Metrology and Measurement Systems

Abstract

When machine tool spindles are running at a high rotation speed, thermal deformation will be introduced due to the generation of large amounts of heat, and machining accuracy will be influenced as a result, which is a generalized issue in numerous industries. In this paper, a new approach based on machine vision is presented for measurements of spindle thermal error. The measuring system is composed of a Complementary Metal-Oxide-Semiconductor (CMOS) camera, a backlight source and a PC. Images are captured at different rotation angles during end milling process. Meanwhile, the Canny edge detection and Gaussian sub-pixel fitting methods are applied to obtain the bottom edge of the end mill which is then used to calculate the lowest point coordinate of the tool. Finally, thermal extension of the spindle is obtained according to the change of the lowest point at different time steps of the machining process. This method is validated through comparison with experimental results from capacitive displacement sensors. Moreover, spindle thermal extension during the processing can be precisely measured and used for compensation in order to improve machining accuracy through the proposed method.