On-machine measurement of tool nose radius and wear during precision/ultra-precision machining

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On-machine measurement of tool nose radius and wear during precision/ultra-precision machining

Jiang Guo , Xing-Yu Wang , Yong Zhao , Chen-Yi Hou , Xu Zhu , Yin-Di Cai , Zhu-Ji Jin , Ren-Ke Kang

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (3) : 368 -381.

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Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (3) : 368 -381. DOI: 10.1007/s40436-022-00397-y

Article

On-machine measurement of tool nose radius and wear during precision/ultra-precision machining

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¹ Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, Liaoning, People’s Republic of China

² Ningbo Institute of Dalian University of Technology, Ningbo 315040, Zhejiang, People’s Republic of China

³ Key Laboratory for Micro/Nano Technology and System of Liaoning Province, Dalian University of Technology, Dalian 116024, Liaoning, People’s Republic of China

^h kangrk@dlut.edu.cn

Jiang Guo is a professor at Dalian University of Technology. He has been actively involved in precision machining-related research for over a decade. His research interests include ultra-precision machining, polishing, actuators, mechatronics, and neutron optics.

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Xing-Yu Wang is a master’s degree candidate at the Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education, Dalian University of Technology. His research interests focus on tool wear measurement technology.

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Yong Zhao is a Ph.D. candidate at the Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education, Dalian University of Technology. His research interest is surface engineering and hot-compression bonding.

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Chen-Yi Hou is currently a master candidate at the Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education, Dalian University of Technology, China. His research interests focus on tool wear measurement technology.

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Xu Zhu is a Ph.D. candidate at the Ningbo Institute of Dalian University of Technology. His research interest is hard and brittle materials ultra-precision machining technology.

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Yin-Di Cai is an associate professor at the Key Laboratory for Micro/Nano Technology and System of Liaoning Province,Dalian University of Technology. Her research interest is optical measurement technology.

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Zhu-Ji Jin is a professor at Dalian University of Technology. His main research interests focus on ultra-precision and non-traditional machining technology, and difficult-to-cut material high-precision machining technology.

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Ren-Ke Kang is a professor at Dalian University of Technology and the head of the Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education. His main research interests focus on ultra-precision and non-traditional machining technology, difficult-to-cut material high-precision machining technology, semiconductor machining technology and equipment, and digital manufacturing equipment.

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Abstract

The tool state exerts a strong influence on surface quality and profile accuracy during precision/ultra-precision machining. However, current on-machine measurement methods cannot precisely obtain the tool nose radius and wear. This study therefore investigated the on-machine measurement of tool nose radius on the order of hundreds of microns and wear on the order of a few microns to tens of microns during precision/ultra-precision machining using the edge reversal method. To provide the necessary replication, pure aluminum and pure copper soft metal substrates were evaluated, with pure copper exhibiting superior performance. The feasibility of the measurement method was then demonstrated by evaluating the replication accuracy using a 3D surface topography instrument; the measurement error was only 0.1%. The wear of the cutting tool was measured using the proposed method to obtain the maximum values for tool arc wear, flank wear, and wear depth of 3.4 µm, 73.5 µm and 3.7 µm, respectively.

Keywords

Edge reversal method / Tool wear measurement / Tool nose radius / On-machine measurement / Precision/ultra-precision machining

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Jiang Guo, Xing-Yu Wang, Yong Zhao, Chen-Yi Hou, Xu Zhu, Yin-Di Cai, Zhu-Ji Jin, Ren-Ke Kang. On-machine measurement of tool nose radius and wear during precision/ultra-precision machining. Advances in Manufacturing, 2022, 10(3): 368-381 DOI:10.1007/s40436-022-00397-y

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Funding

national key research and development program(2018YFA0702900)

national natural science foundation of china http://dx.doi.org/10.13039/501100001809(51975096)

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