Ultra precision process monitoring

In modern applications the needs for highly advanced components with very precise contour accuracy and surface quality are rapidly increasing. To meet the demands for enhanced products, production machines and processes have to be improved with respect to not only the high aims for precision, but also issues of standardization and quality management. In this context process monitoring becomes a key technology to achieve a better understanding of ultra-precision machining and to enable process continuity, quality management and documentation. At Fraunhofer IPT a precision process monitoring system has been developed combining data acquisition, analysis, storage and visualization into one integrated system. The in-process sensor data is mapped onto a virtual tool path generated using the linear scale positions of the machine tool within the process monitoring system. Monitoring the sensor data in 3D with regard to time and location of its acquisition enables variable eval uation possibilities far beyond the state-of-the-art time plot or spectrum analysis methods.