Effects of Key Parameters on the Performance of a New In-Process Optical Measurement Method

Tao, Zhenyi; Gao, Yongsheng

doi:10.4028/www.scientific.net/kem.295-296.405

Cited by 1 publication

(12 citation statements)

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“…In-process measurement of a workpiece surface y(x, z) (figure 1) is a difficult real-time measurement [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19]. It is performed in a harsh and complex measurement environment to acquire workpiece surface y(x, z) when the workpiece is being machined.…”

Section: Introductionmentioning

confidence: 99%

“…In-process measurement of form profiles has been a good choice for high efficiency and high precision machining. Gao et al [10][11][12][13][14][15][16][17][18][19] proposed a number of in-process measurement methods to measure the form profile of workpiece under coolant conditions.…”

Section: Introductionmentioning

confidence: 99%

“…To solve the optical barrier problem [15], several methods have been proposed such as the water beam method [10][11][12], the single air beam method [13][14][15][16], and the multiple air beam method [17,18]. The water beam method [10][11][12] has two main disadvantages. Firstly, water injected into the transparent window will dilute the coolant [14].…”

Section: Introductionmentioning

confidence: 99%

“…This will affect the machining performance. Secondly, measurement light refracts several times during the measurement process [10]. This will cause significant measurement errors.…”

Section: Introductionmentioning

confidence: 99%

“…The single air beam method [13][14][15][16] is a solution to the problems of the water beam method [10][11][12]. However, the single air beam method can only displace coolant from one direction and cannot handle coolant from multiple directions [17,18].…”

Section: Introductionmentioning

confidence: 99%

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Use of dual coolant displacing media for in-process optical measurement of form profiles

Gao

Xie

2018

Meas. Sci. Technol.

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In-process measurement supports feedback control to reduce workpiece surface form error. Without it, the workpiece surface must be measured offline causing significant errors in workpiece positioning and reduced productivity. To offer better performance, a new in-process optical measurement method based on the use of dual coolant displacing media is proposed and studied, which uses an air and liquid phase together to resist coolant and to achieve in-process measurement. In the proposed new design, coolant is used to replace the previously used clean water to avoid coolant dilution. Compared with the previous methods, the distance between the applicator and the workpiece surface can be relaxed to 1 mm. The result is 4 times larger than before, thus permitting measurement of curved surfaces. The use of air is up to 1.5 times less than the best method previously available. For a sample workpiece with curved surfaces, the relative error of profile measurement under coolant conditions can be as small as 0.1% compared with the one under no coolant conditions. Problems in comparing measured 3D surfaces are discussed. A comparative study between a Bruker Npflex optical profiler and the developed new in-process optical profiler was conducted. For a surface area of 5.5 mm × 5.5 mm, the average measurement error under coolant conditions is only 0.693 µm. In addition, the error due to the new method is only 0.10 µm when compared between coolant and no coolant conditions. The effect of a thin liquid film on workpiece surface is discussed. The experimental results show that the new method can successfully solve the coolant dilution problem and is able to accurately measure the workpiece surface whilst fully submerged in the opaque coolant. The proposed new method is advantageous and should be very useful for in-process optical form profile measurement in precision machining.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…This will affect the machining performance. Secondly, measurement light refracts several times during the measurement process [10]. This will cause significant measurement errors.…”

Section: Introductionmentioning

confidence: 99%