Development of the geometric measurement system for machined surface evaluation in cutting

Abstract

• In-situ surface roughness measurement system (GMS) integrated into the production cell. • GMS with a confocal sensor validated using certified calibration specimens. • Reliable roughness measurements demonstrated under industrial conditions. • Enhanced accuracy through robot path correction and advanced data filtering. The Geometric Measurement System (GMS) was developed and integrated into a robotic production cell for real-time geometric and surface measurements. This article explores the evaluation of the GMS in conducting in-situ roughness assessments using a confocal sensor with a resolution of 0.1 µm and a measuring range of ±5 mm. Surface roughness measurements were performed immediately after turning and milling, extending the system’s capabilities to detect surface quality before final finishing operations. The expansion includes the evaluation of profile roughness parameters ( Ra , Rsk , Rku ) based on ISO 21920-2, real-time verification of surface compliance with defined tolerances, and automatic data archiving in a process history database to support traceability and adaptive corrections. The study demonstrates the system’s effectiveness in analyzing challenging surfaces, including those made of difficult-to-machine alloys like NiTi and geometrically complex components such as turbine blades.