Sensor design and evaluation for on-machine probing of extruded tool joints

This paper describes the design and evaluation of two contact probes used to measure the length and bore concentricity of cylindrical, extruded tool joints while clamped in a production lathe spindle. The probes consisted of an LVDT, a spring-preloaded shaft supported by linear bearings used to isolate the LVDT from side loads, and a hardened steel sphere to contact the rough surface. For bore concentricity measurements, a parallelogram leaf-type flexure and 45° surface was used to transfer radial deviations to the spindle/part/LVDT axis. The LVDT output was used in conjunction with the lathe turret position to determine the extruded part dimensions prior to machining. Experimental results are provided for measurements of multiple parts; variations in length, internal diameter, and bore concentricity are compared to the nominal dimensions. Additionally, a calibration artifact is described which enabled evaluation of the measurement accuracies for the two probes. Given the pre-machining part dimensions, it is shown how this information can be used to select from a pre-defined matrix of part programs to reduce cycle time and machining cost.