Technical Brief

Development and Application of Interferometric On-Machine Surface Measurement for Ultraprecision Turning Process

[+] Author and Article Information
Duo Li

EPSRC Future Metrology Hub,
University of Huddersfield,
Huddersfield HD1 3DH, UK
e-mail: duo.li@hud.ac.uk

Xiangqian Jiang

EPSRC Future Metrology Hub,
University of Huddersfield,
Huddersfield HD1 3DH, UK
e-mail: x.jiang@hud.ac.uk

Zhen Tong

EPSRC Future Metrology Hub,
University of Huddersfield,
Huddersfield HD1 3DH, UK
e-mail: z.tong@hud.ac.uk

Liam Blunt

EPSRC Future Metrology Hub,
University of Huddersfield
Huddersfield HD1 3DH, UK
e-mail: l.a.blunt@hud.ac.uk

Manuscript received July 9, 2018; final manuscript received October 1, 2018; published online October 19, 2018. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 141(1), 014502 (Oct 19, 2018) (9 pages) Paper No: MANU-18-1522; doi: 10.1115/1.4041627 History: Received July 09, 2018; Revised October 01, 2018

The continuing evolution of ultraprecision machining places an increasing need to perform surface measurement in the manufacturing environment. Development of on-machine surface measurement (OMSM) tools for ultraprecision machining processes will enable the reduction of measurement cycle time as well as the potential improvement of machining accuracy. In the present study, an in-house designed interferometer probe is integrated onto an ultraprecision diamond turning machine. System configuration, calibration scheme and various scanning strategies are first presented. The benefit of OMSM preserves the consistency between the machining and measurement coordinate system. Two applications of OMSM for ultraprecision turning process are further investigated. To further improve the surface accuracy, corrective machining is carried out based on the on-machine measured data. The profile accuracy of a cosine curve sample was improved after corrective machining with OMSM. Moreover, process investigation with OMSM was employed to model the effect of process parameters on the form error in ultraprecision cylindrical turning process. OMSM enables the consistent measurement of part coordinates for each experimental run, which is critical for acquiring a deterministic response for empirical modeling. A reduced quadratic model was built by means of response surface methodology and verified by the test for significance of the regression model. The confirmation tests show that the model predicted value conformed to the experimental value with a difference less than 4%.

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Fig. 5

On-machine surface measurement setup for corrective machining

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Fig. 6

Framework of corrective machining with OMSM

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Fig. 4

Error plot of on-machine measurement of multiple step height sample

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Fig. 3

On-machine surface measurement of a multiple step height sample

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Fig. 2

Multiple radial (a), multiple circular (b), and spiral measurement path (c) for OMSM

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Fig. 1

On-machine surface measurement system configuration on an ultraprecision turning machine

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Fig. 13

On-machine surface measurement setup for process investigation of cylindrical turning of cosine curve sample

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Fig. 7

On-machine surface measurement data processing for profile corrective machining

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Fig. 8

On-machine surface measurement of cosine curve sample

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Fig. 9

Symmetric folding of profile error

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Fig. 10

Profile error correction results

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Fig. 11

Measurement results and error analysis of DRI on-machine measurement (a) and PGI offline measurement (b)

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Fig. 12

Flow chart of process investigation strategy with OMSM

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Fig. 14

Fitted residual plot in the observation order

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Fig. 15

Three-dimensional response surface graphs



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