Extension of the displacement method by measuring reference pieces using multiple sensors for on-machine surface profile measurement

Yasutake Haramiishi; Yuzairi Abdul Rahim; Tsuyoshi Shimizu; Takaaki Ishii; Mohd Fadzil Ali Ahmad; Hiromi Watanabe

doi:10.15282/jmes.18.3.2024.9.0806

Authors

Yasutake Haramiishi Faculty of Mechatronics, University of Yamanashi, Yamanashi 4008511, Japan. Phone: +81552208445, Fax.: +81552208445
Yuzairi Abdul Rahim Faculty of Mechanical Engineering and Technology, Universiti Malaysia Perlis, Pauh Putra Campus, 02600 Arau, Perlis, Malaysia
Tsuyoshi Shimizu Faculty of Mechatronics, University of Yamanashi, Yamanashi 4008511, Japan. Phone: +81552208445, Fax.: +81552208445
Takaaki Ishii Faculty of Mechatronics, University of Yamanashi, Yamanashi 4008511, Japan. Phone: +81552208445, Fax.: +81552208445
Mohd Fadzil Ali Ahmad Faculty of Manufacturing and Mechatronic Engineering Technology, Universiti Malaysia Pahang Al-Sultan Abdullah, 26600 Pekan, Pahang, Malaysia
Hiromi Watanabe Faculty of Mechatronics, University of Yamanashi, Yamanashi 4008511, Japan. Phone: +81552208445, Fax.: +81552208445

DOI:

https://doi.org/10.15282/jmes.18.3.2024.9.0806

Keywords:

On machine measurement, Displacement method, Surface profile, Motion error, Error compensation, Error budget

Abstract

On-machine measurement is crucial in industrial production because it allows the measurement of the surface properties of products without having to remove them from the machine tool; however, measurement results are superimposed with the motion error caused by the table traverse. Therefore, eliminating motion errors is this field's main objective. This paper discusses measuring a surface profile using an extension of the displacement method to eliminate motion errors. The displacement method can separate the surface profile and motion error of the stages in measurement results; however, it introduces a specific cumulative error. The tolerance of the accumulated error was first investigated by simulating a one-axis measurement. The displacement method was extended to a two-axis stage to measure the surface profile and correct the stage tilt to each axis. Moreover, carbon steel finished using a face mill was measured in the experiments, and a coordinate measuring machine was used to compare the results with those of the extended displacement method. It was found that the extended displacement method was able to remove the motion error. Applying the displacement method resulted in an improvement of approximately 88.9%. Error analyses were also formulated and evaluated for sensor drift, reference piece measurement, motion error, table rotation, and thermal expansion, and the percentage of these errors in the total was clarified. The results showed that the motion error and table rotation for the y-axis of the prototype experimental apparatus were larger than the others. These errors are discussed to analyze each error and listed in the error budget. The proposed extended displacement method can eliminate motion errors despite the simplicity of the measurement principle and can be easily integrated into machine tools and other tables.

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