The form error evaluation of cylinders and cones is very important in precision coordinate metrology. The solution of the traditional least squares technique is prone to over-estimation, as a result unnecessary rejections may be caused. This paper proposes a reliable algorithm to calculate the minimum zone form errors of cylinders and cones, called a hybrid particle swarm optimization-differential evolution algorithm. The optimization is conducted in two stages, so that the program can hold a fast convergence rate, while effectively avoiding local minima. Experimental results demonstrate that the proposed algorithm can obtain very accurate and stable results for the calculation of cylindricity and conicity.
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