Tool center error identification extended by material properties in ultra-precision machining

In single-point diamond turning (SPDT), tool center error (TCE) frequently produces conical or cylindrical residues at the workpiece center, significantly influencing the machined surface quality. Although force-sensing-based online identification methods have been developed, the effectiveness is constrained by variations in cutting mechanisms across different materials. This study systematically investigates the influence of different plastic metal materials on TCE identification. Finite element analysis (FEA) simulations were performed in ABAQUS to evaluate the surface morphology and mechanical responses of various materials under tool-above-center and tool-below-center errors. The results indicate that materials with higher Young’s modulus generate larger cutting forces and alter the surface stress distribution. Moreover, a comparison between simulations and experiments demonstrates that the proposed simulation model for TCE in ultra-precision machining (UPM) achieves high consistency with the measured values, with a maximum absolute error of 1.20 μm. In addition, considering the influence of material properties on TCE, a novel identification model was developed in this study. Compared with previous approaches, the proposed model improves identification accuracy by 5–10%. These findings demonstrate that the proposed extended online identification method is both accurate and reliable, providing a robust foundation for advancing UPM toward higher levels of automation and intelligence.