Journal of Studies on Manufacturing (Vol.1-2010/Iss.

1)
Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

Regression Method for Identifying Spindle

Radial Errors of a Miniaturized Machine Tool

S. Denis Ashok, G. L. Samuel*

Department of Mechanical Engineering,

Indian Institute of Technology Madras, Chennai, India
Tel: +91-44-22574699
*e-mail: samuelgl@iitm.ac.in

Submitted: 10/01/2010
Accepted: 03/02/2010
Appeared: 16/02/2010
HyperSciences.Publisher

Abstract— Miniaturized machine tools have become a promising technique for mechanical micro machining of
micro / meso scale features. High speed spindle is one of the important elements of a miniaturized machine tool for
providing high rotational speed to micro cutting tools. Geometric error sources in the miniaturized machine tool
causes synchronous and asynchronous error motions during spindle rotation which inturn significantly affects the
machining accuracy of components. In this work, radial error of a high speed spindle is measured using a capacitance
sensor and master cylinder for various spindle speeds. This paper presents a regression method for accurate
identification of synchronous and asynchronous components of spindle error data. A sum of sinusoidal function is
used for approximating synchronous components of spindle error data. Asynchronous components are considered as
residuals of the regression model and it is assumed to follow Gaussian probability distribution with zero mean and
constant variance. An iterative least square method is formulated for estimating the parameters of the regression
model. Proposed regression method accurately identifies synchronous and asynchronous components of spindle
error data and they are compared with Fourier transform filtering method. Experimental results indicate a good
correlation between the proposed regression model and the spindle error data. The lower and upper bound values are
determined for predicting the spindle error data at the given discrete time. Performance of proposed method is
evaluated for different number of harmonics and spindle revolutions and the results are presented in this paper.

Keywords: Miniaturized Machine Tool, Spindle Error, Modeling, Analysis, Regression Method
1. INTRODUCTION
NOMENCLATURE

Symbol Meaning Miniaturized machine tools require high speed spindles with
A h, B h Amplitudes of cosine and sine functions precise rotation for realizing submicron level accuracy of
C Mean value of the spindle error data components. High speed spindle is supported by ceramic ball
Dj Basis matrix of the model bearings in the miniaturized machine tool. Error sources such
Ej Sum of squares of residual error as out of roundness of bearing surface, defects in the balls,
fj Discrete frequency values etc causes synchronous and asynchronous error motions
fr Spindle rotational frequency during spindle rotation. Spindle error motions affect the
fs Sampling frequency accurate positioning of the micro tool and it leads to
fmin,fmax Limits for discrete frequency values inaccuracies in feature location, form and surface finish.
f0 Fundamental frequency of spindle data Consequently, measurement and analysis of spindle error
h Harmonic number motion is useful in characterizing the machining performance
H Harmonic cutoff value of the miniaturized machine tool.
mi' Samples of spindle error data
m'si Synchronous components of spindle data Measurement methods and procedures were outlined for
m'pi Prediction bound for spindle error data testing the spindle accuracy of machine tools using spherical
ti Sampling time master, displacement pickups and oscilloscope (Bryan et al,
Xj Set of linear parameters of the model 1967). Digital measuring method was presented for
єi Residual values of spindle error data analysing axis of rotation errors of machine tools. (Vanherck
σ Standard deviation of residual values and Peters, 1973). Terminologies and methods related to
∆f Interval for discrete frequency values spindle error measurements were unified for describing the
truth of axes of rotation in machine tools (Bryan and
Vanherck, 1975). A new measurement principle was reported
for measuring rotational accuracy of rotating tool type
spindle using a stationary master ball (Kakino et al, 1977).

Copyright © 2010 HyperSciences_Publisher. All rights reserved 26 www.hypersciences.org

 Journal of Studies on Manufacturing (Vol.1-2010/Iss.1)
Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

Micro computer based data processor was developed for the holder. Fig. 1 shows the experimental arrangement for
improved evaluation of spindle error motion (Sun and Bryan, spindle radial error measurement.
1985). ANSI/ASME B89.3.4M (2004) laid the modern
foundation for understanding, specifying and testing axes of
rotation errors of machine tool. Multiple capacitive sensors
with larger sensing area were designed for simultaneous
measurement of radial, angular, axial error motions of spindle
(Chapman, 1985). It is difficult to install more number of
inspection devices in the miniaturized machine tool due to
space limitations. Also, the inspection devices used for
testing the miniaturized machine tool spindles require high
bandwidth and resolution for enabling the spindle error
measurement at high speed.

A measurement system consisting of a laser diode and a

quadrant sensor was developed for measuring spindle error
and spindle speed (Jywe and Chen, 2005). Autocollimator
based optical measurement system was proposed for
measuring radial rotational accuracy of an ultra speed spindle Fig.1 Experimental arrangement for radial error measurement
(Kengo Fujimaki and Kimiyuki Mitsui, 2007). However, the Specifications of the capacitive sensor used for spindle radial
laser, optical measurement systems requires more setup time error measurement is shown in Table. 1.
for the optics in the miniaturized machine tool and the
alignment requires more time. An attempt has been made to Table. 1 Specifications of capacitive displacement sensor
measure the radial error motion of a high speed using S. No Details Specified values
capacitive sensors in a miniaturized machine tool (Lee et al, 1 Range 250µm
2005). 2 Standoff 250µm
3 Output voltage 10 to -10 VDC
Spindle error data contains synchronous and asynchronous 4 Output sensitivity 0.08 V/µm
components that characterize the repeatable and non 5 Linearity error 0.05%
repeatable behaviour of the spindle. Averaging method and 6 Peak to peak resolution 47.5nm
Fourier transform method are used for separating
synchronous and asynchronous components of spindle error A computer aided data acquisition system is used for
data (Robert Gredja et al, 2005). These methods are not sampling the measurement data at discrete time interval. To
suitable for analysing the spindle error data acquired at avoid aliasing effects, sampling frequency (fs) is fixed based
discrete time intervals due to variations in speed during on the rotational frequency of the spindle (fr) and the desired
measurement (Marsh, 2008). harmonic cut-off value (H).
fs = 2Hfr (1)
This paper proposes a regression method for accurate
identification of synchronous and asynchronous components In the present work, discrete time samples of spindle error
of spindle error data obtained in time domain. A sum of data are acquired for a harmonic cut-off value (H) of 32
sinusoidal functions is used for approximating synchronous cycles per revolution. Measured spindle error data represents
components of spindle error data. Proposed method uses an the total indicated runout of the spindle and it includes the
iterative least square method for estimating model contribution of centering error, form error of master cylinder
parameters. Residuals of the regression fit are assumed as along with synchronous, asynchronous radial error of the
asynchronous components of spindle error data. Experimental spindle.
results of the proposed regression method are compared with
those obtained using discrete fourier transform filtering 2.2 Discrete time samples of spindle error data
method. The effect of number of harmonics and number of
spindle revolutions on the fitting accuracy and the range of
residuals are analysed and the results are presented.
2. RADIAL ERROR MEASUREMENT

2.1 Experimental arrangement

In the present work, test procedure mentioned in ANSI/

ASME B89.3.4.M standard is followed for conducting
spindle radial error measurement in the miniaturized machine
tool. A master cylinder is mounted in the spindle and Fig. 2.iscrete time samples of spindle error data
capacitive displacement sensor is positioned in the probe

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 Journal of Studies on Manufacturing (Vol.1-2010/Iss.1)
Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

Spindle error data shows a periodic sinusoidal pattern with formulation is explained in Appendix A. Parameters of the
synchronous, asynchronous components superimposed on it. regression model are estimated for the samples of spindle
Periodic sinusoidal component is due to centering error of the error data obtained at the spindle speed of 50,000 rpm as
master cylinder and it represents individual revolution of shown in Fig. 2. Fundamental frequency of spindle error data
spindle. will be around the spindle rotational frequency (50000/60 =
833.333 Hz), hence discrete frequency values are obtained in
Table. 2 show the discrete time samples of spindle error data the frequency interval of 829-838 Hz with a resolution of
for a spindle revolution and it is specified as black dots in 0.01 Hz. Sum squared residual error values are determined
Fig. 2. It can be seen that spindle error data shows a change for the discrete frequency values and it is shown in Fig. 3.
in polarity and it is due to the displacement of master cylinder
from its mean position during spindle rotation.
Table. 2 Samples of spindle error data
S. Sampling time Spindle error
No (x10-3 Sec) data (µm)
1 0.000 -3.6647
2 0.115 -6.2557
3 0.230 -3.6409
4 0.346 -0.3932
5 0.461 4.0524
6 0.576 6.3965
7 0.691 8.8880
8 0.806 6.9975
9 0.922 2.9579
10 1.037 -2.8329 Fig. 3 Fundamental frequency estimation of spindle data
11 1.152 -4.3055
It is noticed that minimum value of sum squared residual
It is difficult to interpret the synchronous and asynchronous error occurs at the frequency of 832.68 Hz and this value
components of spindle error data in time domain. Hence corresponds to the fundamental frequency (f0) of spindle error
suitable methods for required for identifying the components data. Amplitude of sinusoidal functions was estimated for the
of spindle error data. harmonic cut-off value of 32 CPR. Table. 3 list the estimated
amplitude of sinusoidal function for the first 10 harmonic
3. REGRESSION METHOD FOR IDENTIFYING components of spindle error data.
SPINDLE ERROR COMPONENTS Table. 3 Estimated amplitude of sinusoidal function

3.1 Regression model for spindle error data Number of Amplitude of

harmonics sinusoidal function (µ m)
A sum of sinusoidal function is used as regression model for (h) Ah Bh
identifying the synchronous components of spindle error data 1 -6.1664 -2.8938
and it is given by equation (2).
2 0.0432 0.2477
H
m 'i = C + ∑ Ah cos(2π hf 0 ti ) + Bh sin(2π hf 0 ti ) (2)
3 0.5539 -0.1575
h =1 4 -0.0024 -0.0722
5 0.2526 -0.3648
Here C represents the mean value of the spindle error data. 6 -0.0504 -0.0873
This value is estimated using the proposed analysis method.
Ah, Bh represents the amplitudes of cosine and sine 7 -0.1521 0.0684
components of sinusoidal functions. f0 is the fundamental 8 0.0392 0.0233
frequency of spindle error data. H represents the number of 9 0.0172 0.1132
harmonics to be included in the model and its value depends 10 0.0814 0.0020
upon the harmonic cut-off used in Equation (1). Residual
values of the regression fit are considered as asynchronous It is found that the magnitude of first harmonic component is
components. It is assumed that formulated model is true and higher than the other harmonics and it represents the
the residuals follow Gaussian distribution with zero mean and centering error of master cylinder. The constant value (C)
variance. representing the mean position of master cylinder is found to
be 1.657µm.
3.2 Least square estimation of regression model parameters
3.3 Fitting of spindle error data
An iterative least square method is used for determining the Regression fit values are determined for the samples of
parameters of the regression model and its mathematical spindle error data using the estimated model parameters and

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 Journal of Studies on Manufacturing (Vol.1-2010/Iss.1)
Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

it is shown in Fig. 4. A correlation coefficient of 0.987 is

obtained between the regression fit and the spindle error data.
This validates the fitness of the regression model for
analyzing the spindle error data.

(a) Scatter plot

Fig. 4 Regression model fitted to spindle error data

Here the regression fit values represent the synchronous

components and the residuals correspond to the asynchronous
components of spindle error motion. Table 4 provide the fit
and residual values for the samples of spindle error data. It
can be seen that the sum of fit and residual values
corresponds to the magnitude of spindle error data for the (b) Histogram
corresponding sampling time. Thus the regression model
decomposes the spindle error data into synchronous and Fig. 5. Graphical analysis of residuals
asynchronous components.
Table. 4 Regression fit and residual values Histogtram plot is used for verifying the normal probability
assumption of residuals and it is shown in Fig. 5 (b). It can
Sampling Spindle Fit be seen that the shape of the histogram resembles bell curve
Residuals
S.No time error data values of the normal probabilty distribution and it validats the
(µ m)
(x10-3 Sec) (µ m) (µ m) normality assumption of residuals.
1 0 -3.6647 -3.8780 0.2133
2 0.115 -6.2557 -5.9407 -0.3150 3.5 Prediction bounds for the spindle error data
3 0.23 -3.6409 -3.4766 -0.1643 Residuals of the regression fit is furthur analysed for the
determining the satandard deviation and it is found that
4 0.346 -0.3932 -0.5303 0.1371 0.0934µm. This value signifies the non repeatablily of high
5 0.461 4.0524 4.3017 -0.2493 speed spindle and it is useful in determining a prediction
6 0.576 6.3965 6.2097 0.1868 bounds of the spindle error data. Fig. 6 shows the estimated
7 0.691 8.8880 8.7231 0.1649 upper bound and lower bound values of the spindle error data
at 95% probability limits.
8 0.806 6.9975 6.9974 0.0002
9 0.922 2.9579 3.3077 -0.3498
10 1.037 -2.8329 -2.6946 -0.1384
11 1.152 -4.3055 -3.8198 -0.4857

3.4 Validation of regression method

Residuals of spindle error data is analysed graphically using
scatter plot and histogram for validating the assumptions of
regression method and it is illustrated in Fig. 5. Fig. 5 (a)
shows the scatter plot of the residuals. It can be seen that the
residuals are centered on the mean line and it doesn’t show
any trend pattern.
Fig. 6. Prediction bounds for spindle error data

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 Journal of Studies on Manufacturing (Vol.1-2010/Iss.1)
Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

Upper bound and lower bound values for the samples of magnitude of harmonic estimation. Spectral leakage is due to
spindle error data are given in Table. 5. the presence of partial sinusoid or incomplete spindle
revolution. In order to separatre the synchronous and
Table. 5 Estimated prediction bounds for spindle error data
asynchronous components of spindle error data, the
Sampling Spindle Upper Lower components at the integer multiples of fundamental
S. No time error data bound bound frequency is filtered in the frequency doamin as shown in
(x10-3 Sec) (µ m) (µ m) (µ m) Fig. 9.
1 0 -3.6647 -3.4027 -4.3533
2 0.115 -6.2557 -5.4654 -6.4159
3 0.23 -3.6409 -3.0013 -3.9518
4 0.346 -0.3932 -0.0550 -1.0055
5 0.461 4.0524 4.7769 3.8264
6 0.576 6.3965 6.6850 5.7345
7 0.691 8.8880 9.1983 8.2478
8 0.806 6.9975 7.4726 6.5221
9 0.922 2.9579 3.7830 2.8325
10 1.037 -2.8329 -2.2193 -3.1698
11 1.152 -4.3055 -3.3446 -4.2951

It can be seen that the predicted bound almost covers all the
Fig. 7. Spindle error data containing incomplete
data. As the spindle carries the micro cutting tool, prediction
spindle revolution
bound values will be useful in determing tool position errors
and applying componsation to the synchronous and
asynchronous errors of the spindle.
4. PERFORMANCE EVALAUTION OF
PROPOSED METHOD

Proposed regression method is applied to spindle error data

for identifying synchronous and asynchronous compoents. In
order to evaluate the performance of regression method,
results of the propsoed method is compared with discrete
fourier transform (DFT) based frequency domain analysis
method. Correlation coefficient of fit vlaues and the range
of residuals are used as the performance measures for
evlauating regression method. Effect of increase in number
of harmonics and number of spindle revolutions is also Fig. 8. Frequency content of spindle error data
studied and the results are presented for the spindle error data
obtained at spindle speed of 50,000 rpm.

4.1 Comparision with fourier transform filtering method

To demostrate the limitation of the fourier transform method,

samples of spindle error data containing a incomplete spindle
revolution is consisdered analysis. Fig. 7 shows the sample
spindle error data containing an incomplete spindle
revolution. It should be noted that each sinusoidal component
correspond to a complete spindle revolution and the partial
sinusoid represented by the arrow corresponds to the
incomplete spindle revolution.

Frequency content of the spindle error data is estimated using

the discrete fourier transform method and the first 10
harmonic components are shown in Fig. 8.
It is noted that the fundamental frequency content at 1 cycles
per revolution is affected by spectral leakage to the adjacent
frequency bins. This will reduce the accurate estimation of
Fig. 9. Filtering of synchronous components
As the propsoed method processes the data in time domain,
inverse fourier transform method is applied to the filtered
synchronous compoents for comparing the magnitude in time

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 Journal of Studies on Manufacturing (Vol.1-2010/Iss.1)
Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

domain. Fig. 10 shows the comparitive identifications for the
synchronous compoents of spindle erorr data using the
proposed regression method and the discerete fourier
transform filtering method.
It is found that the proposed regression fit follows the
periodic sinusoidal trend with a correlation coefficient of
0.9970, however the synchronous components obtained using
the frequency domain filtering method provides the
correlation coefficient of 0.7156.
It is found that the increase in number of harmonics improves
correlation of the regression model with the spindle error
dasta. Consequently, the range of residual value decerases for
the increase in the number of harmonics. In the present work,
the spindle error data is sampled for harmonic cutoff value of
32 cycles per revolution and it is the limiting value for the
number of harmonics to be included in the regression model.
It is found that when the number of harmonics in the
regression model is incerased to 32 cycle per revolution, a
correlation coefficient reaches a values of 0.999 the range of
residual is found to be 1.2602µ m.

4.3 Effect of increase in number of spindle revolutions

There is no guidelines for choosing the number of spindle

revolutions required for analysing spindle error data (Marsh,
2008). Hence the performance of the regression method is
investigated for the spindle error data containing different
number of revolutions. Number of harmonics included in the
regression model is 32 cycles per revolution. Table. 7 shows
the summary of results for 15 spindle revolutions.
Fig. 10. Comparision regression and fourier trnasform Table 7. Effect of number of spindle revolutions
method
Number of Range of
Correlation
spindle residual
Range of residuals are estimated to be 1.2176 µm and 2.1151 coefficient
revolutions values (µ m)
µm for regression and fourier transfrom mehod
1 1.0000 0.0000
respectively. These results prove the imporved performance
2 0.9991 1.2602
of the proposed regression method for identifying
3 0.9980 1.6021
synchronous and asynchronous components of spindle error
4 0.9964 2.2041
data.
5 0.9805 2.6217
6 0.9965 2.6126
4.2 Effect of increase in number of harmonics 7 0.9957 2.6391
8 0.9956 2.7338
Fitting accuracy of the regression method is evaluated by 9 0.9950 2.8427
increasing the number of harmonics (H) considered in the 10 0.9951 2.9347
regression model. Spindle error data containing two spindle 11 0.9953 2.8943
revolutions are considered for analysis. Correlation 12 0.9954 2.9333
coefficient and the range of residuals are determined and the 13 0.9947 3.1826
results for the first 15 harmonics are shown in Table. 6. 14 0.9940 3.2090
Table 6. Effect of number of harmonics 15 0.9942 3.2511
Harmonics Range of
Correlation
(cycles per residual
coefficient
revolution) values (µ m) When the regression method is applied to the samples of
1 0.9904 3.5742 spindle error data containing a single spindle revolution,
2 0.9906 3.5273 correlation is coefficient is found to be 1.0 for 32 cycles per
3 0.9948 2.5843 revolution. It means that spindle error data in a single
4 0.9948 2.5201 revolution are assumed as synchronous components.
5 0.9965 2.6941
6 0.9966 2.7468 When the spindle error data contain two revolutions, it is
7 0.9969 2.4337 found that the correlation coefficient decreases to 0.9991. It is
8 0.9969 2.4133 due to the random nature of asynchronous components in
9 0.9970 2.2551 each spindle revolution. It is also found that the range of
10 0.9970 2.2565 residuals increases with further increase in number of spindle
11 0.9971 2.2814 revolution. From the results, it is concluded that proposed
12 0.9973 2.2708 method provides accurate identification of synchronous and
13 0.9974 2.1748 asynchronous components for the spindle error data
14 0.9974 2.1608 containing two revolutions. It is found to be the limiting
15 0.9974 2.1948

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 Journal of Studies on Manufacturing (Vol.1-2010/Iss.1)
Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

value for the number of spindle revolutions to be considered
for analysis of spindle error data.
5. CONCLUSION
This paper presented a regression based identification method
for analysing spindle radial error components of a
miniaturized machine tool. A sum of sinusoidal function is
used as regression model for interpreting synchronous and
asynchronous components of spindle radial error.
Experimental results proved a good correlation between the
regression fit and the spindle error data. Spectral leakage
problem is observed in Fourier transform filtering method
when it is applied to the spindle error data containing an
incomplete spindle revolution. However, the present method
overcomes the spectral leakage problem and provides
improved performance for identifying synchronous and
asynchronous components of spindle error data. Proposed
regression method requires minimum number of samples
Publications, Inc, Lancaster, PA 17602, U.S.A.
Robert Grejda, Eric Marsh, Ryan Vallance, (2005).
Techniques of calibrating spindles with nanometre error
motion, Precision Engineering, 29, 113-123.
Sun, S.Y and Bryan, J. B. (1985). A new instrument for axis
of rotation metrology, Annals of the CIRP, 34, 439-444.
Vanherck, P and Peters, J. (1973). Digital axis of rotation
measurements, Annals of the CIRP, 22, 135-136.
APPENDIX A.
LEAST SQUARE METHOD FOR ESTIMATION OF
REGRESSION MODEL PARAMETERS
Regression model for identifying synchronous components of
spindle error data (mi’) is given by
H

containing two spindle revolutions for accurate identification
of spindle error data. This method can be useful in
predicting and compensating tool position errors due to
spindle error motions. This method processes the spindle
error data in time domain and it can be implemented for
online analysis of spindle errors in high speed spindles.
REFERENCES
m 'i = C + ∑ Ah cos(2π hf 0ti ) + Bh sin(2π hf 0ti ) (A.1)
h =1
It is seen that regression model contains linear parameters
(ah, bh) and non linear parameter (f0). Hence an iterative least
square method is followed for estimation model parameters.
Fundamental frequency of spindle error data (f0) will be
around spindle rotational frequency (fr), hence a set of
discrete frequency values (fi) are obtained in a specified
frequency range given by fmin < fr < fmax with a constant
increment of ∆f .

ANSI/ASME B89.3.4M Axes of Rotation, Methods for

Specifying and Testing, 2004 fj = [f1, f2,….,fk] j=1,2,…..,k (A.2)
Bryan, J.B. Richard Clouser and Earl Holland (1967), Spindle
accuracy, American machinist, Report No. 612, 149-
164. For the given discrete frequency fi,, linear regression model
Bryan, J.B. and Vanherck, P. (1975). Unification of given in (A.1) can be represented in matrix form for ‘m’
terminology concerning the error motion of axes of samples of radial error data with a harmonic cut-off ‘H’.
rotation, Annals of CIRP, 24, 555-562.
Chapman, P.D. (1985). A capacitance based ultra-precision  m '1  1 cos(2π f i t1 ) sin(2π fi t1 ) . . cos(2π Hf i t1 ) sin(2π Hf i t1 )  C 
spindle error analyzer, Precision Engineering, 7(3), 129-    cos(2π f i t2 ) sin(2π f i t2 ) . cos(2π Hfi t2 ) sin(2π Hfi t2 )
 
 m '2  1 .   A1 
137.  m '3  1 cos(2π f i t3 ) sin(2π f i t3 ) . . cos(2π Hf i t3 ) sin(2π Hf i t3 )   B1 
    
Jywe, W.Y. and Chen, C.J. (2005). The development of a .  = . . .  . 
.  . . .  .  (A.3)
high speed spindle measurement system using laser     
 m 'm−1  1 cos(2π f i tm−1 ) sin(2π f i tm−1 ) . . cos(2π Hfi tm−1 ) sin(2π Hfi tm−1 )   AH 
diode and quadrant sensor, International Journal of  m '  1 cos(2π f i tm ) sin(2π f i tm ) . . cos(2π Hf i tm ) sin(2π Hf i tm )   BH 
 m  
machine tools & Manufacture, 45(11), 1162-1170.
Kakino, Y.Y, Yammoto, and Ishii, N. (1977) .New measuring
method of rotating accuracy of spindle, Annals of the It is expressed in simplified matrix form as given by
CIRP, 35 (1), 241-244.
m'i = Dj X j (A.4)
Kengo Fujimaki, Kimiyuki Mitsui, (2007). Radial error
measuring device based on auto collimation for
Where D j is the basis matrix of containing ‘m’ rows and
miniature ultra high speed spindles, International Journal
2H+1 columns as given by
of machine tools & Manufacture, 47(11), 1677-1685.
Lee, J.H, Lee, E.S and Yang, S.H. (2005). Assessment of 1 cos(2π fi t1 ) sin(2π fi t1 ) cos(2π Hfi t1 ) sin(2π Hfi t1 ) 
radial errors of high speed spindle in a miniaturized 1 cos(2π fi t2 ) sin(2π fi t2 ) cos(2π Hfi t2 ) sin(2π Hfi t2 ) 

machine tool, International conference of leading Edge 1 cos(2π fi t3 ) sin(2π fi t3 ) cos(2π Hfi t3 ) sin(2π Hfi t3 ) 
 
manufacturing in 21st Century, Oct.19-22, Nagoya, D j = . . 
. . 
Japan, 345-350.   (A.5)
1 cos(2π fi tm−1 ) sin(2π fi tm−1 ) cos(2π Hfi tm−1 ) sin(2π Hfi tm−1 ) 
Marsh, E. R (2008) Precision spindle metrology, DES tech 1 cos(2π fi tm ) sin(2π fi tm ) cos(2π Hfi tm ) sin(2π Hfi tm ) 


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Ashok and Samuel / Regression Method for Identifying Spindle Radial Errors of a … / pp. 26-33

and Xj is the set of unknown linear model parameters as AUTHORS PROFILE

given by
Dr. G. L. Samuel is currently working as Assistant Professor at the
= [ C , A1 , B 1 , A 2 , B 2 ..... A H , B H ] T Department of Mechanical Engineering, Indian Institute of Technology
X j (A.6) Madras, Chennai. He obtained his B. E. Degree in Mechanical Engineering
from Mysore University in 1991, M. Tech. Degree in Production
These leads to a system of over determined of equations (m > Engineering and Systems Technology from Kuvempu University in 1994
2H+1) and it can be solved by least square method by and Ph. D degree in Mechanical Engineering from Indian Institute of
Technology Madras in 2001. He has been a Post Doctoral Fellow at School
minimizing a sum of squared residual error. of Mechanical Engineering, Kyungpook National University, South Korea.
His active areas of research are: measurements and inspection of freeform
surfaces, geometric error compensation in machine tools, and evaluation of
m form errors, micromachining and laser vision systems. He has published over
E j = ∑ε 2i
fifteen papers in refereed international journals.
(A.7)
i =1

Residual error єi is expressed in matrix form as given by
ε i = ( m'i − D j X j )
It is assumed that residuals follow normal probability
distribution. Then the linear least square solution vector of
model parameters for the given discrete frequency (fj) is
obtained by
Xˆ j =  ( D j T D j ) −1 D j T  m 'i = [Cˆ , Aˆ1 , Bˆ1 ,...., Aˆ H , Bˆ H ]
S. Denis Ashok received his Bachelors Degree in Mechanical Engineering
and Masters Degree in Production Engineering from Madurai Kamaraj
University, Madurai, India. Currently, he is pursuing Ph D degree at Indian
(A.8) Institute of Technology Madras, Chennai. He has five years of teaching
experience and his area of interest includes machine tool metrology, spindle
metrology, computer aided inspection. He has presented five papers in the
international/national conferences.
(A.9)

Sum of squares of residual error Ej is determined for all

discrete frequency values (fj). Fundamental frequency ( fˆ0 )
of the spindle error data is determined as the discrete
frequency value fj that minimizes the criterion given by
Equation (A.7).

ˆ si )
Synchronous components of spindle error data ( m
identified by the regression fit is given by.

mˆ si = DXˆ − Cˆ (A.10)

Residual errors are considered as asynchronous components

( ε i ) as presented by

εˆi = m'i − DXˆ (A.11)

Standard deviation (σ) of the residual values is estimated and

the prediction bound for spindle error data is obtained for
95% probability limit as given by

m pi ' = mˆ 'si ± 1.96σ (A.12)

33