Can A Low Cost Sensing System Be Exploited For High Precision Machining?

The aim of the present study is the assessment of the integration of a low cost optical measurement device into a high-precision machine tool for micro manufacturing applications. The measurement system can be effectively integrated into the working volume of different types of machines allowing both tool and workpiece measurements and avoiding its disassembly from the machine stage for off-line measurements and, consequently, reference losses. The fast measurements of tool and workpiece during the machining contribute to increase the accuracy and reduce the overall machining-measurement iterations. The assessment is achieved by a test case where a low cost USB microscope is applied to a micro-EDM machine. The low cost device has been applied for tool electrode measurements and tool wear evaluation after an accuracy enhanced calibration procedure and high performance image processing algorithms, which effectively reduce the lack of the hardware performance. The measurement performance gives a feedback on the deviations of the machined features from nominal geometry and allows their compensations by an adequate machining strategy.