Multi-Scale Surface Characterization and Control Based High Density Measurements

2014 ◽  
Author(s):  
Xin Weng ◽  
Xiaoning Jin ◽  
Jun Ni
Keyword(s):  
Surface Quality ◽  
Process Monitoring ◽  
Surface Characterization ◽  
Quality Evaluation ◽  
Surface Shape ◽  
Machined Surface ◽  
Multi Scale ◽  
And Control ◽  
Scale Surface ◽  
Machined Surfaces

It is widely observed that today’s engineering products demand increasingly strict tolerances. The shape of a machined surface plays a critical role to the desired functionality of a product. Even a small error can be the difference between a successful product launch and a major delay. Thus, it is important to develop measurement tools to ensure the quality and accuracy of products’ machined surfaces. The key to assessing the quality is robust measurement and inspection techniques combined with advanced analysis. However, conventional Geometrical Dimensioning and Tolerancing (GD&T) such as flatness falls short of characterizing the surface shape. With the advancements in metrology methodology utilizing digital holographic interferometry, large amount of surface data can be captured at high resolution and accuracy without changing platform or technique. This captured High Definition Data (HDD) enables the mining of more valuable information from machined surfaces that most current industry practice cannot achieve in a timely manner. Such new metrology system opens the torrent of observable events at plant floor and increases the transparency of machining processes. This presents great opportunities to characterize machined surface into a new level of details, which can be applied in production quality evaluation and process condition monitoring and control. This research work proposes a framework of a multi-scale surface characterization for surface quality evaluation and process monitoring. Case studies are presented to show how proposed metrics could be applied in surface quality evaluation and process monitoring.

Optical Effects of Surface Finish by Ultraprecision Single Point Diamond Machining

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Lei Li ◽  
Stuart A. Collins ◽  
Allen Y. Yi
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Diamond Turning ◽  
Optical Diffraction ◽  
Machining Process ◽  
Machined Surface ◽  
Tool Marks ◽  
Tool Mark ◽  
Machined Surface Quality ◽  
Machined Surfaces

The single point diamond turning process has been used extensively for direct optical surface fabrication. However, the diamond machined surfaces have characteristic periodic tool marks, which contribute to reduced optical performance such as scattering and distortion. In this paper, studies of the characteristics of diamond machined surface and scattering from the diamond machined surfaces are presented. Four different parameters, the first order optical diffraction, the zero order reflection, the surface roughness, and the residual tool mark depth, are used as indicators for the machined surface quality. Four sets of tests are presented showing the relationship between machined surface quality and machining conditions such as spindle speed, feedrate, and machining process. Finally, an empirical model is given based on the measurements.

Characterization of Cutting Force Induced Surface Shape Variation in Face Milling Using High-Definition Metrology1

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Hai Trong Nguyen ◽  
Hui Wang ◽  
S. Jack Hu
Keyword(s):  
Cutting Force ◽  
Process Monitoring ◽  
Face Milling ◽  
Surface Shape ◽  
Machining Process ◽  
High Definition ◽  
Surface Patterns ◽  
Cutting Processes ◽  
And Control ◽  
The Impact

High-definition metrology (HDM) systems with fine lateral resolution are capable of capturing the surface shape on a machined part that is beyond the capability of measurement systems employed in manufacturing plants today. Such surface shapes can precisely reflect the impact of cutting processes on surface quality. Understanding the cutting processes and the resultant surface shape is vital to high-precision machining process monitoring and control. This paper presents modeling and experiments of a face milling process to extract surface patterns from measured HDM data and correlate these patterns with cutting force variation. A relationship is established between the instantaneous cutting forces and the observed dominant surface patterns along the feed and circumferential directions for face milling. Potential applications of this relationship in process monitoring, diagnosis, and control are also discussed for face milling. Finally a systematic methodology for characterizing cutting force induced surface variations for a generic machining process is presented by integrating cutting force modeling and HDM measurements.

scholarly journals Analysis and Characterization of Machined Surfaces with Aesthetic Functionality

2019 ◽  
Vol 13 (2) ◽  
pp. 261-269
Author(s):  
Francesco Giuseppe Biondani ◽  
Giuliano Bissacco ◽  
Lukáš Pilný ◽  
Hans Nørgaard Hansen ◽  
◽  
...  
Keyword(s):  
Surface Characterization ◽  
Linear Trend ◽  
Scattered Light ◽  
Confocal Microscope ◽  
Roughness Parameters ◽  
Machined Surface ◽  
Sem Images ◽  
Aesthetic Quality ◽  
Visual Appearance ◽  
Machined Surfaces

The generation of fine machined surfaces with high gloss is an important topic in mould manufacturing. The surface gloss can be characterized by means of scattered light sensors and a representative parameter such asAq. In this paper, in-line measurements of scattered light distribution are compared with roughness parameters calculated using a confocal microscope, in order to assess surface aesthetic quality. Several surfaces have been machined by means of high precision milling, producing different surface topographies. Surface characterization has been performed on a machine using a scattered light sensor, and using a confocal microscope in laboratory conditions. The calculatedAqparameter is compared with the amplitude roughness parametersSaandSq, and with hybrid parametersSdqandRdqrepresenting the average slope of the surface features. Scanning electron microscope (SEM) images are used as visual benchmarks to identify the parameters’ correlation with the visual appearance. A different linear trend of the relationship betweenAq,Rdq, andSdqis observed. The description of the surface quality throughSaorSqinstead is found to be insufficient. This is explained by means of SEM pictures showing a dramatic influence of the smeared material over the machined surface.

Chacterization of Cutting Force Induced Surface Shape Variation Using High-Definition Metrology

2012 ◽  
Author(s):  
Hai Trong Nguyen ◽  
Hui Wang ◽  
S. Jack Hu
Keyword(s):  
Cutting Force ◽  
Process Monitoring ◽  
Surface Shape ◽  
Machining Process ◽  
Monitoring And Control ◽  
High Definition ◽  
Surface Patterns ◽  
Cutting Processes ◽  
And Control ◽  
The Impact

High-definition metrology (HDM) systems with fine lateral resolution are capable of capturing the surface shape on a machined part that is beyond the scope of measurement systems employed in manufacturing plants today. Such surface shapes can precisely reflect the impact of cutting processes on surface quality. Understanding the cutting processes and the resultant surface shape is vital to identifying opportunities for high-precision machining process monitoring and control. This paper presents modeling and experiments of a face milling process to extract surface patterns from measured HDM data and correlate these patterns with cutting force variation. A relation is established between instantaneous cutting forces and the observed dominant patterns along the feed and circumferential directions. Potential applications of such relationship in process monitoring, diagnosis, and control are also discussed.

scholarly journals Effect of Shift in Speed Turning on Machined Surface Quality

2017 ◽  
Vol 65 (1) ◽  
pp. 135-143
Author(s):  
Pavel Polák ◽  
Petr Dostál ◽  
Katarína Kollárová
Keyword(s):  
Mild Steel ◽  
Surface Quality ◽  
Cutting Tool ◽  
Hardened Steel ◽  
Cutting Conditions ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
The Given ◽  
Machined Surfaces ◽  
Thermally Treated

This article describes the evaluation of machined material roughness in speed turning on a machining centre Doosan Puma 700 LY. The machined surface of semi-finished products from steel 14 260 was compared at selected cutting conditions. A half of compared samples from steel 14 260 was in the original, thermally untreated condition (mild steel), and the second half of samples was thermally treated (hardened steel, with a hardness of samples 50 HRC). The experiment focused on turning the selected samples in order to evaluate the roughness of machined surfaces. Cutting tool shift was variable during individual measurements. This experiment contributes to a quick orientation in the given issue and points out to optimisation of cutting conditions.

Understanding Deformation on Machined Surfaces

2014 ◽  
Author(s):  
Yang Guo ◽  
Dinakar Sagapuram ◽  
Anirban Mahato ◽  
Rachid M’Saoubi ◽  
Kevin P. Trumble ◽  
...  
Keyword(s):  
High Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Surface Strain ◽  
Deformation History ◽  
Machined Surface ◽  
Multi Scale ◽  
Scale Modeling ◽  
Multi Scale Modeling ◽  
Machined Surfaces

The deformation history and state of machined surface in cutting of metals are characterized using high-speed image analysis, complemented by hardness, microstructure and texture measurements. Large surface strains are observed, due to the severe plastic deformation (SPD) intrinsic to chip formation. The deformation history and microstructure/texture of the chip and surface are found to be equivalent. The surface strain distribution is shown to scale with undeformed chip thickness and influenced by the rake angle. Based on the observations, and related prior work on process-microstructure-property correlations, a framework is suggested for controlling deformation levels, microstructure and texture on machined surfaces. The results offer scope also for validation of machining simulations and multi-scale modeling of machining.

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