Investigation and development of an advanced virtual coordinate measuring machine

Abstract

Dimensional measurement plays a critical role in product development and quality control. With the continuously increasing demand for tighter tolerances and more complex workpiece shapes in the industry, dimensional metrology often becomes the bottleneck of taking the quality and performance of manufacturing to the next level. As one kind of the most useful and powerful measuring instruments, coordinate measuring machines (CMMs) are widely employed in manufacturing industries. Since the accuracy and efficiency of a CMM have a vital impact on the product quality, productivity and manufacturing cost, the evaluation and improvement of CMM performance have always been important research topics since the invention of CMM. A novel Advanced Virtual Coordinate Measuring Machine (AVCMM) is proposed against such a background. The proposed AVCMM is a software package that provides an integrated virtual environment, in which user can plan inspection strategy for a given task, carry out virtual measurement, and evaluate the uncertainty associated with the measurement result, all without the need of using a physical machine. The obtained estimate of uncertainty can serve as a rapid feedback for user to optimize the inspection plan in the AVCMM before actual measurement, or as an evaluation of the result of a performed measurement. Without involving a physical CMM in the inspection planning or evaluation of uncertainty, the AVCMM can greatly reduce the time and cost needed for such processes. Furthermore, as the package offers vivid 3D visual representation of the virtual environment and supports operations similar to a physical CMM, it does not only allow the user to easily plan and optimise the inspection strategy, but also provide a cost-effective, risk-free solution for training CMM operators. A modular, multitier architecture has been adopted to develop the AVCMM system, which incorporates a number of functional components covering CMM and workpiece modelling, error simulation, inspection simulation, feature calculation, uncertainty evaluation and 3D representation. A new engine for detecting collision/contact has been developed and utilized, which is suitable for the virtual environment of simulated CMM inspections. A novel approach has been established to calculate errors required for the error simulation, where the data are obtained from FEA simulations in addition to conventional experimental method. Monte Carlo method has been adopted for uncertainty evaluation and has been implemented with multiple options available to meet different requirements. A prototype of the proposed AVCMM system has been developed in this research. Its validity, usability and performance have been verified and evaluated through a set of experiments. The principles for utilising the AVCMM in practical use have also been established and demonstrated. The results have indicated that the proposed AVCMM system has great potentials to improve the functionalities and overall performance of CMMs.