Mansoura University

Faculty of Engineering
Production Engineering & Mechanical Design
Department

Course Name: Production Laboratory

Instructor Name: Dr. Mohamed El-Keran

Subject: Double Ball Bar

Student name: Ahmed Sameh Kandil

 Contents: -

Introduction
Construction Of DBB
Theory
How its work
Reference

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 Introduction
Double ball bar (DBB) system or so-called rapid test device to measure the
contouring errors of machine tools which have a circular interpolation. DBB has
long been used as for measuring the contouring errors, error characterization and
machine tool performance interpretation in the volumetric workspace of machine
tool. Bryan firstly developed the double ball bar method to inspect linear CNC
machines contouring behavior. During the DBB tests the two tested linear axes are
driven simultaneously, causing the measuring ball to move on a circular path
relative to the Centre ball. The change of distance between the two balls results
from motion or dynamic errors of the two driven linear axis and is measured by a
displacement sensor in the ball bar. Bryan proposed a ball bar system composed of
precision balls and linear variable differential transformer (LVDT). Two versions
of the DBB were developed at the Lawrence Livermore National Laboratory. In
first version, the fixed magnetic ball bar is used to test the accuracy of coordinate
measuring machine (CMM) whereas in the second version a telescoping ball bar is
used to test the accuracy of numerically controlled machine tools.

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 Construction Of DBB
DBB is composed of two highly precision balls whose diameter and sphericity is
within a controlled tolerance limits joined with a highly sensitive and precise
displacement sensor or a transducer. This transducer measuring range is fixed but
DBB lengths can be varied by assembling the detachable extension rods of various
lengths as per requirement. The measuring principle of sensor or transducer
depends as per its construction whether it is optical, laser, LVDT or linear encoder
etc. but the metrological characteristics and working principle is almost same.

A DBB system consists of various components in which transducer or sensor is the

front end of the system. It directly interfaces with the machine tool or environment
to be measured and transform the physical displacement into form that further used
and processed thorough the devices like signal conditioners, data acquisition
systems, display devices and data analyzers etc. As the DBB system is composite
form and assembly of all elemental components so calibration of DBB system is
more beneficial than its elemental calibration because it gives the realistic error
picture of the DBB measuring system. A detailed DBB system is mentioned in the
shown figure.

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 Theory
The machine does a circular interpolation around a fixed point, which is usually on
the machine table, and the telescoping ball bar measures any deviation between
that fixed point and the spindle.

The heart of the ball bar is a highly accurate (1-µm) optical linear scale with very
high resolution (0.1 µ). As the ball bar’s length changes due to slight machine
inaccuracies, the optical scale measures what are hoped to be tiny linear
displacement changes. This streaming linear displacement data is transmitted back
to a computer, which is running the ball bar software.

After the test is complete, the software compiles this data and then calculates 22
machine criteria. For instance, we can look at backlash, squareness, and machine
positional capability.

A typical ball bar test may sweep a 150-mm radius, but tests in the range of 50
mm to more than 600 mm are possible, although rare.

Different lengths may be used to increase sensitivity to particular errors. For

example, a longer length may be used to increase sensitivity to geometry errors
such as imperfect squareness, whereas a very small radius may be used to highlight
dynamic errors such as servo mismatch.

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 How its work
The ball bar establishes the machine performance characteristics within the
machine’s operational area being tested. For a small or medium-sized machine, we
usually can obtain sufficient information by swinging a 150-mm- or even a 300-
mm-long ball bar, if axis travel allows. Once we get into much larger machines, a
number of 300-mm long ball bar tests must be made strategically placed within the
machine’s operational area. The software has been designed to enable multiple
tests to be performed in different positions on the same machine.

Probably time. Continually having to move and relocate the ball bar to cover the
whole machine is quite time-consuming and, frankly, probably unnecessary as a
great deal of machine performance data can be established from just a couple of
tests at different points on the machine.

Ball bar tests typically take only 10 to 15 minutes and can be performed in just the
XY plane; if more detailed machine information is required, we can undertake a
dome test in XZ and YZ arcs. Using the software, we can then stitch together these
three tests (XY, ZY, and ZX) and establish a theoretical volumetric machine
capability.

After the ball bar is installed, the machine is programmed to drive its spindle in a
circular (interpolated) path that has a radius equal to the length of the ball bar. The
ball bar tracks spindle movement to 0.0001 mm and then prioritizes machine errors
based on the measured (the interpolated variation) values. It converts the ball bar
data into an error-exaggerating polar plot of the machine’s true movement.

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 An experienced user can identify every error in the machine from this plot;
however, for the less experienced operator, sophisticated algorithms in the ball bar
software produce a comprehensive diagnostic report that enumerates 22 different
dynamic and geometric error values and then ranks them in order of percentage of
total error.

It’s immediately clear if the machine has, for instance, any squareness problems.
The overall positioning capability (true position) of the machine also is calculated.
Reports also may be produced in accordance with ISO, ASME, or JIS standards.

Actually, the plot itself can’t, but the software has a rather neat feature that enables
all machine data to be viewed graphically, against time. We call this our “machine
history” function. This means that any trends can be established and extrapolated if
required.

Using this technique, it is possible to plan machine maintenance downtime and

also ensure any spare parts are ordered well ahead of time. Let’s say that a shop
notices a backlash trend in a machine. This is a linear trend, and hence it’s possible
to establish an approximate point in the future when the machine will not be
capable of making parts.

The ball bar can see almost every motion-affecting

error that exists in the axes. These errors include
backlash, reversal spikes, lateral play, cyclic error,
servo mismatch, scaling errors, and geometry errors
such as imperfect squareness and straightness. It
will even measure the actual machine feedrate.

Early error detection with the ball bar permits optimum efficiency in scheduling
maintenance and repairs. Ball bar testing is included in a number of standards for
machine tool accuracy testing, including ASME B5.54 and ISO 230.

In addition to isolating errors, the ball bar also allows process optimization. For
example, users can determine what feedrate delivers the best accuracy for a
specific cutting procedure -- such as contouring -- through dynamic checking of
the machine tool as it is driven at different federate.

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 Reference

https://www.researchgate.net/publication/253284425_Calibration_of_double
_ball_bar_DBB_system