Modeling and analysis for multi-stage manufacturing error of meso-scale parts based on size effect

Aiming at the machining accuracy of meso-scale component with small size, high precision and various of error sources, a machining accuracy control system included dimensional variation model, Multivariate Statistical Process Control (MSPC) and error source diagnosis was put forward to provide technical basis for multi-stage digital manufacturing of meso-scale parts. Through analyzing the characteristics of meso-scale part in manufacturing, the machining errors model caused by workpieces deformation and tool deformation based on micro cutting scale effect was proposed, and the deviation state space model of meso-scale parts' dimensional error was constructed. A quality monitoring strategy with combination of variation model and MSPC and an error resource diagnosis method were raised to achieve the diagnosis of error and the control of machining accuracy. The effectiveness and feasibility of the model were proved by milling micro grooves in the stainless steel part.