Geometric Accuracy Design of High Performance CNC Machine Tools: Modeling, Analysis, and Optimization

Abstract The CNC machine tool is the fundamental equipment of the manufacturing industry, particularly in sectors where achieving high levels of accuracy is crucial. Geometric accuracy design is an important step in machine tool design and plays an essential role in determining the machining accuracy of the workpiece. Researchers have extensively studied methods to model, extract, optimize, and measure the geometric errors that affect the geometric accuracy of machine tools. This paper provides a comprehensive review of the state-of-the-art approaches and an overview of the latest research progress associated with geometric accuracy design in CNC machine tools. This paper explores the interrelated aspects of CNC machine tool accuracy design: modeling, analysis and optimization. Accuracy analysis, which includes geometric error modeling and sensitivity analysis, determines a machine tool's output accuracy through its volumetric error model, given the known accuracy of its individual components. Conversely, accuracy allocation designs the accuracy of the machine tool components according to given output accuracy requirements to achieve optimization between the objectives of manufacturing cost, quality, reliability, and environmental impact. In addition to discussing design factors and evaluation methods, this paper outlines methods for verifying the accuracy of design results, aiming to provide a practical basis for ensuring that the designed accuracy is achieved. Finally, the challenges and future research directions in geometric accuracy design are highlighted.