In situ- On Machine - Post Process Metrology System Design for Machining System Characterization

The evaluation of machine tool characteristics and their impact on surface quality is challenging, often requiring disruptive traditional methods. This study introduces a novel, non-invasive approach using optical camera images for rapid and accurate assessment. Data robustness was ensured by acquiring initial images outside the machining chamber with consistent external illumination, focusing on detailed intensity profile analysis. Machined surfaces were processed using intensity profile extraction and Fast Fourier Transform (FFT). The dominant spatial wavelength (0.1833 mm) consistently showed excellent agreement (within 1.85%) with the theoretical feed per revolution (0.1800 mm). This robustly validates the method's ability to precisely capture primary kinematic tool marks. Temporal information, inferred from spatial frequencies, underwent subsequent FFT to identify periodic phenomena and harmonics. The comprehensive spatial and temporal FFT analyses offer detailed, quantitative surface characterizations. The clear distinctions in temporal harmonic patterns provide robust, frequency-domain signatures informing machining system performance and process integrity.