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1. INRODUCTION
There are three terms often used in precision practices and they are often
used incorrectly or in a vague manner. The terms are accuracy, repeatability, and resolution. Because
the present discussion is on machining and fabrication methods, the definitions will be in terms
related to machine tools. However, these terms have applicability to metrology, instrumentation, and
experimental procedures, as well.
1.1 Accuracy
In the area of measurements, the quantity to be measured is never known therefore instrument
accuracy is extremely important. Here, accuracy is the ability of the instrument to provide a
quantitative value for the unknown parameter. This has implications beyond that of accuracy in a
machine tool where the "unknown" is the true position of a cutting tool, for example, which was
computed and where the phenomena (the machine tool performance) should be known and
understood with some level of confidence. In instrumentation, the resolution of the output (how many
decimal places are shown) is often mistakenly taken as the instrument accuracy. The accuracy of the
instrument is best quantified by comparison with fundamental standards and careful calibration.
1.2 Repeatability
It is the ability of the machine to re-visit a location and has other implications including from
which direction is the movement made. If the point is repeatedly approached from the same direction,
the term used is repeatability. If the point is approached from two directions, such as the work table
on an ordinary milling machine, then the term is bi-directional repeatability. Good bi-directional
repeatability is more difficult to achieve than repeatability because it involves hysteresis of
mechanical motions, among other possible factors such as feedback dead band.
1.3 Resolution
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The results of a measurement or calculations can be accurate but not precise, precise but not
accurate, neither, or both; if a result is both accurate and precise, it is called valid.
Material removal by either hard cutting tools or energy beams takes place at the
interface of the material and the machining tool. With hard cutting tools such as drills, milling
cutters, etc., the interface is more easily identifiable. With energy beams, the interface is often more
difficult to identify because energy beams will have some non-uniform energy distribution with
respect to spatial dimensions.
The structure of the machine tool which aids in maintaining the contact
point is termed the structural loop. Unknown or uncontrollable changes in the structural loop are the
primary source of kinematic errors in machining.
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The structural loop of the machine includes the cutting tool edge(s), the tool
holder, the slides and stages used to move the tool and/or the work piece, the spindle holding the
work piece or the tool, the chuck, and fixtures, and internal vibration, eccentricities, and other
dynamic effects. Influences outside of the structural loop, which still influence the loop and cause
errors, include floor vibration, temperature changes, and cutting fluids, for example.
The attitude wherein all errors are identifiable and can be quantified is termed
determinism. One may not have the time and/or resources to identify and quantify all errors, but the
attitude of determinism will lead the precision engineer to the solution of many of the sources of
error, rather quickly in many cases. This is not to say that statistical analysis is not good, but the
reliance on or substitution of statistics for determining the cause of errors will not eliminate or reduce
the influence of those errors.
There are many sources of errors in machining. An error will be defined as any
influence which detracts from machining the perfect part. A perfect part is an abstraction and has the
attributes of exacting dimensions (to as many decimal places as can be imagined), an atomically
smooth surface, a geometric shape which is mathematically accurate, and a material which behaves
as desired under all possible applications. There is, of course, no such thing as the perfect part.
Instead, we are satisfied with acceptable parts where tolerances are within some acceptable range,
roughness which does not exceed some allowable limit set by the application, a shape which satisfies
the application, and a material with properties which are at least predictable within some range of
uncertainty. Machining errors help contribute to all of these non-ideal attributes of a part.
The demand for smaller parts also places more demands on the deviations
from the perfect part, especially in terms of tolerances. One definition of precision is that the
tolerance on a characteristic dimension does not exceed one part in ten-thousand of that
characteristic dimension. As parts become smaller, and the need for precision in terms of absolute
numbers becomes more demanding, thermal errors become dominant. However, errors due to
temperature variations manifest themselves in a variety of ways. As kinematic and material errors are
introduced, keep in mind how thermal growth can also influence these error sources.
Most machining operations can be divided into those that remove metal from an
item, and those that form metal in an item..
Metal can be formed into a desired shape much more easily than materials such
as wood or stone, especially when the metal is heated. A machinist may use a forging machine to
hammer or mold a hot metal workpiece into a desired shape. Dies or molds may be used if the metal
is soft enough, or under high pressures. A press is used to flatten a piece of metal into a desired
shape.
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The inferior finish found on the machined surface of a workpiece may be caused
by insufficent clamping, cutting conditions or perhaps an incorrectly adjusted machine. It is evident
by an undulating or irregular finish, and the appearance of waves on the surface.
3. FEEDBACK VARIABLES
To know the position, and therefore the velocity and acceleration, of the
machine tool it is necessary for the machine to be under closed-loop control. This requires
feedback information. The basic tenet of precision machining and precision engineering is if the
position of a specific point is required to be known, then measure the location of that point! This
may seem overly simple, but is most often overlooked or is not possible. Referring back to the
previous statement regarding the location of the machining interface, the point of contact between
the tool and the workpiece is where the feedback device should be located. Needless to say, that
is normally not possible. At the other end of the spectrum, a feedback device may often be placed
on the actuation mechanism causing the desired, or at least commanded, motion. An example of
this is an encoder attached to a drive motor which provides information on a change in angular
position of the motor. Simply put, this feedback strategy will only provide information about the
angular change in the lead-screw drive mechanism and not about the lead-screw or the linear
position of the stage. The motor could be slipping on the lead-screw or the lead-screw may have
non-linearities. In either case, false information could be returned.
Although the deflection of the machine tool structure is not a feedback signal, it can
influence the accuracy of feedback devices. This is especially important for loads on vertically moving
stages, such as the spindle in a z-active milling machine. If the spindle weight is not somehow
counterbalanced, the lead-screw will stretch due to elastic strain. Because the deflection of an axially
loaded member is proportional to the length of the member, when the stage is near the top of the
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travel the deflection is nearly zero and the true position of the spindle will coincide with the indicated
position as measured by an uncoupled feedback device (angular encoder). As the spindle moves
toward the bottom of its travel, the member length is relatively large and the axial deflection of the
lead-screw and the spindle will be relatively large. The true position of the spindle will be lower than
the indicated position as given by the rotary encoder. There are other instances where static
deflections can cause feedback errors and these are specific to more particular instances.
Again, the wear of the cutting tool is normally not a directly measured variable
but can result in an inaccurate machining condition akin to a feedback error. Because the tool edge is
not where it is thought to be due to wear, and its location can not be readily measured in use, this
results in the same type error as not measuring the location of interest. If the tool edge is assumed to
have a constant spatial coordinate or a constant length from some other known point on the tool
holder, typically the tool slide at the base of the tool holder sensed by a linear encoder, then any
change in that information will result in an error. As the tool edge wears, it is shortened and will
result in a larger than commanded workpiece dimension. If the operation is turning, the shaft will be
larger in diameter.
Each of these variables was defined previously and are summarized as a group.
Machined parts are made by commanding the machine tool to move the tool and/or workpiece to
locations within a three-dimensional volume, called the work volume or work envelope. The locations
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to move to are computed by CAD/CAM software or by the machine controller based on user
commands. This implies that each move of the tool or workpiece is to a location the machine has not
previously visited (memorized or been taught) and a certain set of feedback (encoder) parameters is
unknown. The ability of the machine tool to locate the desired point(s) for the machining operation
will affect the accuracy.
Accuracy will be affected by resolution, for example. All moves are integer multiples of the
minimum, or worst, machine resolution. A linear motor with high resolution, fed by low resolution
encoder feedback, can have high resolution moves but low resolution of known position, and therefore
low accuracy. The machine can not interpolate between the least counts of the resolution, and
therefore will stop as soon as the commanded position is met. This can cause repeatability errors
depending from which direction the commanded point is approached.
The previous statements are not meant to imply that feedback sensors can not be interpolated. For
example, a laser interferometer may use interference fringes where the dark-to-dark fringe pattern
can be interpolated in a "gray-scale" manner. Most oftern, a heterodyne interferometer is used where
the Doppler shift in a two-beam beat frequency is integrated over time to determine changes in
position. Incremental encoders utilizing quadrature techniques are capable of interpolating between
encoder slits to improve resolution and even detect rotation direction. The point is, the least count of
resolution will affect both accuracy and repeatability, but high resolution is subsequently easy to
accomplish so the actual affect on accuracy and repeatability is generally small. Overall machine tool
accuracy and repeatability is also closely coupled with many of the other error sources described
4.2. Stiffness
Machine tool stiffness tends to have several other influences. Stiff structures
tend to transmit vibration at higher frequencies than compliant (un-stiff) structures. Machining causes
vibration, period. Stiff machines, with low internal or external damping, will transmit this vibration
throughout the structure. This vibration will cause time-varying deflections of the structure which, if
the vibrations are near a fundamental frequency of the machine, can be amplified in the machined
part. Therefore, a very stiff machine tool is not necessarily an ideal solution to deformations. One
could argue the best way to compensate for a deflection, especially a time-varying deflection which
may be difficult to predict, is to continually sense the deflection and compensate for it with the
machine motions. This may require high frequency measurements and motions which are impossible
to attain, however it demonstrates the attitude of determinism where it may be possible to sense at
high frequency, filter to low frequency, and perform the required compensation.
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impacts the performance of the machine. The damping characteristic of steel is different from cast
iron and from granite, for example. Additional damping can be realized in granite, for example, by
casting the shapes from a mix of granite particles and elastomers in a matrix material. Different
materials may also have non-linear damping characteristics whereby one material may dampen the
vibration very well during the first few milliseconds but then "ring" for a relatively long time. Other
materials may lower the vibration more gradually at first but at a more constant rate so the vibration
dies out faster than the material that rings. One needs to investigate these phenomena if machine
stiffness is to be fully quantified
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conditions) can be identified. All other effects are undesirable and by knowing their frequency
content, one can quickly identify the physical parameter contributing to that error.
Different materials will behave differently when machined and this can
influence surface finish, precision, etc. About the only way to quantify these factors is through
experimentation. Materials which machine at either the large or small scales with one tool material
may well machine differently with another tool material. One such material is 6061-T6 aluminum.
Using a steel or carbide tool, this material generally adheres to the tool leaving a built-up edge and
relatively poor surface finish. This is also generally true with polycrystalline diamond which is a
composite material made of a metallic binder with diamond particles imbedded into it. Single crystal
diamond however, will give relatively good surface finish although over time aluminum can be seen
adhering to the rake face of the tool. This may take a low power microscope to observe this.
Generally, the built-up aluminum can be removed by a weak hydroxide solution.
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Different materials will also wear the tool at different rates. Focusing on
single crystal diamond, ferrous (and a few other) materials will rapidly wear the diamond because
these materials have a high affinity for carbon. As machining takes place, the temperature at the
cutting interface will increase and the rate of diffusion of the diamond into the work material will
greatly increase. Examples of the wear of diamond on chromium and copper have been quantified.
5.3. Coolants
6. ENVIRONMENTAL EFFECTS
6.1. Vibration
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Many precision and micromachining tools use air spindles for part or
tool rotation. Air spindles have internal orifices through which compressed air is passed to develop the
load carrying capability of the spindle. The air has been compressed and then dried, normally by
refrigeration-type dryers which cool the air to condense out water. The cooled and compreesed air is
then expanded in the bearing and further Joule-Thomson cooling takes place. If the spindle is allowed
to sit motionless for prolonged periods with cold air impinging on the same location(s), differential
contraction among locations in the spindle will take place causing the spindle to warp. This warpage
can cause out-of-round motion due to a bending of the spindle and a localized reduction in the size of
the spindle which will alter the interior clearances and the stiffness. This effect can be reduced by
shutting off the air supply if the spindle will be idle for extended periods of time or by slowly rotating
the spindle with the air on, if the idle time is not excessive. This will help reduce temperature
gradients in the spindle reducing warping.
7. THERMAL ERRORS
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Assumption:-
(a) There was no time varying change in the temperature of the machine
system, and no thermal gradients within the machine system, there could still be a fixed temperature
difference between the machine and the desired temperature, 20 C for instance. This fixed error could
be compensated by analyzing its effect on the dimensions of the work piece. A problem would arise,
however, because the machine, the cutting tool, and the work piece are probably of different
materials with different thermal expansion coefficients. This can cause warping of machine elements
and the work piece if it is rigidly attached to the machine.
(b) No time varying temperature changes, the machine system could have
thermal gradients due to temperature differences within the machine structure due to a nearby
steady state thermal influence, for example. The gradients could cause further distortion (warping) of
machine elements and the work piece which are very difficult to correct, in real time. If the
thermal/physical scharacteristics of the machine system can be modeled a priori as a system of
distributed lump masses, then monitoring the temperature at a few key points could provide sufficient
input to the model to calculate distortions in real time for error correction.
The more complex situation arises when there is a time varying thermal
disturbance subjecting the machine system to a periodic or random thermal forcing function. To
reduce vibration, deformation due to static and dynamic forces, etc, machines are typically massive.
This results in a long thermal time constant and a slow response to the thermal input. This can be
good in that the machine will not respond to rapid thermal influences. It can also be bad in that any
thermal corrective measures, or even knowledge of the effect of the thermal disturbance on the
machine system, is slow to be realized..
Clearly, machining systems are much more massive than the block and
have a much longer time constant, which could approach many hours to perhaps a few days. This is
even more important if the system is made of a low expansion material such as granite which has a
lower heat transfer coefficient than steel. This would add to the time required to bring the entire
structure into thermal equilibrium assuming a constant surrounding temperature. The larger the film
coefficient and the greater the machine material thermal conductivity, the faster the machine will
respond to thermal disturbances. Some typical film coefficients are given below.
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changes. If the machine is in an environment which has temperature control of some kind, either
heating or cooling, the temperature fluctuations will normally be about some mean value which is
relatively constant. Such a time varying forcing function, into a first order thermal system will result
in a logarithmic response with time lag. This can be easily approximated as a periodic step input (not
entirely accurate but easier to visualize for this example). If the input frequency is high, the steady
state amplitude of the temperature variation will be small and at high frequency, resulting in small
dimensional changes. If the temperature variation frequency is low, the thermal mass of the machine
system can follow the input better and larger, lower frequency dimensional changes will result.
Because the dimensional changes are required to remain small, the higher the temperature
fluctuation frequency the smaller will be the thermally-induced error
8.CONCLUSION
Precision engineering deals with many source of error and its solution. Precision is the most important
think in the manufacturing field. Machining is the important part of manufacturing process. Many factor
like feed back variables, machine tool variables, spindle variabls,wokpice vaiabls,envronmantal effect
thermal errors etc.. affect the accuracy of machine. Main goal of precision engineering is to reduce the
uncertainty of dimensions. Achieve the exact dimension is vary difficult . So tolerance is allowed on
work piece.
REFERENCE
1.PRECISION ENGINEERING AND PRACTICES BY R.L.MURTY
2.A TEXT OF METROLOGY BY MAHAJAN
3.SEMINAR TOPIC FROM :: www.edufive.com/seminartopics.html
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