Analysis of a High-Precision Dual-Axis Roller-Cam Turntable and Investigation of Intelligent Diagnostic Technologies

The demand for high-precision multiaxis machining in aerospace and advanced manufacturing has increased. As a result, dual-axis roller-cam rotary tables have become critical for achieving accurate positioning and stable dynamic performance. This work developed a methodology that combined numerical modeling, physical testing, and data-driven health assessment into a single evaluation platform. The dynamic rigidity of the system was validated through complementary numerical simulations and experimental modal analysis. VDI3441-based accuracy testing demonstrated that indexing precision was 11.6″–19.8″ and repeatability was within 2.2″ across the C1, C2, and tilting axes. Tests performed at different speeds showed stable performance under low-speed operation (Pa ≈ 3.5). However, accuracy decreased at high speeds (Pa up to 9.2), with synchronization-induced error coupling between the dual C axes. A dual-axis intelligent monitoring system was implemented using principal component analysis and Gaussian mixture models. A classification accuracy of 93.5% was achieved (area under the receiver operating characteristic curve > 0.92), and the system outperformed fast-Fourier-transform-based and wavelet-based methods under varying load conditions. The proposed method exhibits reliable dynamic performance and the capability for real-time predictive health management, thereby enabling a transition toward intelligent, sustainable, and data-centric high-precision manufacturing systems.