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This paper presents novel surface profilometry for both geometric part error and metallurgical material property distribution measurements of the additively manufactured and post-processed rods. The measurement system, the so-called fiber optic-eddy current sensor, consists of a fiber optic displacement sensor and an eddy current sensor. The electromagnetic coil was wrapped around the probe of the fiber optic displacement sensor. The fiber optic displacement sensor was used to measure the surface profile, and the eddy current sensor was used to measure the change in permeability of the rod under varying electromagnetic excitation conditions. The permeability of the material changes upon exposure to mechanical forces, such as compression or extension and high temperatures. The geometric part error and material property profiles of the rods were successfully extracted by using a reversal method that is conventionally used for spindle error separation. The fiber optic displacement sensor and the eddy current sensor developed in this study have a resolution of 0.286 µm and 0.00359 μr, respectively. The proposed method was applied not only to characterize the rods but also to characterize composite rods.

This paper introduces an optical measurement technique to enhance knife-edge interferometry (KEI) for edge topography characterization with a high resolution by shaping a beam of light incident on the sharp edge. The enhanced KEI forms spherical wavelets as a new light source by focusing a beam before the sharp edge by using an objective lens, and those wavelets interfere with the secondary wavelets diffracted at the sharp edge along the propagation direction. Unlike a conventional KEI that is limited to low spatial resolution due to a relatively large beam diameter, the enhanced KEI can increase the fringe spatial frequency and produce more data necessary for fringe analysis toward edge topography characterization. Edge samples with various edge conditions were used for validation. As a result, the enhanced KEI improved the resolution of edge topography characterization compared to the conventional KEI. This study has the potential to be utilized in high-resolution optical microscopy for edge topography characterization.

This paper presents a new dimensional metrological sensing principle for a curved surface based on curved edge diffraction. Spindle error measurement technology utilizes a cylindrical or spherical target artifact attached to the spindle with non-contact sensors, typically a capacitive sensor (CS) or an eddy current sensor, pointed at the artifact. However, these sensors are designed for flat surface measurement. Therefore, measuring a target with a curved surface causes error. This is due to electric fields behaving differently between a flat and curved surface than between two flat surfaces. In this study, a laser is positioned incident to the cylindrical surface of the spindle, and a photodetector collects the total field produced by the diffraction around the target surface. The proposed sensor was compared with a CS within a range of 500 μm. The discrepancy between the proposed sensor and CS was 0.017% of the full range. Its sensing performance showed a resolution of 14 nm and a drift of less than 10 nm for 7 min of operation. This sensor was also used to measure dynamic characteristics of the spindle system (natural frequency 181.8 Hz, damping ratio 0.042) and spindle runout (22.0 μm at 2000 rpm). The combined standard uncertainty was estimated as 85.9 nm under current experiment conditions. It is anticipated that this measurement technique allows for in situ health monitoring of a precision spindle system in an accurate, convenient, and low cost manner.