This work, carried out for Rolls-Royce, developed novel methods of verifying that machine tools are capable of machining parts to within specification, immediately before carrying out critical material removal operations, and with negligible impact on process times. The primary method used is artefact probing using touch trigger probes. This enables all the kinematic errors in a machine tool to be verified within 1-minute using a fully automated cycle with all data stored and processed natively on the machine tool controller. The verification cycle can therefore be called up as a sub-routine within machining programs and if the machine is no longer capable the process will stop and signal for machine maintenance.
Title: Rapid Machine Tool Verification
By J E Muelaner, B R Yang, C Davy, M R Verma, P G Maropoulos
Presented at the 8th International Conference on Digital Enterprise Technology – DET 2014 – “Disruptive Innovation in
Manufacturing Engineering towards the 4th Industrial Revolution in Stuttgart, Germany, 26-28 March 2014.
Abstract: This paper describes work carried out to develop methods of verifying that machine tools are capable of machining parts to within specification, immediately before carrying out critical material removal operations, and with negligible impact on process times. A review of machine tool calibration and verification technologies identified that current techniques were not suitable due to requirements for significant time and skilled human intervention. A ‘solution toolkit’ is presented consisting of a selection circular tests and artefact probing which are able to rapidly verify the kinematic errors and in some cases also dynamic errors for different types of machine tool, as well as supplementary
methods for tool and spindle error detection. A novel artefact probing process is introduced which simplifies data processing so that the process can be readily automated using only the native machine tool controller. Laboratory testing and industrial case studies are described which demonstrate the effectiveness of this approach.