Accuracy Analysis of Machining Process Using a Spindle Probe and a CMM to Reduce the Scrap

Abstract

In-process part inspection using a spindle touch probe has gained a significant importance, mainly because parts can remain on the machine without disrupting the machine setup while inspection is being conducted. This practice leads to a shorter inspection time, improved part accuracies, and reduction of scraps. Recently, intense domestic and international competition has put more importance on part quality in terms of producing parts right the first time and maintaining the consistent quality standards. A literature review revealed that a comparative analysis between in-process gauging using a touch probe and post-process inspection using a coordinate measuring machine (CMM) to ascertain part quality has not been adequately studied. Therefore, there is a need for a study to measure the characteristics of the two inspection techniques. To address the problem, cutting experiments were conducted and measurement data were analyzed using a state-of-the-art CNC machine, a CMM, a touch probe, and a high-precision ballbar system. The experimental data show that machined features and touch probe measurements are affected by the inherent shortcomings in machine tool structure, suggesting a machine tool capability analysis be undertaken in tune with the required tolerance specifications prior to machining operations, rather than solely relying on the touch probe inspection for part quality assessment.