An evaluation of optical tool inspection and compensation technologies. CRADA final report for CRADA Number Y-1291-0052

A Cooperative Research And Development Agreement (CRADA) was established April 1992 between Martin Marietta Energy Systems, Inc. and United Technologies Corporation, Pratt and Whitney Division to evaluate the existing applicability of the Energy Systems optical tool inspection and compensation system (OTICS) for use at Pratt and Whitney`s East Hartford Plant. The OTICS was developed at the Oak Ridge Y-12 Plant and optically measures the shape of a single point cutting tool. The tool shape inspection provides process information relating to tool wear and if desired the tool shape geometry can be used to generate a new numerical control machining program that is compensated for the tool forms errors. The tool wear measurement capability of OTICS was successfully evaluated in the Phase-1 testing. The testing verified that OTICS can easily detect tool wear and the {+-} 0.0001 inch resolution obtained was sufficient for the larger cutter inserts used by Pratt and Whitney (P and W). During the tool wear experiments at P and W, a second potential use identified for OTICS was the accurate on-machine dimensional verification of special ground contour forming tools. The OTICS tool path compensation experiment demonstrated the varied technologies that are integrated in the tool path compensation process. The OTICS system was successful at inspecting the 0.125 in. radius tool and compensating the tool path for tool form errors. The need for automated interfaces between the OTICS computer and controller along with the part program requirements and the overall compensation methodology were highlighted in the demonstration