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Work Coordinate Setup in the Ultra-precision Machine Tool Using Electrical Breakdown

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Abstract

Work coordinate setup in an ultra-precision machine tool is one of the important tasks to fabricate a structure at the desired position with high accuracy. Setting up the work coordinate is very challenging because it requires high precision, direct measurement, and non-contact preferred. This paper proposes a new method to measure the relative distance between tool-work materials using the electrical breakdown where current flows through electrical insulator when an applied voltage is higher than the breakdown voltage. The applied voltage is linearly proportional to the relative distance in nanoscale. Experiment with Al6061, SS316, AISI1018 steel, and OFHC Cu work materials, and WC and CBN tools showed a successful and easy application of this method in work coordinate setup with 70 nm uncertainty at low applied voltage. Surface damages by the electrical breakdown of Al6061, SS316, AISI1018 steel, and OFHC Cu were not found at less than or equal to 1, 2, and 3 V, respectively. An automated detection test was conducted and found approaching speed of 0.1 mm/min without surface damage. Standard uncertainty analysis validated the confidence of the proposed method.

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Acknowledgements

Authors gratefully acknowledge the help of Dr. Edward Hwang and kind support from the FANUC Corporation, Japan, for the loan of the ROBONANO α-0iB, one of the latest ultra-precision machine tool, to MIN LAB at UW-Madison. This work also was supported by the Hongik University new faculty research fund.

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Authors and Affiliations

  1. Mechanical and System Design Engineering, Hongik University, Seoul, 04066, South Korea

    Sangjin Maeng

  2. School of Mechanical Engineering, University of Wisconsin, Madison, WI, 53706, USA

    Sangkee Min

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Correspondence to Sangkee Min.

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Maeng, S., Min, S. Work Coordinate Setup in the Ultra-precision Machine Tool Using Electrical Breakdown. Int. J. Precis. Eng. Manuf. 24, 745–753 (2023). https://doi.org/10.1007/s12541-023-00779-7

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  • DOI: https://doi.org/10.1007/s12541-023-00779-7

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