Estimation of Position and Size of a Contaminant in Aluminum Casting Using a Thin-Film Magnetic Sensor

Advanced manufacturing processes require an in-line full inspection system. A nondestructive inspection system able to detect a contaminant such as tool chipping was utilized for the purpose of detecting a defective product as well as damaged machine tools used to fabricate the product. In a previous study, a system able to detect magnetic tool steel chipping in conductive material such as aluminum was developed and tested. In this study, a method of position and size estimation for magnetic chipping was investigated and is described. An experimental confirmation of the proposed method was also carried out using an actual prototype system.