Rakels, Jan Henricus (1987) An in-process, non-contact surface finish sensor for high quality components generated using diamond turning. PhD thesis, University of Warwick.

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Abstract

The object of this Ph.D. project was to design and construct an
in-process, non contact surface finish sensor for high quality
components generated using diamond turning. For this application the
instrument must have the following properties:
i rapid acquisition of data.
ii capability of measuring translating and or rotating surfaces.
iii ruggedness for in-process use.
iv insensitivity to moderate vibrations.
v remoteness from the surfaces to be measured.
The remoteness requirement virtually excludes the otherwise
ubiquitous stylus instrument, while the rapid gathering of data from
rotating surfaces excludes other profiling techniques. The above
mentioned properties strongly suggest an optical method. An optical
diffraction technique has been chosen, since it produces an optical
Fourier Transform of the surface. This transform is produced at the
speed of light, since the optical system has the property of parallel
data processing, unlike a typical electronic computer. With the aid
of a microprocessor various surface finish parameters can be
extracted from the optical transform. These parameters are
respectively the rms surface roughness, slope and wavelength.
The actual sensor consists of a measuring head and a minicomputer.
It fulfils the above mentioned requirements. Its only
limitations are:
i limited to surface finishes up to 100nm ii
presence of cutting fluids has to be avoided, although
certain modern lubricating fluids can be tolerated.
The algorithms devised to extract the surface finish parameters
from the optical transforms have initially been tested on optical
spectra produced by Thwaite. Comparison of the optical roughness
values and the values quoted by Thwaite show close agreement.
Thwaite's values are obtained by a stylus instrument.
Rqopt (um) Rqstylus (um)
0.16 0.156
0.38 0.37
0.44 0.40
In addition a computer program has been devised which simulates
the optical sensor head. The input data can be obtained by a
profiling instrument, or generated by a computer program. This last
option enables the creation of surface profiles with "controllable"
machining errors. This program can be utilised to create an atlas,
which maps optical diffraction patterns versus machine-tool errors.

Item Type:	Thesis (PhD)
Subjects:	T Technology > TA Engineering (General). Civil engineering (General)
Library of Congress Subject Headings (LCSH):	Diamond turning, Surfaces (Technology), Detectors -- Design and construction, Optical measurements
Official Date:	April 1987
Dates:	Date Event April 1987 Submitted
Institution:	University of Warwick
Theses Department:	School of Engineering
Thesis Type:	PhD
Publication Status:	Unpublished
Supervisor(s)/Advisor:	Whitehouse, D. J. (David J.)
Extent:	xiv, 287, [115] leaves
Language:	eng

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