A Novel Detection Method for Workpiece Surface Morphology with Arbitrary Rotation Angles

The spindle motion error significantly affects the surface quality and dynamic precision of machined workpieces. This study proposes a novel detection method for workpiece surface morphology with arbitrary rotation angles. A mathematical model was established for the relationship between the detection signal, spindle error, and workpiece contour when the workpiece rotates at different angles. Unlike traditional reversal methods, this approach allows a flexible selection of workpiece rotation angles and simplifies calculations. Simulation results demonstrate the method’s accuracy, with the slight mean square errors and determination coefficients R² approaching 1. Experimental validation confirms the method’s reliability. Furthermore, the influences of asynchronous errors and sensor errors on measurement results were systematically investigated, highlighting the importance of increasing sampling periods and accurate positioning of sensors. This method offers a cost-effective and versatile solution for precision machining and can be extended to other rotating machinery applications.