Factorial and Preliminary Parameter Tests for the Water Beam Assisted Form Error In-Process Optical Measurement

Zhang, Y.; Gao, Yongsheng; Lai, Yongqing; Wang, J.X.

doi:10.4028/www.scientific.net/kem.437.444

Cited by 4 publications

(23 citation statements)

References 6 publications

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“…Optical measurement is typically at very high resolution [1,2] and is the best choice if the opaque barrier, which is the first key problem, is solved [2]. A water beam approach has been proposed to solve this difficult problem [2,[5][6][7][8][9][10][11][12]. We also proposed an air beam technique to solve the coolant problem [13][14][15].…”

Section: Opaque Barriermentioning

confidence: 99%

“…The key technique in the proposed methods [2,5,13,14] is the use of an assisting fluid to overcome the opaque barrier of coolant through the use of an applicator [2,5,13,14] (figure 1) to build a small zone that is optically clean. An area of this kind is termed a transparent window to make the workpiece surface accessible to an optical measurement system of our choice [2,[5][6][7][8][9][10][11][12][13][14][15].…”

Section: Opaque Barriermentioning

confidence: 99%

“…To address the above problems in a single device for grinding research and for industrial use, based on our existing studies [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][17][18][19][20][21], a new single laser sensor design together with two techniques for in-process form error measurement is proposed. The proposed design is based on the use of an air beam [13,14] and is simple and costs less.…”

Section: Vibrationmentioning

confidence: 99%

See 2 more Smart Citations

An in-process form error measurement system for precision machining

Gao¹,

Huang²,

Zhang³

2010

Meas. Sci. Technol.

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In-process form error measurement for precision machining is studied. Due to two key problems, opaque barrier and vibration, the study of in-process form error optical measurement for precision machining has been a hard topic and so far very few existing research works can be found. In this project, an in-process form error measurement device is proposed to deal with the two key problems. Based on our existing studies, a prototype system has been developed. It is the first one of the kind that overcomes the two key problems. The prototype is based on a single laser sensor design of 50 nm resolution together with two techniques, a damping technique and a moving average technique, proposed for use with the device. The proposed damping technique is able to improve vibration attenuation by up to 21 times compared to the case of natural attenuation. The proposed moving average technique is able to reduce errors by seven to ten times without distortion to the form profile results. The two proposed techniques are simple but they are especially useful for the proposed device. For a workpiece sample, the measurement result under coolant condition is only 2.5% larger compared with the one under no coolant condition. For a certified Wyko test sample, the overall system measurement error can be as low as 0.3 µm. The measurement repeatability error can be as low as 2.2%. The experimental results give confidence in using the proposed in-process form error measurement device. For better results, further improvement in design and tests are necessary.

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Section: Opaque Barriermentioning

confidence: 99%

Section: Opaque Barriermentioning

confidence: 99%

Section: Vibrationmentioning

confidence: 99%

See 1 more Smart Citation

An in-process form error measurement system for precision machining

Gao¹,

Huang²,

Zhang³

2010

Meas. Sci. Technol.

View full text Add to dashboard Cite

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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%

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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Characteristic study of multiple air beam approach for in-process measurement with coolant condition

2024

Journal of Manufacturing Processes

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Factorial and Preliminary Parameter Tests for the Water Beam Assisted Form Error In-Process Optical Measurement

Cited by 4 publications

References 6 publications

An in-process form error measurement system for precision machining

An in-process form error measurement system for precision machining

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

Characteristic study of multiple air beam approach for in-process measurement with coolant condition

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