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A new system for on‐machine measurement of workpieces is described. The system is based on a fine touch sensor that enables the cutting tool itself to act as a contact probe to inspect the workpiece. The proposed measurement technology combines the Q‐setter with the fine touch sensor. This low cost measurement system is applied to automatic workpiece setup and improving workpiece dimensional accuracy on a CNC turning center. It is shown that using the proposed measurement system results in workpiece setting time decrease and workpiece machining accuracy improvement. The development of the on‐machine measurement system makes the fine touch sensor extremely attractive for CNC machine retrofitting.

In any machining process, the surface profile of the workpiece is continuously changing with respect to time and input parameters. In a conventional machining process, input parameters are feed and depth of cut whilst other parameters are considered to be constant throughout the process.

The direct and indirect participation of this instantaneous curvature can be used to optimize the strategy of cutting operation in terms of different parameters like heat generation-induced stresses, etc. The concepts of the metric tensor and Riemannian curvature tensor are made use in this study as a representation of curvature itself. The objective of this study is to create a mathematical methodology that can be implemented on a highly flexible machining process to find an optimum cutting strategy for a particular output parameter.

The study also includes different case studies for the validation of this newly introduced mathematical methodology.

The study will also find its position in other mechanical processes like forging and casting where instantaneous curvature affects various mechanical properties.