Cost-Effective Surface Quality Measurement and Advanced Data Analysis for Reamed Bores

This paper presents a cost-effective approach for automated surface quality measurement in reamed bores. The study involved drilling 4000 holes into 42CrMo S4V steel, of which 3600 underwent subsequent reaming. Utilizing a CNC-controlled gantry coupled with a mobile roughness measurement device through a compliant mechanism, surface data of every bore were efficiently gathered and processed. Additionally, analytical methods are presented that extend beyond standardized, aggregated metrics. We propose the evaluation of retraction grooves by using autocovariance. In addition, the correlation between the phase position of the waviness profile and the positional deviation of the bore is analyzed. The position deviation is also associated with bending moments that occur during reaming using a sensory tool holder. Furthermore, a 360-degree surface scan is presented to visually inspect the retraction groove. This approach aims to enhance understanding of the reaming process, ultimately improving bore quality, reducing component rejects, and extending tool lifespan.