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A machine vision based on-machine inspection system in PCD tool manufacturing

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Abstract

Polycrystalline diamond (PCD) milling tools are widely used in industry because of their outstanding hardness and durability. Although on-machine inspection of PCD tools in cutting edge manufacturing can reduce repeated clamping errors and shorten the manufacturing time compared with offline inspection, on-machine dimension measuring is challenging due to possible damage to cutting edges by contact probes. To solve this problem, this paper developed an on-machine inspection system for cutting edge dimensions of PCD tools before edge machining. First, a method to obtain the surface of rotation (SOR) generatrix of a single cutting edge is established based on the properties of the rake and flank faces of PCD tools. Then, the shapes and dimensions of the cutting edges are calculated based on the axis equation of the tool shank after extracting the shank and the SOR generatrix. Finally, experiments are conducted on different types of PCD cutting tools for system validation. The results show that the maximum diameter error of the proposed system is 0.86% for a calibration ball and 2.59% for different PCD tools. Experimental results validate the potential of the proposed on-machine inspection system.

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Funding

Support for the study was provided by the Research Fund (20202000479).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Yushun Zhang & Fuzhu Han

  2. Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipment and Control, Tsinghua University, Beijing, 100084, China

    Yushun Zhang & Fuzhu Han

Authors
  1. Yushun Zhang
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  2. Fuzhu Han
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Contributions

Yushun Zhang: conceptualization, methodology, experiment, data curation and analysis, validation, writing—original draft preparation, writing—review and editing; Fuzhu Han: supervision, project administration, funding acquisition.

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Correspondence to Fuzhu Han.

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Zhang, Y., Han, F. A machine vision based on-machine inspection system in PCD tool manufacturing. Int J Adv Manuf Technol 128, 4153–4168 (2023). https://doi.org/10.1007/s00170-023-12041-5

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