On-machine measurement of microtool wear and cutting edge chipping by using a diamond edge artifact |
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| Affiliation: | 1. Department of Nanomechanics, Tohoku University, Sendai 980-8579, Japan;2. The State Key Lab of Fluid Power Transmission and Control, Zhejiang University, Hangzhou 310027, China;1. The State Key Laboratory of Fluid Power Transmission and Control, Zhejiang University, Hangzhou 310027, PR China;2. Graduate School of Engineering, Tohoku University, Aoba 6-6-01, Aramaki, Aoba-ku, Sendai 980-8579, Japan;3. Engineering Management 3, Nanjing Audit University, Nanjing 210000, PR China;1. State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou, 310027, PR China;2. State Key Laboratory of Precision Measuring Technology and Instruments, Centre of MicroNano Manufacturing Technology, Tianjin University, 300072, PR China;3. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, J.S., 210094, PR China;1. Department of Mechanical Engineering, National Kaohsiung University of Science and Technology, Taiwan;2. Department of Mechatronics Engineering, National Kaohsiung University of Science and Technology, No. 1, University Rd., Yanchao 824, Kaohsiung, Taiwan |
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| Abstract: | This paper presents precision on-machine measurement of microwear and microcutting edge chipping of the diamond tool used in a force sensor integrated fast tool servo (FS-FTS) mounted on a three-axis diamond turning machine. A diamond edge artifact with a nanometric sharpness is mounted on the machine spindle with its axis of rotation along the Z-axis to serve as a reference edge artifact. The diamond tool is placed in the tool holder of the FS-FTS to generate cutting motion along the Z-axis. By moving the X-slide on which the FS-FTS is mounted, the reference edge can be scanned by the diamond tool. During the scanning, the Z-directional position of the tool is closed-loop controlled by the FS-FTS in such a way that the contact force between the tool tip and the reference edge is kept constant based on the force sensor output of the FS-FTS. The tool edge contour can be obtained from the scan trace of the tool tip, whose X- and Z-directional coordinates are provided by the output of the linear encoder of the X-slide and that of the displacement sensor in the FS-FTS, respectively. Since the reference edge artifact has a good hardness and a nanometric sharpness to ensure the lateral resolution of measurement, a microwear on the cutting edge of the diamond tool can be indentified from the measured tool edge contour. Experiments of on-machine measurement of tool edge contour and microtool wear are carried out to demonstrate the feasibility of the proposed system. |
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| Keywords: | On-machine measurement Cutting edge contour Diamond tool Wear Fast tool servo Force sensor Cutting force |
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