In-Machine Measurement and CNC machining quality and time reduction.

Measuring workpieces after machining is essential to ensure product quality. Generally, this metrology procedure is commonly practiced out of the machine, usually with a separate go/no-go measuring instrument or machine. Most of the times, if there is any machining issues, you'll get a lot of defective parts before the production problem is detected, and there goes a lot of time and effort, not to mention, money.

By introducing in-machine measurement to automatically measure the workpiece inside the machine tool, the probability of large batches of defective produced parts being made is highly reduced, and machine tool issues can be quickly detected, specially related to problems related to cutting tools or cutting componentes (holders, spindles, chucks, cutting chips stuck inside jigs, etc), reducing both the time and manpower required to address production problems. This article will explain what in-machine measurement is and will provide examples of problems that have been solved using in-machine measurement.

In-Machine vs Out-of-Machine measurements.

As you may already guessed, In-Machine measurement defines, well... measuring inside a machine tool's working area, but the important part is that this measuring is done as part of the machine tool's machining cycle. Out-of-Machine measurement is performed outside of the machine tool's working space and after the machining cycle is finished, and at best, in the same position as the CNC machine, avoiding out-of-specification parts to go further up the manufacturing process. Of course, metrology laboratories have a much precise measurement procedures, but the metrology lab's work final intention is different from in-line immediate measuring.

In-Machine measuring advantages.

Why should you implement In-Machine measuring? In order to detect early issues or defects within the machining process, such as thermal expansion issues within the machine tool (probably caused from lack of lubrication os ball screws, for example), worn, chipped or broken cutting tools, shaving chips stuck inside CNC's moving parts or other non easy to see issues. Early direct In-Machine measuring will help detect and reduce this kind of problems which are inevitable when continuosly operating CNC machines during large periods, reducing number of machine inspections and quickening manteinance services.

Also, In-Measuring can help you in special machining situations where the machining zero-point position may shift slightly, such as small batch machining where previous quality conditions may be a little more slack, correcting misaligments. And, quality-related, early detection of errors, avoids expensive product recalls and back-inspections of previous production batches.

What can you measure In-Machine?

Machining Zero Point: through the use of a touch probe or a contact sensor, the machining zero point can be re-assesed on situations where misalignment may occur, such as thermal displacement, loading/unloading issues or robot transportation errors.

Tool breakage detection: prevent errors due to cutting tool breaking, wearing out or chipping away, which produce incomplete or out-of-spec machining. 

Start-up tool measurment: avoid manual measuring of tool holder set-up outside of the CNC before start-up and warm-up time, reducing setup times.

Tool specs detection: sometimes solid cutting tools may slip into the holder or fall due to improper holder/tool setting, or runout errors due to different possible machine issues. Also, you can detect misplaced holders or tools by checking their dimensions.

Go/No-go workpiece revision: defects may pass on from previous processes and in-measuring may ensure that only compliant pieces be machined.

Types of In-Machine measuring tools:

YAMAZEN distributes several brands of In-Machine measuring tools which include: 

BLUM-Novotest:

• Tool sensors: Z-Nano / Z-pico / Speed ZX / TC53-20 / TC63-20 / TC76.
• Measuring Probes: TC DIGILOG Ruby Tipped Series.
• LaserControl: DIGILOG / MicroCompact NT / Portable SpindleControl.
• Roughness Meters: TC Series.
• Hole Measuring: BG Series. 

In-Machine measuring results:

Proper implementantion of In-Machine measuring will reduce downtimes, reduce machining errors and therefore wasted product, catch product defects and machine issues early on and, in general, reduce costs and improve productivity.

We invite you to consult with your YAMAZEN sales agent or tech service representative so we may provide a proper assesment on what tools will help you realize your production goals and how to implement them.