Title: Integrated inspection and process control for machining a circular contour on a two-axis vertical turning lathe

Authors: A.H. Chen, T.R. Kurfess

Addresses: Georgia Institute of Technology, Atlanta, GA 30332, USA. ' Clemson University, Clemson, SC 29634, USA.

Abstract: This paper examines the integration of readily available commercial hardware into a simple methodology for machine tool performance enhancement through process-intermittent inspection, process stability monitoring, and tool path compensation. Workpiece-specific process-intermittent inspection is performed on-machine and is calibrated using a simple spherical artifact. The developed methodology focuses on integrating the use of readily available commercial hardware. The on-machine probe is used for process-intermittent workpiece inspection and for process monitoring, while the ball bar is used for preliminary assessment of machine tool|s ability to compensate for motion and positioning errors. The methodology uses on-machine inspection of initial machining operations to generate compensation trajectories, which are then implemented during the second machining operation. Cutting tests using the developed methodology are performed on an Okuma & Howa V40R two-axis vertical turning centre. The results show that the average absolute deviation of the machined contour of a hemispherical workpiece (90° circular tool path) is reduced to 2.54 µm (0.0001 in) as verified by a coordinate measuring machine.

Keywords: on-machine inspection; process-intermittent inspection; turning; vertical lathes; tool path compensation; spherical artifacts; precision machining; process control; process monitoring; circular contours; machine tool performance; performance enhancement; positioning errors; motion errors; machine tool accuracy; error compensation; CMM verification; coordinate measuring machines; integration; precision machining.

DOI: 10.1504/IJMR.2006.010707

International Journal of Manufacturing Research, 2006 Vol.1 No.1, pp.101 - 117

Published online: 19 Aug 2006 *

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