Hexahedral Workpiece with Reference Surfaces for On-Machine Tool Inspection
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Solution Overview
Problem
Conventional methods for inspecting machine tool accuracy require a coordinate measuring machine and are influenced by environmental factors, making on-machine measurement unreliable and prone to errors.
Innovation Solution
A processing inspection workpiece with known reference surfaces, allowing for on-machine measurement using a measurement sensor to detect contact points on both reference and processing surfaces, enabling accurate inspection without a coordinate measuring machine by averaging multiple measurements on a circle centered at each point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If on-machine measurement is performed using the machine tool itself to process and measure a test piece, then the measurement can be performed without a coordinate measuring machine, but the measurement accuracy becomes unreliable and prone to errors
Solution Approach 1:
The workpiece is divided into distinct functional areas: processing surfaces for machine tool operations and reference surfaces with known coordinates for measurement. This segmentation allows the measurement system to distinguish between processed features and reference features, enabling accurate error detection by comparing measured positions against known reference coordinates.
Solution Approach 2:
Reference surfaces with precisely known coordinates serve as an intermediary standard between the machine tool's measurement system and the true geometric positions. These reference surfaces act as a mediator that provides a reliable coordinate framework, allowing the machine tool to accurately determine its working accuracy by comparing measurements against the known reference positions.
2Measurement precision
If a coordinate measuring machine is used to measure the processed test piece, then the working accuracy can be inspected, but the measurement requires specialized equipment and is influenced by environmental factors
Solution Approach 1:
The machine tool performs both processing and measurement functions using its own measurement system. The workpiece includes reference surfaces that enable the machine tool to self-diagnose its working accuracy by comparing measured positions against known reference coordinates, eliminating the need for external coordinate measuring machines and reducing environmental influence.
Solution Approach 2:
The reference surfaces create a known coordinate copy or model that exists directly on the workpiece. Instead of requiring a separate coordinate measuring machine to establish reference coordinates, the workpiece itself contains embedded reference features with precisely known positions, allowing the machine tool to use these as a local coordinate standard for accuracy inspection.
3Reliability
If multiple measurements are performed on a circle centered at each measurement point, then error data can be eliminated and measurement reliability enhanced, but the measurement time and complexity increase
Solution Approach 1:
The measurement system performs measurements at multiple positions around each reference point (excessive action) to ensure accurate determination of coordinates. By measuring at multiple angular positions around the circle and averaging the results, the system obtains more reliable data that eliminates errors, accepting the additional measurement time as necessary for high-accuracy inspection.
Data Source
AI summary
Provided is a processing inspection workpiece for a machine tool with which it is possible to inspect tool precision by subjecting the machine tool to on-machine measurement. Also provided is an on-machine measurement method using said workpiece. In a processing inspection workpiece, five surfaces, excluding a hexahedron bottom surface, function as processing surfaces, and multiple reference surfaces, which are in the same direction as the respective processing surfaces and for which multiple in-plane coordinates are already known, are disposed on each processing surface. A machine tool is subjected to on-machine measurement using said processing inspection workpiece.