Metrology and Standards for Coordinated 5-Axis Motion

This project will develop mathematical models, measurement methods and tools to characterize the performance of complex precisely coordinated 5-axis motion that enables the production of complex shapes such as turbine blades.  The mathematical models and simulation tools based on motion control theory and kinematic relationships of the coordinated axes of motion will be used to predict limiting behavior and to identify the performance parameters to be tested.  The new measurement methods, test patterns, and analysis tools will be used to verify the model predictions.  These methods will lead to new standards for testing complex 4- and 5-axes machines used in the production of high-value complex products.

The high-value, complex (free-form) products of the future require manufacturing processes and equipment capable of generating accurate complex motion, including coordinated multi-axis linear and rotational motion. Existing measurement methods and standards focus on evaluating the single-axis motion needed for the manufacture of simple, prismatic products. Although methods are available to examine errors associated with coordinated motion of two simply-moving components, precise measurement methods for the complex motion of manufacturing equipment with five or more degrees of freedom, necessary to fabricate the complex, free-form products of the future, are currently non-existent. The measurement problem is compounded for the manufacture of meso/micro-scale products since traditional metrology instruments are typically too large and cannot fit within the workspaces of the manufacturing systems needed at this scale. New measurement methods, systems, standards, and performance metrics are urgently needed by U.S. manufacturers to understand and apply the capabilities of the next-generation, multi-axis reconfigurable manufacturing equipment for innovative new products.