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A high-accuracy roundness measurement for cylindrical components by a morphological filter considering eccentricity, probe offset, tip head radius and tilt error

A morphological filter is proposed to obtain a high-accuracy roundness measurement based on the four-parameter roundness measurement model, which takes into account eccentricity, probe offset, probe tip head radius and tilt error. This paper analyses the sample angle deviations caused by the four systematic errors to design a morphological filter based on the distribution of the sample angle. The effectiveness of the proposed method is verified through simulations and experiments performed with a roundness measuring machine. Compared to the morphological filter with the uniform sample angle, the accuracy of the roundness measurement can be increased by approximately 0.09 μm using the morphological filter with a non-uniform sample angle based on the four-parameter roundness measurement model, when eccentricity is above 16 μm, probe offset is approximately 1000 μm, tilt error is approximately 1″, the probe tip head radius is 1 mm and the cylindrical component radius is approximately 37 mm. The accuracy and reliability of roundness measurements are improved by using the proposed method for cylindrical components with a small radius, especially if the eccentricity and probe offset are large, and the tilt error and probe tip head radius are small. The proposed morphological filter method can be used for precision and ultra-precision roundness measurements, especially for functional assessments of roundness profiles.