single-au.php

IJAT Vol.8 No.1 pp. 4-19
doi: 10.20965/ijat.2014.p0004
(2014)

Review:

In-Process and On-Machine Measurement of Machining Accuracy for Process and Product Quality Management: A Review

Yasuhiro Takaya

Department of Mechanical Engineering, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan

Received:
October 15, 2013
Accepted:
November 30, 2013
Online released:
January 5, 2014
Published:
January 5, 2014
Keywords:
in-process measurement, on-machine measurement, manufacturing metrology, machine tools, quality management
Abstract

In-process and on-machine measurements are used to evaluate a variety of machining factors and conditions as well as the work done on the machine tool. With the increasing complexity of machining processes and greater requirements for accuracy and precision, the demand for advanced methods for process optimization has also increased. To meet this demand, process quality management (QM) requires an expansion of manufacturing metrology to include comprehensive closed-loop control of the machining process. To eliminate the effects of disturbances on the machining process and adjust the control quantities to optimal values for robustness, in-process and on-machine measurements are very essential. In this paper, we review technical trends in in-process and on-machine measurements for process QM and conventional quality control (QC) of products. Spreading measurement targets and applications are comprehensively reviewed.

References
  1. [1] N. Taniguchi, “Current status in, and future trends of, ultraprecision machining and ultrafine materials processing,” Annals of CIRP, Vol.32, Issue 2, pp. 573-582, 1983.
  2. [2] M. Shiraishi, “Scope of in-process measurement, monitoring, and control techniques in machining processes – Part 1: In-process techniques for tools,” Precision Engineering, Vol.10, No.4, pp. 179-189, 1988.
  3. [3] M. Shiraishi, “Scope of in-process measurement, monitoring, and control techniques in machining processes – Part 2: In-process techniques for workpieces,” Precision Engineering, Vol.11, No.1, pp. 27-37, 1989.
  4. [4] M. Shiraishi, “Scope of in-process measurement, monitoring, and control techniques in machining processes – Part 3: In-process techniques for cutting ptocesses and machine tools,” Precision Engineering, Vol.11, No.1, pp. 39-47, 1989.
  5. [5] S. Ueno, “On machine measuring system for machine tools,” J. of the Japan Society for Precision Engineering, Vol.75, No.11, pp. 1269-1272, 2009. (in Japanese)
  6. [6] ISO 230-10, “Test code for machine tools – Part 10: Determination of the measuring performance of probing systems of numerically controlled machine tools,” 2011.
  7. [7] Y. Takaya, “Trend in In-Process &On-MachineMeasureemnt,” Mechanical Engineering, Vol.60, No.7, pp. 17-23, 2012. (in Japanese)
  8. [8] International Organization for Standardization, “Guide to Expression of Uncertainty of Measurement,” JCGM 100, 2008.
  9. [9] A. Weckenmann and M. Rinnagl, “Acceptance of processes: do we need decision rules?” Precision Engineering, Vol.24, pp. 264-269, 2000.
  10. [10] T. Kohno, M. Omoda, Y. Okazaki, N. Ozawa, and K. Mitsui, “Inprocess measurement and workpiece-refered form accuracy control (1st report) : Concept of the method and preliminary experiment,” J. of the Japan Society for Precision Engineering, Vol.54, No.8, pp. 1463-1468, 1988. (in Japanese)
  11. [11] T. Kohno, Y. Okazaki, N. Ozawa, K. Mitsui, and M. Omoda, “Inprocess measurement and a workpiece-referred form accuracy control system (WORFAC): concept of the method and preliminary experiment,” Precision Engineering, Vol.11, No.1, pp. 9-14, 1989.
  12. [12] Y. Uda, T. Kohno, and T. Yazawa, “In-process measurement and a workpiece-referred form accuracy control system (WORFAC): application to cylindrical turning using an ordinary lathe,” Precision Engineering, Vol.18, No.1, pp. 50-55, 1996.
  13. [13] T. Yazawa, T. Yamazaki, and T. Kohno, “In-process measurement and workpiece-refered form accuracy control (7th report) : Controlled cutting with reference surface for central part and expansion to periphery,” J. of the Japan Society for Precision Engineering, Vol.64, No.11, pp. 1689-1693, 1998. (in Japanese)
  14. [14] S. Ibaraki and W. Knapp, “Indirect Measurement of Volumetric Accuracy for Three-Axis and Five-Axis Machine Tools: A Review,” Int. J. of Automation Technology, Vol.6, No.2, pp. 110-124, 2012.
  15. [15] Y. Ihara, “Ball Bar Measurement on Machine Tools with Rotary Axes,” Int. J. of Automation Technology, Vol.6, No.2, pp. 180-187, 2012.
  16. [16] S. Ibaraki, Y. Kakino, T. Akai, N. Takayama, I. Yamaji, and K. Ogawa, “Identification of Motion Error Sources on Five-axis Machine Tools by Ball-bar Measurements (1st Report) – Classification ofMotion Error Components and Development of the Modified Ball Bar Device (DBB5) –,” J. of the Japan Society for Precision Engineering, Vol.76, No.3, pp. 333-337, 2010. (in Japanese)
  17. [17] T. Matsushita and A. Matsubara, “Identification and compensation of geometric errors in five-axis machine tools with a tilting rotary table using conic trajectories measured by double ball bar,” J. of the Japan Society for Precision Engineering, Vol.77, No.6, pp. 594-598, 2011. (in Japanese)
  18. [18] S. Aguado, J. Santolaria, D. Samper, and J. J. Aguilar, “Influence of measurement noise and laser arrangement on measurement uncertainty of laser tracker multilateration in machine tool volumetric verification,” Precision Engineering, 2013. (in-press)
  19. [19] T. Saiki, M. Tsutsumi, H. Suzuki, M. Kouya, and M. Ushio, “Development ofMeasurement for Motion Accuracy of 5 Axis NC Machine Tool,” Int. J. of Automation Technology, Vol.2, No.2, pp. 111-118, 2008.
  20. [20] E. Trapet, J.-J. Aguilar Martín, J.-A. Yagu, H. Spaan, V. Zelený, “Self-centering probes with parallel kinematics to verify machinetools,” Precision Engineering, Vol.30, pp. 165-179, 2006.
  21. [21] W. Gao, M. Tano, T. Araki, S. Kiyono, and C. H. Park, “Measurement and compensation of error motions of a diamond turning machine,” Precision Engineering, Vol.31, pp. 310-316, 2007.
  22. [22] T. Nomura, K. Yoshikawa, H. Tashiro, K. Takeuchi, N. Ozawa, Y. Okazaki, M. Suzuki, F. Kobayashi, and M. Usuki, “On machine shape measurement of workpiece surface with Fizeau interferometer,” Precision Engineering, Vol.14, No.3, pp. 155-159, 1992.
  23. [23] T. Nomura, H. Miyashiro, K. Kamiya, K. Yoshikawa, H. Tashiro, M. Suzuki, M. Usuki, and F. Kobayashi, “Shape measurement of workpiece surface with zone-plate interferometer during machine running,” Precision Engineering, Vol.15, No.2, pp. 86-92, 1993.
  24. [24] T. Nomura, K. Kamiya, H. Miyashiro, S. Okuda, H. Tashiro, and K. Yoshikawa, “Shape measurement of mirror surfaces with a lateral-shearing interferometer during machine running,” Precision Engineering, Vol.22, No.4, pp. 185-189, 1998.
  25. [25] T. Kohno, D. Matsumoto, T. Hosogoe, T. Yazawa, and Y. Uda, “Radial shearing interferometer for on-machine measurement,” J. of the Japan Society for Precision Engineering, Vol.65, No.3, pp. 443-446, 1999. (in Japanese)
  26. [26] T. Kohno, T. Yazawa, D. Saito, and S. Kohno, “Figure error control for diamond turning by in-process measurement,” Precision Engineering, Vol.29, pp. 391-395, 2005.
  27. [27] C. P. Keferstein, D. Honegger, H. Thurnherr, B. Gschwend, A. L. Cooke1, “Process monitoring in non-circular grinding with optical sensor,” Annals of the CIRP, Vol.57, No.1, pp. 533-536, 2008.
  28. [28] Y. Koike, D. Kono, A. Matsubara, and I. Yamaji, “In-situ measurement by using a measurement-fused machining system,” J. of the Japan Society for Precision Engineering, Vol.76, No.8, pp. 945-949, 2010. (in Japanese)
  29. [29] K. Furutani, K. Iwamoto, H. Takezawa, and N. Mohri, “Multiple degrees-of-freedom arm with passive joints for on-the-machine measurement system by calibrating with geometric solids,” Precision Engineering, Vol.23, pp. 113-125, 1999.
  30. [30] A. Katsuki, H. Onikura, T. Sajima, H. Murakami, T. Sato, T. Caetano, H. M. Ali, and O. Ohnishi, “Study on high-speed onmachine measurement of deep-hole accuracy,” J. of the Japan Society for Precision Engineering, Vol.77, No.7, pp. 681-687, 2011. (in Japanese)
  31. [31] A. Graziano, T. L. Schmitz, “Sensor design and evaluation for onmachine probing of extruded tool joints,” Precision Engineering, Vol.35, pp. 525-535, 2011.
  32. [32] H. Suzuki, J. Sugawara, M. Kondo, Y. Yamagata, S. Morita, T. Makino, K. Yoshida, and T. Higuchi, “Development of Ultra-Precision On-machine Aspherical Measurement System by Constant Contact Angle Scanning Method,” Die and Mold Technology, Vol.24, No.8, pp. 130-131, 2009. (in Japanese)
  33. [33] Y.Zi-qiang, L. Sheng-yi, “Exact straightness reconstruction for onmachine measuring precision workpiece,” Precision Engineering, Vol.29, pp. 456-466, 2005.
  34. [34] Y. Zi-qiang, L. Sheng-yi, “High accuracy error separation technique for on-machine measuring straightness,” Precision Engineering, Vol.30, pp. 192-200, 2006.
  35. [35] W. Gao, M. Tano, S. Sato, and S. Kiyono, “On-machine measurement of a cylindrical surface with sinusoidal micro-structures by an optical slope sensor,” Precision Engineering, Vol.30, pp. 274-279, 2006.
  36. [36] H. Sawano, M. Takahashi, H. Yoshioka, H. Shinno, and K. Mitsui, “On-Machine Optical Surface Profile Measuring System for Nano-Machining,” Int. J. of Automation Technology, Vol.5, No.3, pp. 369-376, 2011.
  37. [37] Y. Quinsat and C. Tournier, “In situ non-contact measurements of surface roughness,” Precision Engineering, Vol.36, pp. 97-103, 2012.
  38. [38] X. Jiang, “In situ real-time measurement for micro-structured surfaces,” Annals of the CIRP, Vol.60, No.1, pp. 563-566, 2011.
  39. [39] A. Taguchi, T. Miyoshi, Y. Takaya, and S. Takahashi, “Optical 3D profilometer for in-process measurement of microsurface based on phase retrieval technique,” Precision Engineering, Vol.28, pp. 152-163, 2004.
  40. [40] T. Asai, S. Ferdous, Y. Arai, Y. Yang, and W. Gao, “On-Machine Measurement of Tool Cutting Edge Profiles,” Int. J. of Automation Technology, Vol.3, No.4, pp. 408-414, 2009.
  41. [41] T. Asai, Y. Arai, and W. Gao, “A Precision Instrument for 3D Edge Profile Measurement of Single Point Diamond Micro-Cutting Tools,” J. of the Japan Society for Precision Engineering, Vol.75, No.7, pp. 892-896, 2009. (in Japanese)
  42. [42] P. Khajornrungruang, K. Kimura, Y. Takaya, and K. Suzuki, “High Precision Tool Cutting Edge Monitoring Using Laser Diffraction for On-Machine Measurement,” Int. J. of Automation Technology, Vol.6, No.2, pp. 163-167, 2012.
  43. [43] K. Furutani, N. T. Hieu, N. Ohguro, and T. Nakamura, “Automatic compensation for grinding wheel wear by pressure based in-process measurement in wet grinding,” Precision Engineering, Vol.27, pp. 9-13, 2003.
  44. [44] K. Narukawa and T. Kawai, “Development of cutting force measurement technique for milling process with small diameter end mill,” J. of the Japan Society for Precision Engineering, Vol.76, No.7, pp. 814-818, 2010. (in Japanese)
  45. [45] K. Kasahara, Y. Tanaka, and A. Hirota, “Analysis of tool deflection and mechanism of surface generation in ball end milling of an inclined surface (2nd Report): – On the properties of machined surface and machining error caused with tool deflection –,” J. of the Japan Society for Precision Engineering, Vol.76, No.8, pp. 901-906, 2010. (in Japanese)
  46. [46] S. Yoshimitsu, S. Satonaka, Y. Kawano, D. Zuo, and S. Yamashita, “Two-dimensional monitoring system for tool behavior in end milling with small diameter tool,” J. of the Japan Society for Precision Engineering, Vol.77, No.9, pp. 889-894, 2011. (in Japanese)
  47. [47] T. Yamamoto, M. Yauchi, and K. Nagai, “The function of a Tool Measuring Instrument with CCD Camera,” J. of Die and Mold Technology, Vol.25, No.12, pp. 26-27, 2010. (in Japanese)
  48. [48] Y. Sato, “Sample Case of High Accuracy Measurement on Machine by Optical Type Tool Measurement System,” J. of Die and Mold Technology, Vol.26, No.12, pp. 28-29, 2011. (in Japanese)
  49. [49] Y. Takeyasu, H. Sasaki, M. Mondo, and T. Tsutsumoto, “Stopmotion-monitoring of Rotating Machine Tool using Synchronized Flash Light,” J. of Die and Mold Technology, Vol.26, No.12, pp. 30-31, 2011. (in Japanese)
  50. [50] A. Matsubara and S. Ibaraki, “Monitoring and Control of Cutting Forces in Machining Processes: A Review,” Int. J. of Automation Technology, Vol.3, No.4, pp. 445-456, 2009.
  51. [51] R. Arai, N. Morita, T. Nishi, Y. Choushu, K. Oguchi, N. Takei, S. Nakayama, and T. Tanaka, “Development of sensor built-in spindle for micro drilling with a detection mechanism of cutting force,” J. of the Japan Society for Precision Engineering, Vol.77, No.10, pp. 944-949, 2011. (in Japanese)
  52. [52] E. R. Marsha, A. W. Moerleina, T. R. S. Deakynea, and M. J. VanDoren, “In-process measurement of form error and force in cylindrical-plunge grinding,” Precision Engineering, Vol.32, pp. 348-352, 2008.
  53. [53] H. Yoshioka, M. Hayashi, and H. Shinno, “Status Monitoring of Ultraprecision Machining Using Micro Thermo Sensor and AE Sensor,” Int. J. of Automation Technology, Vol.3, No.4, pp. 422-427, 2009.
  54. [54] M. A. Davies, T. Ueda, R. M’Saoubi, B.Mullany, and A. L. Cooke1, “On The Measurement of Temperature in Material Removal Processes,” Annals of the CIRP, Vol.56, No.2, pp. 581-604, 2007.
  55. [55] D. Stoebener1 and M. Dijkman, “An Ultrasound In-Process-Measuring System to Ensure a Minimum Roundness Deviation for Rings During Turning,” Annals of the CIRP, Vol.56, No.1, pp. 513-516, 2007.
  56. [56] D. Kono, A. Matsubara, Y. Koike, and I. Yamaji, “Measurement of the copying rate of tool edge motions by using ameasurement-fused machining system,” J. of the Japan Society for Precision Engineering, Vol.75, No.4, pp. 520-524, 2009. (in Japanese)
  57. [57] K. Inagaki, N. Morita, K. Ashida, and J. Saito, “Study for development of nano-machining and measurement system of machining center type,” J. of the Japan Society for Precision Engineering, Vol.74, No.11, pp. 1176-1181, 2008. (in Japanese)
  58. [58] E. Manske, G. Jager, and T. Hausotte, “Combination of multi sensor technology and multiple measurement strategies in micro- and nanometrology,” Proc. of the 10th Int. Symp. on Measurement and Quality Control, pp. D6-075-1, 2010.
  59. [59] P. Yanga, T. Takamura, S. Takahashi, K. Takamasua, O. Sato, S. Osawa, and T. Takatsuji, “Multi-probe scanning system comprising three laser interferometers and one autocollimator for measuring flat bar mirror profile with nanometer accuracy,” Precision Engineering, Vol.35, pp. 686-692, 2011.
  60. [60] A. Weckenmann, “The role of metrology in the exchange of goods and in the development of manufacturing technologies,” Proc. of the 10th Int. Symp. on Measurement and Quality Control, pp. 1-4, 2010.

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, IE9,10,11, Opera.

Last updated on Mar. 28, 2017