In-process Measurement Of Surface Roughness Research Articles

In-process measurement of surface roughness using machine vision with sub-pixel edge detection in finish turning

Common methods of in-process surface roughness measurement are capable of providing a limited number of amplitude parameters for roughness assessment. This is mainly due to the averaging effect of the sensors used. In this work, we measured the amplitude, spacing, hybrid as well as functional surface roughness parameters during dry turning of AISI 1035 carbon steel using machine vision. A commercial DSLR camera with high shutter speed was used to capture a blur-free image of the workpiece surface profile diametrically opposite the cutting tool. The edge of the surface profile was detected to sub-pixel accuracy using the grey level invariant moment and the roughness parameters were determined from the profile. The tool nose wear and machining time were correlated with amplitude, hybrid, and spacing surface roughness parameters, as well as the bearing area curve parameters. Three new roughness parameters, namely average slope of profile peaks (Φp), average slope of profile valleys (Φv), relative length of peaks (Rrl), were introduced to study the effect of changes in tool nose micro geometry due to wear on the surface roughness. Among these new parameters Φp and Rrl showed better correlation with machining time and nose wear compared to all other parameters.

In-process surface roughness measurement of bulk metallic glass using an adaptive optics system for aberration correction

Bulk metallic glasses (BMGs) have received extensive attention recently due to amorphous-related extraordinary properties such as high strength, elasticity, and excellent corrosion resistance. In particular, Zr-based BMGs are recognized as a biocompatible material and surface roughness may affect many aspects of cell attachment, proliferation and differentiation. Therefore, this study presents an in-process measurement of surface roughness by combining an optical probe of laser-scattering phenomena and adaptive optics (AO) for aberration correction. Measurement results of six Zr-based BMGs samples with a roughness ranging from 0.06 to 0.98μm demonstrate excellent correlation between the peak power and average roughness with a determination coefficient (R2) of 0.9974. The proposed adaptive-optics-assisted (AO-assisted) system is in good agreement with the stylus method, and less than 8.42% error values are obtained for average sample roughness in the range of 0.05–0.58μm. The proposed system can be used as a rapid in-process roughness monitor/estimator to further increase the precision and stability of manufacturing processes for all classes of BMGs materials in situ.

Rapid in-process measurement of surface roughness using adaptive optics

We present an in-process measurement of surface roughness by combining an optical probe of laser-scattering phenomena and adaptive optics for aberration correction. Measurement results of five steel samples with a roughness ranging from 0.2 to 3.125 μm demonstrate excellent correlation between the peak power and average roughness with a correlation coefficient (R(2)) of 0.9967. The proposed adaptive-optics-assisted system is in good agreement with the stylus method, and error values of less than 8.7% are obtained for average sample roughness in the range of 0.265 to 1.119 μm. The proposed system can be used as a rapid in-process roughness monitor/estimator to further increase the precision and stability of manufacturing processes in situ.

Approaches to In-Process Measurement of Surface Roughness in Cylindrical Grinding

The purpose of this study is to develop an in-process of measurement technique of surface roughness using thermoelectric effect in cylindrical grinding. The electromotive force (EMF) generates depend on the surface roughness of workpiece and the variation of workpiece temperature when the sensor with thermocouple wires rubs on the workpiece surface in grinding process. In this paper, the in-process measurement technique of surface roughness in cylindrical plunge grinding is proposed, conceiving the cancellation of the EMF caused by the variation of workpiece temperature in the sensor output. Also a new type in-process sensor was developed for high accuracy to overcome the problem which was clarified in the cancellation method of the influence of workpiece temperature at a basic sensor.

D32 熱電効果を利用した研削面粗さのインプロセス測定の高精度化(OS-7 研削・砥粒加工(2))

The purpose of this study is the development of in-process measurement technique of surface roughness in grinding using the thermoelectric effect. In the proposed measurement, the electromotive force generates depending on the surface roughness of workpiece when the sensor with separate thermocouple wires rubs on the workpiece surface. In this report, the sensor was improved by adjustment of measurement point and attaching the elastic support pad. As a result, the in-process measurement of surface roughness can be carried out quantitatively with high stability.

研削加工における表面粗さのインプロセス測定（第2報）―工作物表面温度変化を考慮したインプロセス測定の試み―

研削加工における表面粗さのインプロセス測定（第2報）―工作物表面温度変化を考慮したインプロセス測定の試み―

Surface roughness measurement on machined surfaces using angular speckle correlation

Surface roughness is of great importance in fields, such as tribology, semiconductor technology and medicine. Stylus techniques, in which a stylus is drawn along the surface and the vertical movement of the stylus is recorded, have been used traditionally in measuring surface roughness. Non-contact methods, such as optical ones, have the advantage that they can be used for the in-process measurement of surface roughness. In this paper, results of the measurement of surface roughness using angular speckle-correlation on machined surfaces are presented. Surfaces of approximately 1.6 < R a < 6.3 μm have been measured, the surfaces being classified in the same manner as when using a stylus instrument. ASC is a technique that also allows in-process measurement of the roughness of surfaces on machined surfaces. A new technique to achieve increased repeatability by using an angle detection unit is also presented in this paper.

研磨ロボット用光学的表面粗さセンサの研究 ２ 実験結果

In-process measurement of surface roughness is an important factor in automatic precise polishing. The authors have proposed a new optical method to evaluate roughness of polished metallic surface. By applying a Torrance-Sparrow model, it is theoretically shown that the variance of the intensity of the reflected light is given as the summation of that of the light source and the rms value of the surface roughness.In order to insure that the proposed method is effective, some experiments have been carried out. The test pieces were made by brass. From the results of the experiments, the measured surface roughness agree quite well with the root-mean-square roughness represented in Rq (roughness in root mean square) measured by a stylus roughness meter.

The in-process surface roughness measurement using fringe field capacitive (FFC) method

The problem of the in-process roughness control is of special importance in case of the finishing process. The analysis of the metrological features methods and the preliminary investigation have shown that the FFC method offers the greatest hope for its implementation into the in-process roughness control. The theoretical and experimental research of fringe field capacitance method for use to the in-process roughness control have been conducted at the Warsaw University of Technology. The measuring signal obtained from FFC-based devices for the measuring system is a function of the surface average height of roughness and of the bearing ratio distribution for non-filtered profile. The capacitance method enables the in-process roughness control of surfaces (Ra>0, 1 μm) revolving with high speeds. It is not sensitive to the type of material and is susceptibility to the influence of the working liquid and other disturbances is very low.

In-process measurement of surface roughness using light scattering

This article present an instrument applicable to in-process measurement of surface roughness. In the process a grinding machine is used. In the first experiment surfaces in the roughness area of 0/09 μm ≤ R a≤0.06 μm were measured, in the second 3.0 μm ≤ R a≤3.4 μm. The method presented here is generally applicable, i.e., more rough surfaces can be measured if a laser with appropriate wavelength and a detector sensitive to that wavelength is chosen.

In-Process Monitoring of Surface Roughness Utilizing Ultrasound

This paper presents the capability of an ultrasonic system for the in-process surface roughness measurement of machined parts. The system uses a focused ultrasonic transducer to measure the reflected amplitude variation of an ultrasonic beam incident on the surface. The robustness of the system is examined by applying the technique to different machined surfaces and investigating the effect of various coupling fluids. Experimental results show that the technique is applicable to the surfaces produced by most production processes. In addition, the capability of in-process measurements is demonstrated by adapting the system to a CNC machining center. Results show in-process measurements correlate well with off-line profilometer data. Tolerance to machine vibration is also shown by comparing the measurement data with the machine spindle on and off.

Measurement of surface roughness using infrared scattering

Non-contact measurement applied to in-process measurement of surface roughness is essential to engineering industries inasmuch as the function of a surface and its roughness are closely related. The measurement range of light-scattering techniques can be extended by using IR-light, e.g. γ = 10.6 μm. The experiments described in this paper illustrate the possibility of using light-scattering techniques to measure roughness on surfaces with an approximate R a < 4 μm, R a being the arithmetical mean deviation of the profile. The light-scattering techniques presented in this paper classify the specimens in the same manner as the stylus instrument.

The fibre optic sensor in the in-process measurement of surface roughness

In the paper, a NFF type fibre optic displacement sensor is proposed, which now has been adopted to measure surface roughness. The system with this sensor is designed to be suitable for in-process measurement, in which a Z8 single-chip microcomputer is matched. The whole system is supported by assembly programs and is automatic, intelligent and flexible. The output changes of the sensor are discussed respectively for several special cases, and some necessary measures are described for the real operational environments.

In-process measurement of surface roughness during cylindrical grinding process

An in-process surface roughness sensor developed by the author has been applied to cylindrical grinding operations. The sensor utilizes fibre optics to illuminate a workpiece surfacec and to detect the intensity of the reflected light. A change of surface roughness during one plunge grinding cycle is measured for various grinding conditions. It is confirmed by the measurements that the surface roughness is closely related to changes of the workpiece radius during a grinding cycle. The result is quite simple and it is useful in determining the cycle time of a grinding operation.

In-Process Measurement of Surface Roughness in Turning by Laser Beams

A new technique for in-process measurement of surface roughness is introduced which employs an optical method by using double laser beams. This makes it possible to detect the surface roughness not only along the circumferential path but also along the feed direction even during machining. The experimental results show that the presence of chipping and chattering can be detected sensitively along both measurements directions and the maximum roughness value is always obtainable from the reading along the feed direction.