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Estimation of Surface Roughness on Milled Surface Using Capacitance Sensor Based Micro Gantry System through

Rajendran Mathiyazhagan1, SenthamaraiKannan SampathKumar2, Palanisamy Karthikeyan1

  • 1Department of Production Technology, Madras Institute of Technology Campus, Anna University, Chennai 600044, Tamil Nadu, India.

Micromachines
|October 27, 2022
PubMed
Summary

This study introduces a noncontact method for measuring surface roughness using a capacitive sensor and a micro gantry system. The approach accurately estimates roughness between 0.3 µm and 2.9 µm, overcoming previous limitations.

Keywords:
FEA analysiscapacitance techniquemicro gantryroughness estimation

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Area of Science:

  • Manufacturing Engineering
  • Metrology
  • Sensor Technology

Background:

  • Surface roughness measurement is challenging due to small feature sizes and sensor proximity risks.
  • Capacitive sensors offer potential for noncontact measurement but require careful system integration.

Purpose of the Study:

  • To develop and validate a noncontact surface roughness measurement system using a capacitive sensor.
  • To address limitations of traditional methods and sensor fragility in machining environments.

Main Methods:

  • A single-shot approach with a 5.6 mm diameter capacitive sensor was employed.
  • An automated micro gantry XYZ system was integrated for precise sensor positioning and measurement.
  • A regression model was developed using sensor data to estimate surface roughness (R).
  • Comparison with a stylus profilometer was conducted for validation.

Main Results:

  • The developed system achieved accurate noncontact roughness estimation in the range of 0.3 µm to 2.9 µm.
  • The single-shot method with the specified sensor and gantry system demonstrated improved performance.
  • Finite Element Analysis (FEA) was used to analyze the influence of tilt and waviness.

Conclusions:

  • The proposed system offers a viable solution for instantaneous, noncontact surface roughness measurement.
  • The integration of a larger diameter capacitive sensor and micro gantry system overcomes prior challenges.
  • The regression model effectively estimates surface roughness, providing a valuable tool for quality control.