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Advances in Manufacturing

Published in:

26-05-2022

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

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

Published in: Advances in Manufacturing | Issue 3/2022

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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.

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Title: On-machine measurement of tool nose radius and wear during precision/ultra-precision machining
Authors: Jiang Guo
Xing-Yu Wang
Yong Zhao
Chen-Yi Hou
Xu Zhu
Yin-Di Cai
Zhu-Ji Jin
Ren-Ke Kang
Publication date: 26-05-2022
Publisher: Shanghai University
Published in: Advances in Manufacturing / Issue 3/2022
Print ISSN: 2095-3127
Electronic ISSN: 2195-3597
DOI: https://doi.org/10.1007/s40436-022-00397-y

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