Five-point cylindricity error separation technique.

• Three probes target a measured section and two probes target two fixed sections. • Eccentricity of each sectional profile is detected by an error separation model. • The detected eccentricity vector is based on a fixed spatial straight line. • Robust immunity to interferences is obtained by the non-cumulative calculation. • A cylindrical profile is measured and reconstructed with accuracy and precision. This study focuses on developing a new error separation technique for the in situ measurement and reconstruction of cylindrical profile. Based on a five-point system proposed, the center vectors of the least squares circle in the cross-sectional profile of the cylinder can are accurately extracted by the error separation model. The vectors are based on a spatial straight line that connects two least squares centers of the fixed cross-sectional profiles, which makes the double integration calculations avoided and the ability to resist interference improved. A cylindrical profile conforming to the mathematical definition can be reconstructed for cylindricity error evaluation. Theories, numerical validations and experiments verified that the spindle's radial and tilt error motions as well as the probe carriage's straightness deviations are all removed. This innovative technique solved a crucial problem regarding the accurate and high-precision reconstruction of a cylindrical profile in the in situ measurement. [ABSTRACT FROM AUTHOR]