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Pose Reliability-Oriented Accuracy Synthesis: A Framework With Validation on a Five-Axis Hybrid Kinematic Machining Unit.

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Title: Pose Reliability-Oriented Accuracy Synthesis: A Framework With Validation on a Five-Axis Hybrid Kinematic Machining Unit.
Authors: Tang, Tengfei1,2 tengfei@zstu.edu.cn, Wu, Zaiqing1 wzzzq0306@163.com, Shen, Yifeng1 yifengshen2000@163.com, Ye, Wei1 wye@zstu.edu.cn, Zhang, Jun3 zhang_jun@fzu.edu.cn
Source: Journal of Mechanical Design. Mar2026, Vol. 148 Issue 3, p1-14. 14p.
Subjects: Tolerance analysis (Engineering), Parallel kinematic machines, Machining, Manufacturing industries, Optimization algorithms, Fault tolerance (Engineering)
Abstract: This article presents a reliability-oriented accuracy synthesis framework for five-axis hybrid kinematic machining units (HKMUs) that harmonize geometric accuracy, computational efficiency, and manufacturing economy. Current tolerance design methods struggle with the geometric error propagation inherent in parallel-serial HKMUs, which may lead to unreliable pose accuracy. To address this, a trilayer architecture is proposed: (1) a foundational geometric error model employing equivalent joint decomposition and screw theory establishes matrix-form error mappings; (2) a computational layer introduces a dual-criteria pose reliability algorithm (position sphere/orientation cone) accelerated via fourth-moment-maximum-entropy integration, reducing computational load versus Monte Carlo methods; (3) an optimization layer formulates tolerance allocation as a reliability-constrained nonlinear program, solved by a Proportional-Integral-Differential (PID) search algorithm (PSA) to avoid local minima. Validated on a 2PRU&1PRS-2P HKMU ("R", "U", "S", and "P" represent revolute joint, universal joint, spherical joint and actuated prismatic joint, respectively), the framework quantifies the mapping relationships between 9 geometric tolerances and 16 uncompensatable key source errors through the Small Displacement Torsor (SDT) method. Under allowable errors of 0.10 mm (position) and 0.02 deg (orientation), PSA achieves 90% pose reliability--a 203.7% improvement over baseline--while increasing manufacturing costs by only 11.8%. The framework provides a systematic roadmap for designing economically viable, high-reliability HKMUs essential for precision manufacturing. [ABSTRACT FROM AUTHOR]
Copyright of Journal of Mechanical Design is the property of American Society of Mechanical Engineers and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
An: 192337314
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Label: Title
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  Data: Pose Reliability-Oriented Accuracy Synthesis: A Framework With Validation on a Five-Axis Hybrid Kinematic Machining Unit.
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  Data: <searchLink fieldCode="AR" term="%22Tang%2C+Tengfei%22">Tang, Tengfei</searchLink><relatesTo>1,2</relatesTo><i> tengfei@zstu.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Wu%2C+Zaiqing%22">Wu, Zaiqing</searchLink><relatesTo>1</relatesTo><i> wzzzq0306@163.com</i><br /><searchLink fieldCode="AR" term="%22Shen%2C+Yifeng%22">Shen, Yifeng</searchLink><relatesTo>1</relatesTo><i> yifengshen2000@163.com</i><br /><searchLink fieldCode="AR" term="%22Ye%2C+Wei%22">Ye, Wei</searchLink><relatesTo>1</relatesTo><i> wye@zstu.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Zhang%2C+Jun%22">Zhang, Jun</searchLink><relatesTo>3</relatesTo><i> zhang_jun@fzu.edu.cn</i>
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+Mechanical+Design%22">Journal of Mechanical Design</searchLink>. Mar2026, Vol. 148 Issue 3, p1-14. 14p.
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  Data: <searchLink fieldCode="DE" term="%22Tolerance+analysis+%28Engineering%29%22">Tolerance analysis (Engineering)</searchLink><br /><searchLink fieldCode="DE" term="%22Parallel+kinematic+machines%22">Parallel kinematic machines</searchLink><br /><searchLink fieldCode="DE" term="%22Machining%22">Machining</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+industries%22">Manufacturing industries</searchLink><br /><searchLink fieldCode="DE" term="%22Optimization+algorithms%22">Optimization algorithms</searchLink><br /><searchLink fieldCode="DE" term="%22Fault+tolerance+%28Engineering%29%22">Fault tolerance (Engineering)</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: This article presents a reliability-oriented accuracy synthesis framework for five-axis hybrid kinematic machining units (HKMUs) that harmonize geometric accuracy, computational efficiency, and manufacturing economy. Current tolerance design methods struggle with the geometric error propagation inherent in parallel-serial HKMUs, which may lead to unreliable pose accuracy. To address this, a trilayer architecture is proposed: (1) a foundational geometric error model employing equivalent joint decomposition and screw theory establishes matrix-form error mappings; (2) a computational layer introduces a dual-criteria pose reliability algorithm (position sphere/orientation cone) accelerated via fourth-moment-maximum-entropy integration, reducing computational load versus Monte Carlo methods; (3) an optimization layer formulates tolerance allocation as a reliability-constrained nonlinear program, solved by a Proportional-Integral-Differential (PID) search algorithm (PSA) to avoid local minima. Validated on a 2PRU&1PRS-2P HKMU ("R", "U", "S", and "P" represent revolute joint, universal joint, spherical joint and actuated prismatic joint, respectively), the framework quantifies the mapping relationships between 9 geometric tolerances and 16 uncompensatable key source errors through the Small Displacement Torsor (SDT) method. Under allowable errors of 0.10 mm (position) and 0.02 deg (orientation), PSA achieves 90% pose reliability--a 203.7% improvement over baseline--while increasing manufacturing costs by only 11.8%. The framework provides a systematic roadmap for designing economically viable, high-reliability HKMUs essential for precision manufacturing. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Journal of Mechanical Design is the property of American Society of Mechanical Engineers and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1115/1.4069403
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      – Code: eng
        Text: English
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        PageCount: 14
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      – SubjectFull: Tolerance analysis (Engineering)
        Type: general
      – SubjectFull: Parallel kinematic machines
        Type: general
      – SubjectFull: Machining
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      – SubjectFull: Manufacturing industries
        Type: general
      – SubjectFull: Optimization algorithms
        Type: general
      – SubjectFull: Fault tolerance (Engineering)
        Type: general
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      – TitleFull: Pose Reliability-Oriented Accuracy Synthesis: A Framework With Validation on a Five-Axis Hybrid Kinematic Machining Unit.
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            NameFull: Tang, Tengfei
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            NameFull: Wu, Zaiqing
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            NameFull: Shen, Yifeng
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            NameFull: Ye, Wei
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            – D: 01
              M: 03
              Text: Mar2026
              Type: published
              Y: 2026
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              Value: 148
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