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5D precision process monitoring

: Brecher, C.; Lindemann, D.; Merz, A.; Wenzel, C.

Blunt, L. ; European Society for Precision Engineering and Nanotechnology -EUSPEN-:
Laser metrology and machine performance X : 10th International Conference and Exhibition on Laser Metrology, Machine Tool, CMM & Robotic Performance, Lamdamap 2013. 20 - 21 March 2013, Chicheley Hall, Newport Pagnell, Bucks, Buckinghamshire, UK
Cranfield: Euspen, 2013
ISBN: 978-0-9566790-1-7
International Conference and Exhibition on Laser Metrology, Coordinate Measuring Machine and Machine Tool Performance (LAMDAMAP) <10, 2013, Newport Pagnell>
Fraunhofer IPT ()

Process monitoring, well established for standard machine tools, currently becomes more important for ultra-precision processes as the demands for process reliability, production continuity and quality management rise steadily. In this context, state-of-the-art process monitoring methods have to be carefully adapted to the high requirements of ultra-precision components and the according manufacturing processes. Acoustic emission sensors have proven a reliable, easy to integrate and very sensitive technology to detect effects of tool wear, machining dynamics or material inhomogeneity. Nevertheless, the acquired data has to be intensively processed to allow for a suitable evaluation. State-of-the-art method use data filtering, Fourier transform or image processing algorithms to generate evaluation criteria for the determined processes, trying to allow for automated process estimation. In contrast to these time or spectrum plots, the Fraunhofer IPT approach adds the position information captured by the linear scales of the machine tool to the evaluation algorithms. In this manner, the sensor data can be visualized not only time-based but locally associated to the tool path of the manufactured workpiece. Hence, an online evaluation by the machine operator can be performed intuitively while the precision part is being machined. The paper presents the process monitoring approach, the hardware and software concepts and first experimental results.