Use of dual coolant displacing media for in-process optical measurement of form profiles

In-process measurement supports feedback control to reduce workpiece surface form error. Without it, the workpiece surface must be measured offline causing significant errors in workpiece positioning and reduced productivity. To offer better performance, a new in-process optical measurement method based on the use of dual coolant displacing media is proposed and studied, which uses an air and liquid phase together to resist coolant and to achieve in-process measurement. In the proposed new design, coolant is used to replace the previously used clean water to avoid coolant dilution. Compared with the previous methods, the distance between the applicator and the workpiece surface can be relaxed to 1 mm. The result is 4 times larger than before, thus permitting measurement of curved surfaces. The use of air is up to 1.5 times less than the best method previously available. For a sample workpiece with curved surfaces, the relative error of profile measurement under coolant conditions can be as small as 0.1% compared with the one under no coolant conditions. Problems in comparing measured 3D surfaces are discussed. A comparative study between a Bruker Npflex optical profiler and the developed new in-process optical profiler was conducted. For a surface area of 5.5 mm × 5.5 mm, the average measurement error under coolant conditions is only 0.693 µm. In addition, the error due to the new method is only 0.10 µm when compared between coolant and no coolant conditions. The effect of a thin liquid film on workpiece surface is discussed. The experimental results show that the new method can successfully solve the coolant dilution problem and is able to accurately measure the workpiece surface whilst fully submerged in the opaque coolant. The proposed new method is advantageous and should be very useful for in-process optical form profile measurement in precision machining.