Abstract
On-machine measurement is being used increasingly to inspect the features of machined components without removing the workpiece from the machine tool. In the present work, a laser displacement sensor is integrated on a machine tool to measure the elementary features of a step, hole, cylinder, and plane. An iterative calibration method is introduced to obtain the position and direction of the sensor accurately, and data processing is performed for filtration and edge recognition. The accuracy and uncertainty of detecting the characteristic parameters of height, diameter, roundness, and flatness by the laser-based on-machine measurement are evaluated and are compared with those of a mechanical probe. Furthermore, the capability of the on-machine measurement process on the adopted machine tool is assessed according to ISO 22514-7. The results show that the difference between the calibrated and actual sphere center is reduced to 4.7 μm after five iterations. The on-machine measurement by the mechanical probe is more accurate, while that by the laser displacement sensor is more efficient. The uncertainties of the two methods are evaluated as being in the ranges of 2.4–3.7 μm and 4.8–5.8 μm, respectively. The accessible tolerances can be obtained to determine whether the machine tool is competent for requirement as a measuring device.
Similar content being viewed by others
Data availability
Not applicable.
Code availability
Not applicable.
References
Mutilba U, Gomez-Acedo E, Kortaberria G, Olarra A, Yagüe-Fabra JA (2017) Traceability of on-machine tool measurement: a review. Sensors 17:1605
Kim HS, Lee KI, Lee KM, Bang YB (2009) Fabrication of free-form surfaces using a long-stroke fast tool servo and corrective figuring with on-machine measurement. Int J Mach Tools Manuf 49:991–997
Chen FJ, Yin SH, Huang H, Ohmori H, Wang Y, Fan YF, Zhu YJ (2010) Profile error compensation in ultra-precision grinding of aspheric surfaces with on-machine measurement. Int J Mach Tools Manuf 50:480–486
Zhao JL, Sang Y, Duan FH, Ji XM (2019) Improvement of measurement resolution of a mechanical touch-trigger probe method for static radial runout measurements based on digital image correlation. Int J Adv Manuf Technol 105:3127–3136
Zou YY, Zuo KZ, Liu HH, Zhou DL (2020) Laser-based precise measurement of tailor welded blanks: a case study. Int J Adv Manuf Technol 107:3795–3805
Kolchinskiy V, Shih CH, Lo I, Roman R (2017) Refractive index measurement using the laser profile. Phys Procedia 86:176–180
Kondo Y, Hasegawa K, Kawamata H, Morishita T, Naito F (2012) On-machine non-contact dimension-measurement system with laser displacement sensor for vane-tip machining of RFQs. Nucl Instrum Meth A 667:5–10
Auerswald MM, Freyberg A, Fischer A (2019) Laser line triangulation for fast 3D measurements on large gears. Int J Adv Manuf Technol 100:2423–2433
Li XQ, Wang Z, Fu LH (2016) A laser-based measuring system for online quality control of car engine block. Sensors 16:1877
Ko TJ, Park JW, Kim HS, Kim SH (2007) On-machine measurement using a noncontact sensor based on a CAD model. Int J Adv Manuf Technol 32:739–746
Li D, Wang B, Tong Z, Blunt L, Jiang XQ (2019) On-machine surface measurement and applications for ultra-precision machining: a state-of-the-art review. Int J Adv Manuf Technol 104:831–847
Uekita M, Takaya Y (2016) On-machine dimensional measurement of large parts by compensating for volumetric errors of machine tools. Precis Eng 43:200–210
Nishikawa S, Ohno K, Mori M, Fujishima M (2014) Non-contact type on-machine measurement system for turbine blade. Procedia CIRP 24:1–6
Shiou FJ, Chen MJ (2003) Intermittent process measurement of a freeform surface profile with a circular triangulation laser prove on a machining center. Int J Adv Manuf Technol 21:365–376
Holub M, Jankovych R, Andrs O, Kolibal Z (2018) Capability assessment of CNC machining centers as measuring devices. Measurement 118:52–60
Li Z, Brand U, Ahbe T (2016) Step height measurement of microscale thermoplastic polymer specimens using contact stylus profulometry. Precis Eng 45:110–117
Abdullah AB, Sapuan SM, Samad Z (2015) Roundness error evaluation of cold embossed hole based on profile measurement technique. Int J Adv Manuf Technol 80:293–300
Yin LJ, Wang ZZ (2019) Measurement of the flatness or the shapes of mirrors by one-shot projection of structured light dot pattern. Results Phys 15:102594
Chen YL, Machida Y, Shimizu Y, Matsukuma H, Gao W (2018) A stitching linear-scan method for roundness measurement of small cylinders. CIRP Ann Manuf Technol 67:535–538
Ma S, Xie F, Wang YZ, Chen L (2015) A high precision step height measurement system of optical fiber multiplexed interferometry. Measurement 59:290–295
Lee NKS, Chow JKH, Chan ACK (2009) Design of precision measurement system for metallic hole. Int J Adv Manuf Technol 44:539–547
Mekid S, Vacharanukul K (2011) In-process out-of-roundness measurement probe for turned workpieces. Measurement 44:762–766
Kim WS, Raman S (2000) On the selection of flatness measurement points in coordinate measuring machine inspection. Int J Mach Tool Manu 40:427–443
Lu J, Cai ZQ, Yao B, Cai SJ, Ma XF, Liu WS (2020) Error compensation and accuracy analysis of laser measurement system based on laser-beam calibration. Int J Adv Manuf Technol 200:163272
Farahi N, Abolbashari M, Babaie J, Ziegert J, Farahi F (2019) On machine test of Inverse Projected-Fringe system for measurement of form deviation and surface profile of axisymmetric objects. Precis Eng 57:211–219
Sun CZ, Wang BS, Liu YM, Wang XM, Li CT, Wang HY, Tan JB (2019) Design of high accuracy cylindrical profile measurement model for low-pressure turbine shaft of aero engine. Aerosp Sci Technol 95:105442
Gallagher CV, Bruton K, Leahy K, O’Sullivan DTJ (2018) The suitability of machine learning to minimize uncertainty in the measurement and verification of energy savings. Energ Buildings 158:647–655
Vukašinović N, Bračun D, Možina J, Duhovnik J (2012) A new method for defining the measurement uncertainty model of CNC laser-triangulation scanner. Int J Adv Manuf Technol 58:1097–1104
Aggogeri F, Barbato G, Barini EM, Genta G, Levi R (2011) Measurement uncertainty assessment of Coordinate Measuring Machines by simulation and planned experimentation. CIRP J Manuf Sci Technol 4:51–56
Xiao GF, Li YT, Xia QX, Cheng XQ, Chen WP (2019) Research on the on-line dimensional accuracy measurement method of conical spun workpieces based on machine vision technology. Measurement 148:106881
Xu LM, Fan F, Zhang Z, Chao XJ, Niu M (2019) Fast on-machine profile characterization of grinding wheels and error compensation of wheel dressing. Precis Eng 55:417–425
Mutilba U, Sanda A, Vega I, Acedo EG, Bengoetxea I, Fabra JAY (2019) Traceability of on-MT measurement: Uncertainty budget assessment on shop floor conditions. Measurement 135:180–188
Mutilba U, Sanda A, Vega I, Acedo EG, Bengoetxea I, Fabra JAY (2019) Uncertainty assessment for on-MT measurement: An alternative approach to the ISO 15530-3 technical specification. Precis Eng 57:45–53
Lin PD, Liu TH (1996) Machining and dimensional inspection of spatial cams on 5-axis machine tools. Int J Adv Manuf Technol 12:356–365
Conte J, Majarena AC, Acero R, Santolaria J, Aguilar JJ (2015) Performance evaluation of laser tracker kinematic models and parameter identification. Int J Adv Manuf Technol 77:1353–1364
Díaz-Tena E, Ugalde U, López de Lacalle LN, de la Iglesia A, Calleja A, Campa FJ (2013) Propagation of assembly errors in multitasking machines by the homogenous matrix method. Int J Adv Manuf Technol 68:149–164
Iñigo B, Ibabe A, Aguirre G, Urreta H, de Lacalle LNL (2019) Analysis of laser tracker-based volumetric error mapping strategies for large machine tools. Metals 9:757
Olvera D, de Lacalle LNL, Compeán FI, Fz-Valdivielso A, Lamikiz A, Campa FJ (2012) Analysis of the tool tip radial stiffness of turn-milling centers. Int J Adv Manuf Technol 60:883–891
Alvarez A, Calleja A, Ortega N, de Lacalle LNL (2018) Five-axis milling of large spiral bevel gears: toolpath definition, finishing, and shape errors. Metal 8:353
Gonzalez H, Calleja A, Pereira O, Ortega N, de Lacalle LNL, Barton M (2018) Super abrasive machining of integral rotary components using grinding flank tools. Metal 8:24
Li HL (2015) Uncertainty models and its evaluation methods of dimension measurement results for CMM. Dissertation, Hefei University of Technology
Acedo EG, Olarra A, Orive J, Calle LNL (2013) Methodology for the design of a thermal distortion compensation for large machine tools based in state-space representation with Kalman filter. Int J Mach Tools Manuf 75:100–108
Ding YY, Zhang XB, Kovacevic R (2016) A laser-based machine vision measurement system for laser forming. Measurement 82:345–354
Funding
This work is partially supported by the National Natural Science Foundation of China (No. 51805258), Natural Science Foundation of Jiangsu Province (No. BK20180441), Fundamental Research Funds for Central Universities (No. NT2019016), National Science Foundation for Post-doctoral Scientists of China (No. 2019M661824), and Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology.
Author information
Authors and Affiliations
Contributions
Dawei Ding conceived research, collected data, analyzed the data, and wrote the manuscript. Zhengcai Zhao conceived research and participated in the writing of the manuscript. Yao Li participated analyzed the data. Yucan Fu conceived research and participated in the revising of the manuscript.
Corresponding author
Ethics declarations
Conflict of interest
Not applicable.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Ding, D., Zhao, Z., Li, Y. et al. Calibration and capability assessment of on-machine measurement by integrating a laser displacement sensor. Int J Adv Manuf Technol 113, 2301–2313 (2021). https://doi.org/10.1007/s00170-021-06676-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-06676-5