Comparative Performance Evaluation of Multiconfiguration Touch-Trigger Probes for Closed-Loop Machining of Large Jet...

Area of Science:

• Manufacturing Engineering
• Metrology
• Aerospace Materials Science

Background:

• Automated machining of large, complex components like jet engine cases requires precise measurement.
• Five-axis, tilting-head machine tools are crucial for complex geometries.
• Evaluating probe configurations is essential for ensuring measurement accuracy in manufacturing environments.

Purpose of the Study:

• To compare the measurement capabilities of various probe configurations for five-axis machine tools.
• To assess the suitability of different probes under manufacturing conditions for aerospace applications.
• To identify application limitations of probes for adaptive process flow.

Main Methods:

• Rapid comparison of multiple probe configurations using master artifacts.
• Testing on five-axis, tilting-head machine tools.
• Analysis of repeatability and reproducibility (R&R) and measurement errors.

Main Results:

• The T1 straight probe achieved acceptable repeatability and reproducibility (<10%), with a conditional acceptance for one measurement (15.4% R&R).
• Straight probe configurations generally achieved errors below 10 μm for true position and reference diameter measurements.
• Custom styli probes (T4, T6) showed unacceptable errors (>0.30 mm) for Y-axis positioning, and variability was observed based on shop floor conditions.

Conclusions:

• The T1 straight probe configuration demonstrates potential for use in manufacturing environments for specific measurements.
• Custom styli probes require further development to meet accuracy requirements for complex aerospace part machining.
• Understanding probe measurement errors and limitations is critical for implementing adaptive process flows in automated manufacturing.