Quick On-Machine Measurement of Ground Surface Finish Available for Mass Production Cylindrical Grinding Processes

Kazuhito Ohashi; Kazuya Tan; Tomoya Ashida; Shinya Tsukamoto

doi:10.20965/ijat.2015.p0176

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IJAT Vol.9 No.2 pp. 176-183

doi: 10.20965/ijat.2015.p0176

(2015)

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Quick On-Machine Measurement of Ground Surface Finish Available for Mass Production Cylindrical Grinding Processes

Kazuhito Ohashi, Kazuya Tan, Tomoya Ashida, and Shinya Tsukamoto

Okayama University
3-1-1 Tsushima-Naka, Kita-ku, Okayama 700-8530, Japan

Received:

October 20, 2014

Accepted:

February 5, 2015

Published:

March 5, 2015

Keywords:

surface finish, cylindrical grinding, on-machine measurement, electromotive force, mass-production

Abstract

In mass production cylindrical grinding operations, the ground surface finish has never been measured in each grinding cycles because existing surface roughness testers take a relatively long time to measure surface finishes, and the introduction of a surface roughness tester in each grinding cycle would affect mass production processes. Therefore, the surface finish of all parts manufactured in a production lot is generally evaluated based on the measured results of only few parts by sampling checks. We have proposed a unique quick technique for measuring surface roughness. It uses electromotive force based on the slight frictional heat to evaluate the surface finish of cylindrical workpieces rotating on cylindrical grinding machines, and it can do this in a split second just after each grinding cycle, so it does not hamper mass production grinding processes. The proposed quick measurement system can capture the variations in surface finish in a set of repeated cylindrical grinding cycles without dressing. The possibility of accurate judging dressing time by using the quick measurement system in mass production grinding processes is shown experimentally.

Cite this article as:

K. Ohashi, K. Tan, T. Ashida, and S. Tsukamoto, “Quick On-Machine Measurement of Ground Surface Finish Available for Mass Production Cylindrical Grinding Processes,” Int. J. Automation Technol., Vol.9 No.2, pp. 176-183, 2015.

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References

[1] T. Nakajima and N. Narutaki, “Machining Technology,” Corona Publishing Co., Ltd., Tokyo, p. 7, 1983. (in Japanese)
[2] Y. Takaya, “In-Process and On-Machine Measurement of Machining Accuracy for Process and Product Quality Management: A Review,” Int. J. of Automation Technology, Vol.8, No.1, pp. 4-19, 2014.
[3] T. Hirose, Y. Kami, T. Shimizu, M. Yabuya, and Y. Morimoto, “Development of On-Machine Measurement Unit for Correction Processing of Aspheric Lens Mold with High Numerical Aperture,” Int. J. of Automation Technology, Vol.8, No.1, pp. 34-42, 2014.
[4] S. A. Coker, S. J. Oh, and Y. C. Shin, “In-Process Monitoring of Surface Roughness Utilizing Ultrasound,” Trans. ASME J. Manuf. Sci. Eng., Vol.120, No.1, pp. 197-200, 1998.
[5] Y. C. Shin, S. J. Oh, and S. A. Coker, “Surface Roughness Measurement by Ultrasonic Sensing for In-Process Monitoring,” Trans. ASME J. Eng. Ind., Vol.117, No.3, pp. 439-447, 1995.
[6] B. Bridge and G. J. Bollini, “The effect of surface roughness on ultrasonic backscatter monitoring of intrinsic (subsurface) structure,” Br. J. Non-Destr. Test, Vol.29, No.4, pp. 228-237, 1987.
[7] M. Adach, T. Inari, and M. Kamei, “Monitoring of Roughness Profile of Metal Surface Using Diffuse Reflection of Laser Light,” J. Soc. Instrum. Control. Eng., Vol.20, No.2, pp. 536-541, 1984. (in Japanese)
[8] T. Yoshimura, E. Miyazaki, and K. Nakanishi, “Monitoring surface roughness by means of doubly scattered image speckle,” Opt. Eng., Vol.32, No.6, pp. 1354-1359, 1993.
[9] T. S. Reddy, “On-line monitoring of tool wear and surface roughness by acoustic emission in CNC turning,” Int. J. Robot Autom., Vol.26, No.3, pp. 305-312, 2011.
[10] S. Tangjitsitcharoen, “Intelligent Monitoring and Estimation of Surface Roughness on CNC Turning,” Key Eng. Mater., Vol.443, pp. 376-381, 2010.
[11] M. Shiraishi and H. Sumiya, “Surface Roughness Monitoring and Dimensional Error Control in Turning by Quasi-Sensor Fusion,” Proc. Am. Control Conf., Vol.1995, No.3, pp. 1727-1731, 1995.
[12] W. Lin, B. Lee, and H. Chen, “Monitoring Surface Roughness of Turning by Using Image Processing Technology,” Mater. Sci. Forum, Vol.532/533, pp. 1164-1167, 2006.
[13] S. Varghese and V. Radhakriahnan, “A multi sensor approach to in-process monitoring of surface roughness,” J. Mater. Process Technol., Vol.44, No.3/4, pp. 353-362, 1994.
[14] C. S. Lee, S. W. Kim, and D. Y. Yim, “An in-process measurement technique using laser for non-contact monitoring of surface roughness and form accuracy of ground surfaces,” CIRP Ann. (Int. Inst. Prod. Eng. Res.), Vol.36, No.1, pp. 425-428, 1987.
[15] J. G. Valliant, M. P. Foley, and J. M. Bennett, “Instrument for on-line monitoring of surface roughness of machined surfaces,” Opt. Eng., Vol.39, No.12, pp. 3247-3254, 2000.
[16] M. S. Sodhi and K. Tiliouine, “Surface roughness monitoring using computer vision,” Int. J. Mach. Tools Manuf., Vol.36, No.7, pp. 817-828, 1996.
[17] J. A. Leather, “On-line monitoring of surface roughness,” Int. Conf. Adv. Surf. Coating Technol., No.1, pp. 81-86, 1978.
[18] F. Kobayashi, F. Arai, and T. Fukuda, “Intelligent Monitoring System for Grinding Process by Recurrent Fuzzy Inference. Evaluation of Inferred Surface Roughness Using Degree of Fuzziness,” J. Robot Mechatron, Vol.11, No.5, pp. 423-430, 1999.
[19] E. Saljé, “Rauheitsmessung Beim Schleifen verbessert Steuermöglichke,” Maschinenmarkt iten, Vol.84, No.58, pp. 1156-1157, 1978.
[20] Y. Ito and T. Moriwaki, “Machine Tool Engineering,” Corona Publishing Co., Ltd., Tokyo, p. 161, 1989. (in Japanese)
[21] K. Ohashi, R. Nagata, S. Tsukamoto, and H. Hasegawa, “Novel On-Machine Measurement of Surface Finish with Thermoelectric Effect for Rotating Ground Workpiece,” Advance in Abrasive Technology, Vol.X, pp. 519-526, 2007.
[22] T. Nanajima, S. Tsukamoto, and M. Yoshikawa, “Effects of Water Soluble Type Grinding Fluids (3^rd Report) – Relations between Cooling and Lubricant Actions of Surface Active Agents and Grinding Results –,” J. Jpn. Soc. Precis. Eng., Vol.54, No.2, pp. 414-419, 1988. (in Japanese)

This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

[1] [1] T. Nakajima and N. Narutaki, “Machining Technology,” Corona Publishing Co., Ltd., Tokyo, p. 7, 1983. (in Japanese)

[2] [2] Y. Takaya, “In-Process and On-Machine Measurement of Machining Accuracy for Process and Product Quality Management: A Review,” Int. J. of Automation Technology, Vol.8, No.1, pp. 4-19, 2014.

[3] [3] T. Hirose, Y. Kami, T. Shimizu, M. Yabuya, and Y. Morimoto, “Development of On-Machine Measurement Unit for Correction Processing of Aspheric Lens Mold with High Numerical Aperture,” Int. J. of Automation Technology, Vol.8, No.1, pp. 34-42, 2014.

[4] [4] S. A. Coker, S. J. Oh, and Y. C. Shin, “In-Process Monitoring of Surface Roughness Utilizing Ultrasound,” Trans. ASME J. Manuf. Sci. Eng., Vol.120, No.1, pp. 197-200, 1998.

[5] [5] Y. C. Shin, S. J. Oh, and S. A. Coker, “Surface Roughness Measurement by Ultrasonic Sensing for In-Process Monitoring,” Trans. ASME J. Eng. Ind., Vol.117, No.3, pp. 439-447, 1995.

[6] [6] B. Bridge and G. J. Bollini, “The effect of surface roughness on ultrasonic backscatter monitoring of intrinsic (subsurface) structure,” Br. J. Non-Destr. Test, Vol.29, No.4, pp. 228-237, 1987.

[7] [7] M. Adach, T. Inari, and M. Kamei, “Monitoring of Roughness Profile of Metal Surface Using Diffuse Reflection of Laser Light,” J. Soc. Instrum. Control. Eng., Vol.20, No.2, pp. 536-541, 1984. (in Japanese)

[8] [8] T. Yoshimura, E. Miyazaki, and K. Nakanishi, “Monitoring surface roughness by means of doubly scattered image speckle,” Opt. Eng., Vol.32, No.6, pp. 1354-1359, 1993.

[9] [9] T. S. Reddy, “On-line monitoring of tool wear and surface roughness by acoustic emission in CNC turning,” Int. J. Robot Autom., Vol.26, No.3, pp. 305-312, 2011.

[10] [10] S. Tangjitsitcharoen, “Intelligent Monitoring and Estimation of Surface Roughness on CNC Turning,” Key Eng. Mater., Vol.443, pp. 376-381, 2010.

[11] [11] M. Shiraishi and H. Sumiya, “Surface Roughness Monitoring and Dimensional Error Control in Turning by Quasi-Sensor Fusion,” Proc. Am. Control Conf., Vol.1995, No.3, pp. 1727-1731, 1995.

[12] [12] W. Lin, B. Lee, and H. Chen, “Monitoring Surface Roughness of Turning by Using Image Processing Technology,” Mater. Sci. Forum, Vol.532/533, pp. 1164-1167, 2006.

[13] [13] S. Varghese and V. Radhakriahnan, “A multi sensor approach to in-process monitoring of surface roughness,” J. Mater. Process Technol., Vol.44, No.3/4, pp. 353-362, 1994.

[14] [14] C. S. Lee, S. W. Kim, and D. Y. Yim, “An in-process measurement technique using laser for non-contact monitoring of surface roughness and form accuracy of ground surfaces,” CIRP Ann. (Int. Inst. Prod. Eng. Res.), Vol.36, No.1, pp. 425-428, 1987.

[15] [15] J. G. Valliant, M. P. Foley, and J. M. Bennett, “Instrument for on-line monitoring of surface roughness of machined surfaces,” Opt. Eng., Vol.39, No.12, pp. 3247-3254, 2000.

[16] [16] M. S. Sodhi and K. Tiliouine, “Surface roughness monitoring using computer vision,” Int. J. Mach. Tools Manuf., Vol.36, No.7, pp. 817-828, 1996.

[17] [17] J. A. Leather, “On-line monitoring of surface roughness,” Int. Conf. Adv. Surf. Coating Technol., No.1, pp. 81-86, 1978.

[18] [18] F. Kobayashi, F. Arai, and T. Fukuda, “Intelligent Monitoring System for Grinding Process by Recurrent Fuzzy Inference. Evaluation of Inferred Surface Roughness Using Degree of Fuzziness,” J. Robot Mechatron, Vol.11, No.5, pp. 423-430, 1999.

[19] [19] E. Saljé, “Rauheitsmessung Beim Schleifen verbessert Steuermöglichke,” Maschinenmarkt iten, Vol.84, No.58, pp. 1156-1157, 1978.

[20] [20] Y. Ito and T. Moriwaki, “Machine Tool Engineering,” Corona Publishing Co., Ltd., Tokyo, p. 161, 1989. (in Japanese)

[21] [21] K. Ohashi, R. Nagata, S. Tsukamoto, and H. Hasegawa, “Novel On-Machine Measurement of Surface Finish with Thermoelectric Effect for Rotating Ground Workpiece,” Advance in Abrasive Technology, Vol.X, pp. 519-526, 2007.

[22] [22] T. Nanajima, S. Tsukamoto, and M. Yoshikawa, “Effects of Water Soluble Type Grinding Fluids (3^rd Report) – Relations between Cooling and Lubricant Actions of Surface Active Agents and Grinding Results –,” J. Jpn. Soc. Precis. Eng., Vol.54, No.2, pp. 414-419, 1988. (in Japanese)