In this paper, the width and depth of rectangular surface-breaking defects were successfully gauged using an all-optical laser-ultrasonic system. The finite element method was used to simulate propagating paths of defect-induced reflected and transmitted Rayleigh waves. It is observed that most Rayleigh waves with wavelengths less than the depth of the defect are reflected by the defect. A small part of the Rayleigh waves with wavelengths greater than the depth of the defect directly transmits through the bottom edge of the defect without acting on the left edge of the defect. Based on the simulation results, a three-step detection method of width and depth gauging of rectangular surface-breaking defects is proposed. In the first step, the pulsed laser and detection laser are irradiated on one side of the defect. In the second step, the sample is moved to a certain distance to ensure that both lasers reach the other side of the defect. In the third step, two lasers are irradiated on both sides of the defect. The width and depth of the defect are calculated according to the arrival time of the incident, reflected, and transmitted Rayleigh waves, as well as the movement distance of the sample. Experimental results are consistent with the reference-results measured by using a digital microscope. The proposed three-step detection method is proved to be feasible in simultaneous measurement of the width and depth of rectangular surface-breaking defects. Furthermore, it may be potentially useful for measuring other types of defect structures.
Measurement and compensation of the geometric errors can improve the machining accuracy of machine tool. However, measuring bar of the double ball bar (DBB) is not variable. In this paper, a novel measuring equipment based on telescopic ball bar with an indexing joint (IJ-TBB) is proposed for the geometric errors. Firstly, the basic structure and measuring principle of IJ-TBB are introduced. Then, the effect of structural errors of IJ-TBB on the measurement accuracy is studied. Next, the error amplification characteristic and measurement resolution of IJ-TBB are analyzed. Finally, an experiment was carried out to validate the accuracy of IJ-TBB. The results reveal that the IJ-TBB has a high precision and high efficiency. In addition, the measurement resolution of IJ-TBB can reach up to 0.03μm, which is much higher than DBB. It is valuable to extend the measurement range and improve the measurement accuracy of machine tool.
Multiaxis machine tools are widely used in manufacturing. The measurement of motion error is important to improve the machining accuracy of machine tools. A double ball bar (DBB), as a high-precision single-dimensional position reading device, is widely used to measure the motion error of the circular path of machine tools. However, the motion errors contain the cylindrical radial and axial errors with respect to the circular path plane. Therefore, the measurement results of the DBB are incomplete because they do not contain axial errors. To measure the motion error of the circular path accurately, completely and concisely, a novel measurement method based on the combined double ball bar (C-DBB) is proposed in this paper, which can directly measure the radius and axial motion error of the circular path in one measurement. First, the measuring principle of the C-DBB method is introduced, and the measurement model of the radius and axial motion error of the circular path is established. Then, a measuring device using the C-DBB method was designed based on the lever principle, and the error parameters of the designed device were analyzed. According to the error analysis results, the measurement results of the C-DBB method were compensated and corrected. Finally, the C-DBB method is used to measure the circular path on the vertical CNC milling machine, and the results are compared with the measurement results using the DBB method. It is shown that the proposed C-DBB method can obtain high-precision multidimensional motion error in a single measurement, and the designed measuring device based on the C-DBB method has high repeatability and good circular path measuring ability. The proposed method provides an effective method for machine tool multidimensional motion error measurement and compensation.
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