of the
groove, there is still the same friction force. Fric-
tion b e t w e e n the balls a n d grooves is theoretically
zero when the surfaces of the V-grooves follow the
m o v e m e n t of the balls, when the p r e l o a d increases
or decreases. T h e n there is no relative m o v e m e n t
b e t w e e n balls and surfaces of the grooves. This can
be achieved by providing the V-grooves with self-
adjusting surfaces, by means of elastic hinges in
the material b e n e a t h the surfaces o f the V-grooves.
Such elastic hinges are created by drilling two
holes next to each o t h e r in the material and mak-
ing saw-cuts from the surface to these holes, as
shown in Figure 3.
In Figure 4 the V-groove-ball situation is de-
picted, showing the elastic hinges in the material
b e n e a t h the surfaces o f the V-groove. The situa-
tion is simplified by assuming that the left elastic
hinge has a very low rotational stiffness k0 (0
means a rotation a r o u n d the z-axis) and the right
half o f the V-groove has stiffnesses c,, a n d ct in the
ball-groove-contact and stiffnesses of the elastic
hinge; cx normal to the surface and cy tangential to
the surface. Because o f the very low rotational
48
stiffness o f the left elastic hinge, the tangential
deflection S t in is also very low; whereas, the tan-
gential stiffness ct (= F J ~ t ) in the left contact is
very high. If a is approximately 45 °, the m o v e m e n t
u 0 o f the left surface of the V-groove by m e a n s o f
p u r e rotation of the elastic hinge almost equals
the normal deflection ~,,,x in the contact of the
ball with the right half o f the V-groove. O f course ct
is n o t infinite, b u t because o f the m o v e m e n t o f the
surface with the m o v e m e n t o f the ball, the tangen-
tial force F¢ is very small a n d so is the d e f e c t i o n S t.
For a certain ball diameter in contact with flat
surfaces o f the V-groove, the m a x i m u m contact
stiffness, normal to a surface o f the V-groove Cn.nla,,
is calculated with the help of the Hertzian theory.
So the stress in the contacts equals the admissible
stress o f c e m e n t e d carbide. 7 Stiffness of the elastic
hinge normal to the surface cx is chosen to be ten
times as large as C,,,ma,,. T h e total normal stiffness
c,,,x (this is a series c o n n e c t i o n of stiffness c,, a n d
Cx) is only 9% less than the normal stiffness with-
o u t the elastic hinge. With the help of a theory
r e p o r t e d by J o h n s o n , 8 a relationship b e t w e e n the
tangential a n d the normal stiffness in the contact
is derived (Equation (2)). W h e n the m a x i m u m
normal stiffness Cn,max is given, it is now possible to
calculate the m a x i m u m tangential stiffness c¢.... ,,
in the contact. T h e stiffnesses o f the elastic hinge;
cx (normal to the surface), cy (tangential to the
surface) a n d k0 (rotational stiffness) are calculated
with equations given in a university textbook. 1
W h e n the distance b e t w e e n hinge and contact is a,
the tangential stiffness in the contact, caused bff
the rotational stiffness of the hinge, is co -~ k o / a 2.
T h e total tangential stiffness in contact Ct,y,O is a
series c o n n e c t i o n o f the stiffnesses ct, cy, and c0.
The total normal stiffness almost equals the nor-
mal stiffness without the elastic hinge. However,
the rotational stiffness has to be low to achieve the
r e q u i r e d mobility of the surfaces, so the tangential
stiffness (with the elastic hinge) has to be m u c h
less than the tangential stiffness without elastic
ua= 5n,X"sin 2a
5n~ / cy
Figure 4 Ball in a V-groove with elastic hinges
JANUARY 1997 V O L 20 N O 1
 Schouten et al.: Kinematic coupling for precision applications
hinge. So, unfortunately, a disadvantage o f a cou-
pling with elastic hinges is that the total stiffness is
lower than the total stiffness of a coupling with
conventional V-grooves.
T h e total axial stiffness Ca,totaI of the coupling
with elastic self-adjusting V-grooves can be de-
scribed with7:
Ca,tota~ = 6 " COS2CX " Cn,x + 6 • s i n 2 a • ct, v,o
The total radial stiffness C,;totaI of this coupling can
be described withY:
Craota, = 3 " sin2eL(Cn,x -- Ct, v,,) + 3 " (ct, v,e + ct)
T h e total axial a n d radial stiffness of a coupling
with conventianal V-grooves can be described with
the same Equations (6) and (7), w h e n c,, and ct are
substituted for c,,,x respectively ct,y,o.
Because ct < % (with V ~ 0,25 equation [2]
becomes: ct ~ 0.86- %) a n d ct,y e << c,~,, (q,ye "~
0.01 • c,,,x), the axial stiffness cfecreasesl anal' the
radial stiffness increases as the angle of inclination
0t increases. So, the best choice for the angle of
inclination is if C~;tota I = Ca,tota I. For the kinematic
coupling with elastic self-adjusting V-grooves, this
is 37 °7. For the conventional coupling it is 550, 7
but this value is less critical, because the tangential
stiffness c¢ has the same o r d e r of m a g n i t u d e as the
n o r m a l stiffness %
Also i m p o r t a n t is the stiffness of the total
coupling u n d e r eccentric load (in tangential di-
rection). T h e equation for the so-called total tan-
gential stiffness ct,tot~1 of the coupling with elastic
self-adjusting V-grooves can be described withY:
Cr, tota I " 3 • (ca, x" s i n 2 ~ + Ct, y,O" CO S2OL)
Ct, tota I
cr,tota~ + 3 • (Cn,x" S i n 2or + Ct, v,e" COS 2or)
T h e angle o f inclination oL has to be of such a
value that the coupling does not self-lock d u r i n g
positioning. Positioning of the coupling with elas-
tic self-adjusting surfaces does n o t give that prob-
lem, because of the mobility of the V-groove sur-
faces. In case of a conventional coupling, the
c h a n g e that self-locking does o c c u r is the smallest
tbr an angle of inclination o f 43 °7. This angle of
inclination is n o t critical. For an angle of 2 9 - 5 6 ° ,
the admissible coefficient o f friction is m o r e than
0.2 (the coefficient of friction of c e m e n t e d car-
bide).
Design of a kinematic coupling and
test results
A special kinematic coupling was designed. O n e
part o f this coupling has six V-grooves: three con-
ventional a n d three self-adjusting, all with an a n -
PRECISION ENGINEERING
gle of inclination of 40 °. O n tile c o u n t e r p a r t o f the
coupling, consisting of a disc, three (15-mm diam-
eter) ball segments are m o u n t e d equally divided
on the same radius. T h e coupling is m a d e of steel;
c e m e n t e d carbide is used only at the points of
contact. T h e material properties of c e m e n t e d car-
bide are: an elastic Young's m o d u l e s E o f 6 • 105
N / m m 2, an admissible stress of 5" 103 N / m m 2,
(6)
Poisson ratio v of 0.25, and a coefficient of friction
f o f 0.2. C e m e n t e d carbide tiles, with a thickness of
2 m m , are glued on the surfaces o f the V-grooves,
a n d three c e m e n t e d carbide ball segments are
(7) glued on the o t h e r part o f the coupling. The glue
used is a t h e r m o s e t with an elastic Young's mod-
ules of 2 • 109 N / m 2. Because the glue layer is very
thin (only a few micrometers) a n d the contact
area fairly large (1.8 • 10 - 4 m 2 ) , this layer is very
stiff. This design enables comparison between a
conventional coupling a n d a coupling with sell=
adjusting surfaces (by means of elastic hinges). For
this purpose, two holes are drilled next to each
o t h e r in the material b e n e a t h the two surfaces of
three V-grooves. T h e middle o f the d a m between
the holes coincides with the n o r m a l to the surface
of the V-groove t h r o u g h the contact (of the ball
with the V-groove). Cuts make the surfaces rela-
tively flexible in the tangential direction with re-
spect to the rest of the coupling, f i g u r e 5 is a
p h o t o g r a p h of the kinematic coupling.
T h e coupling was tested with the help of a
testing system, as shown in b~gure 6. By moving a
mass M, the kinematic coupling is provided with a
varying preload in vertical direction, by way of a
beam, two rods, a second beam, a n d finally a ball
on the middle of the coupling. T h e relative move-
m e n t of the disc with the three ball segments with
(8) regard to the part with the V-grooves, attributable
to the compression in the vertical direction (by
elastic deflection o f the contact surfaces), is mea-
sured with a displacement t r a n s d u c e r fixed to the
u p p e r disc o f the coupling. The preload varies
progressively a n d is m e a s u r e d with a d y n a m o m e -
ter, fixed to the b o t t o m of the lowest beam. T h e
d y n a m o m e t e r measures the pulling force on the
beam. T h e r e f o r e , the m e a s u r e m e n t s have to be
c o r r e c t e d with the static mass o f the disc, the
beams, the rods and the ball (a total weight of 3.5
kg).
Elastic deflection and hysteresis
T h e coupling should be provided with a load to
attain the r e q u i r e d stiffness. This load is called a
preload a n d is m u c h larger than the external loads
in use, which are typically one Newton. Preload
versus displacement is recorded. T h e vertical dis-
49
Schouten et al.: Kinematic coupling for precision applications
Total axial stiffness of the coupling
The tangent (for a specific preload) on the pre-
l o a d - c o m p r e s s i o n graphs of Figure 7 gives the ax-
ial stiffness of the coupling. If the preload is
1.5 • 10 3 N, the axial stiffness of the conventional
coupling is about 6.1 • 1 0 2 N/lxm and for the cou-
pling with self-adjusting surfaces about 3.6" 10 9
N/lxm.

b ~05"0.

Figure 5 (a) The kinematic coupling parts; (b) de-

tail drawing: an elastic hinge

placement is the relative m o v e m e n t between the

two halves of the coupling, which is the result of
the elastic deflection of the contact surfaces, is
plotted on the x-axis. The preload is plotted on the
y-axis. In Figure 7, the p r e l o a d - c o m p r e s s i o n
graphs for both couplings are shown next to each
other. displacement
transducer
Hysteresis is the difference between the
compression w h e n the preload increases and the I v ~., v, I
//////////
compression w h e n the preload decreases. As ex-
plained earlier, this hysteresis is the result of
friction between balls and V-grooves. W h e n the
preload decreases, the friction force is in the dynamometer
f /

opposite direction to the friction force with an

increasing preload. T h e r e is no relative move-
m e n t of the bodies in contact until the friction
has c h a n g e d direction. Figure 7 shows that hyster-
esis decreases by a factor of 10 if the surfaces of /~ L "f
the V-grooves are provided with these elastic Figure 6 (a) The testing system; (b) diagram of the
hinges. testing system

50 JANUARY 1997 VOL 20 NO 1

 S c h o u t e n et al.: Kinematic coupling for precision applications

tained if the force in the radial direction is divided

1500
7 / by the radial deviation. T h e radial stiffness o f the
conventional coupling is a b o u t 6.0" 1 0 2 N / t x m
Fp rN]l a n d a b o u t 3.7 • 1 0 2 N / t x m for the coupling with
self-adjusting surfaces.
1 Conventional V-grooves
2 Self-adjusting V-grooves /' Total tangential stiffness of the coupling

//
1000 In the same way as for the radial stiffness, the
tangential stiffness of the coupling (stiffness u n d e r
eccentric load) is m e a s u r e d with the set up. Now
the additional force is in the tangential direction
and the deviation is m e a s u r e d in the direction of
this force.
In Table 1, the results of the m e a s u r e m e n t s
s0o
a n d the calculated values are shown. All measure-
ments are taken with a p r e l o a d Fp of 1.5 • 103 N,
and calculations are m a d e for the same value of

/ the preload. The u n c e r t a i n ~ of the e x p e r i m e n t s

1 2 3 4 8p [IJm]
Figure 7 Measurements of preload Fpversus elas-
tic deflection Gp; results: hysteresis and axial stiff-
ness
Total radial stiffness of the coupling
T h e radial stiffness o f the coupling is m e a s u r e d
with the same setup. Again, the kinematic cou-
pling is provided with a central p r e l o a d o f 1.5 • 103
N in the vertical direction, as shown in Figure 6.
Using a spring-type force gauge, an additional
force in the radial direction is i n t r o d u c e d to the
b o t t o m of the u p p e r disc (at the height o f the
contacts). T h e radial deviation of the disc with
respect to the base, which is the result o f the radial
force, is m e a s u r e d with a d i s p l a c e m e n t transducer.
An a p p r o x i m a t i o n of the radial stiffness is ob-
was estimated to be +__ 5 • 10 N/Ixm.
Calculated values a n d m e a s u r e d values of the
axial a n d radial stiffness of the coupling agree well
(Equations [6] a n d [7]). These values are highly
predictable. It is m o r e difficult to make a g o o d
estimate o f the tangential stiffness of the coupling
(Equation [8] ).
For the conventional coupling, the m a x i m u m
value of hysteresis is calculated with Equation (5)
at a total p r e l o a d of 7.5 • 1 0 2 N (after a variation
from 0 to 1.5 • 103 N). The e x p e r i m e n t a l value of
hysteresis of the conventional coupling is less than
this calculated value, b u t n o t less than one-tenth o f
a micrometer. By providing the grooves with self-
adjusting surfaces, hysteresis is r e d u c e d consider-
ably. Because the m a x i m u m value of the friction
force F~......~x (= f " F,, ~ 66 N) is m u c h larger than
the real tangential force F t ( ~ 3.3 N) hysteresis
caused by m a c r o slip is theoretically zero. Results
o f the e x p e r i m e n t s show that there still is some
micro slip in the contacts.

Table 1 Comparison of theory with experiments for a preload Fvof 1.5.103 N

Conventional V-grooves Self-adjusting V-grooves

Calculations Experiments Calculations Experiments

Axial stiffness, 6.5 " 10 2 6.1 • 10 2 3.7 • 102 3.6 • 102

%total, N/t xm
Radial stiffness, 6.1 • 109 6.0 • 10 2 4.3 " 10 2 3.7 • 109
c,~t,,tal, N/b~m
Tangential stiffness 3.1 • 102 1.4" 10`2 1.6" 102 1.1 • 109
Ct,total, N / ~ m
Hysteresis, btm max 0.79 0.42 None 0.03

PRECISION ENGINEERING 51
 Schouten et al.: gdnematic coupling for precision applications
Conclusions T T e m p e r a t u r e , °C, K
u Movement, m, m m
Hysteresis is very undesirable w h e n repeatability x
Axis o f coordinates, m, m m
between the u p p e r part a n d the base of a tool Axis of coordinates, m, m m
turret m o u n t e d on a precision lathe (to r e t u r n a Y
z Axis of coordinates, m, m m
tool several times to the original position) must be
better than one-tenth of a m i c r o m e t e r . After an Greek
external force or t e m p e r a t u r e variation, hysteresis 0~ Angle of inclination, [°], rad
can occur. By providing the grooves of a kinematic 5 Compression (elastic deflection), /xm
coupling with self-adjusting surfaces, hysteresis is 0 Spin parameter, rad
r e d u c e d by 95% and is less than one-tenth of a v Poisson ratio, [ - ]
m i c r o m e t e r for a preload of 1.5 • 103 N. This pre- ~p Spin parameter, rad
load is necessary to attain the r e q u i r e d stiffness in Spin parameter, tad
all directions. If it is possible to r e p r o d u c e the
preload with high accuracy, repeatability only de- Subscripts
pends u p o n the stability of t e m p e r a t u r e and ex- a Axial
pansion of the design. The static stiffness of the e Equivalent
coupling is highly predictable, with the equations f Friction
given in this article, for the conventional coupling F o f the force
as well as for the coupling with self-adjusting sur- max Maximum
faces. If the preload is as large as possible, which n Normal
d e p e n d s u p o n the admissible load of the material, P Pre-
r Radial
the stiffness o f both kinematic couplings are suffi- t Tangential
cient for most purposes, total Total
x in direction o f x
Acknowledgments y in direction of y
The e x p e r i m e n t s were carried out in the m e c h a n - z in direction of z
ical d e p a r t m e n t of the Philips Research Laborato- 0 Rotation a r o u n d z
ries Eindhoven. We thank all contributors, espe- ~P Rotation a r o u n d x
cially F. Jaartsveld a n d J. J. Baalbergen, for their Rotation a r o u n d y
advice, help, and skill, which were essential to this References
project. 1 Design Principles. Eindhoven, The Netherlands: Eindhoven
University of Technology (no. 4007), 1996
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