Geometric deviations of free-form surfaces are attributed to many phenomena that occur during machining, both systematic (deterministic) and random in character. Measurements of free-form surfaces are performed with the use of numerically controlled CMMs on the basis of a CAD model, which results in obtaining coordinates of discrete measurement points. The spatial coordinates assigned at each measurement point include both a deterministic component and a random component at different proportions. The deterministic component of deviations is in fact the systematic component of processing errors, which is repetitive in nature. A CAD representation of deterministic geometric deviations might constitute the basis for completing a number of tasks connected with measurement and processing of free-form surfaces. The paper presents the results of testing a methodology of determining CAD models by estimating deterministic geometric deviations. The research was performed on simulated deviations superimposed on the CAD model of a nominal surface. Regression analysis, an iterative procedure, spatial statistics methods, and NURBS modelling were used for establishing the model.

Local geometric deviations of free-form surfaces are determined as normal deviations of measurement points from the nominal surface. Different sources of errors in the manufacturing process result in deviations of different character, deterministic and random. The different nature of geometric deviations may be the basis for decomposing the random and deterministic components in order to compute deterministic geometric deviations and further to introduce corrections to the processing program. Local geometric deviations constitute a spatial process. The article suggests applying the methods of spatial statistics to research on geometric deviations of free-form surfaces in order to test the existence of spatial autocorrelation. Identifying spatial correlation of measurement data proves the existence of a systematic, repetitive processing error. In such a case, the spatial modelling methods may be applied to fitting a surface regression model representing the deterministic deviations. The first step in model diagnosing is to examine the model residuals for the probability distribution and then the existence of spatial autocorrelation.

Freeform surfaces have wider engineering applications. Designers use B-splines, Non-Uniform Rational B-splines, etc. to represent the freeform surfaces in CAD, while the manufacturers employ machines with controllers based on approximating functions or splines. Different errors also creep in during machining operations. Therefore the manufactured freeform surfaces have to be verified for conformance to design specification. Different points on the surface are probed using a coordinate measuring machine and substitute geometry of surface established from the measured points is compared with the design surface. The sampling points are distributed according to different strategies. In the present work, two new strategies of distributing the points on the basis of uniform surface area and dominant points are proposed, considering the geometrical nature of the surfaces. Metrological aspects such as probe contact and margins to be provided along the sides have also been included. The results are discussed in terms of deviation between measured points and substitute surface as well as between design and substitute surfaces, and compared with those obtained with the methods reported in the literature.