Extraction of workpiece rotary symmetrical error and its deterministic removal by fluid jet polishing

Rotary symmetric error (RSE) is a typical type of surface machining errors for precision components, related to the relative tool-workpiece movements adopted. A quick removal method of the workpiece surface RSE using a fluid jet polishing (FJP) process, in which the tool nozzle and workpiece move relatively as in an end-face turning process, is presented. Efficient improvement in the workpiece surface form accuracy was achieved using a relatively simple device. Two methods to extract the RSE from the measured surface error curves, i.e., the average and minimum methods, are introduced and compared. The influence of the local jet rotation radius on the removal function of FJP was investigated experimentally. The algorithm for solving the dwell time curve in two-dimensional FJP process was derived. Deterministic FJP experiments were conducted to remove the RSE by means of the end-face turning movement. Experimental results show that the proportion of the RSE to the overall surface error on most workpieces was reduced from >60% to <20%, whereas the volume of the nonrotary symmetric error (non-RSE) fluctuates slightly before and after the FJP process. Using the average RSE extraction method and combining it with the zero-phase filtering method to filter the dwell time can effectively reduce the frequency of residual circular error in the polishing surface and avoid increasing of power spectral density in the mid-high frequency after polishing.