AE 224 Metrology and Computer Aided Inspection - III

Prof.V.Radhakrishnan

Measurement of Surfaces
Surface errors:
Form error: Deviation from the specified form. They can be considered as very long wave length irregularities. Example: A cylindrical surface having a taper. Medium wave length irregularities on the surface. Example: Surface errors having a wave length of 0.8 mm and above may be considered as waviness. Short wave length irregularities on the surface.

Waviness:

Roughness:

Measurement of Surfaces
Significance of Surface errors.
Form errors are deviations on the form of the part or the surface. A flat surface may have a slope on the surface or a large curvature. This error is to be within the tolerance specified on the part. Hence close toleranced parts should not have much form error. This can be checked by inspection of the part or by gauging. Form error normally covers surface wavelengths above 100mm.(Flatness measurement of a surface plate). Form deviations affect the assembly of parts, contact area between surfaces, surface distortions(Antenna surface). Form errors can be controlled well by using precision machine tools to produce them.

Measurement of Surfaces
Waviness of the surface covers medium wavelength irregularities. Wave lengths that are considered as waviness falls between 0.25 to 2.5 mm. In certain applications this range is extended on both sides. (0.08 to 8 mm). Waviness is generated on the surface by the manufacturing process and is often caused by the error in the guidance of the tool. In a lathe the guide way errors are reproduced on the part that is turned. The role of waviness is complex and covers variations in the contact areas between contacting surfaces, noise generation during relative motion between contacting surfaces (ball bearing), reflection of light, microwaves etc.

Measurement of Surfaces
Roughness has got very short wavelengths. These are below the wavelengths chosen for waviness. Hence depending on the selection of the waviness by the cut-off wave length used the roughness could increase or decrease for the same surface profile. Hence it is important to specify the cut-off used in roughness measurement. Roughness is significant for many surface related phenomena. These cover bearing area of a surface, friction between surfaces in relative motion , heat transfer , reflectivity, fluid flow, coating adhesion etc.

Measurement of Surfaces
Roughness is created by the process used to generate the surface. Like the cutting action of the tool in turning, grinding, milling, lapping etc. In fact these processes leave their marks on the surface and the direction of these visible marks is called the lay of the surface.

Surface Finish-Instrumentation
Stylus instruments Optical Instruments Scanning probe instruments

Stylus instruments
Diamond Stylus Radius 1.5 12 mm

2 D Surface

Stylus instruments take a surface section profile. This profile taken by the instrument is a distorted one as the vertical magnifications used are many times the horizontal ones used.

Roughness and Waviness

3D Surface

3D Surface and the 2D Profile

Filters used in Metrology

Filtering

Filters are used for separating waviness from roughness. By selecting the right cut-off value for the filter one can select the wave lengths that are to be removed as waviness. The sketch shows the effect of cut-off values on the filtered profiles.

Rk Value of Roughness

Specifying Roughness

Scanning the surface using an Autofocus system

Ra Value

Stylus Instrument (CFA)

Static Calibration

Dynamic InstrumentsDynamic Calibration

Stylus Instruments Fixed Datum

Stylus Instruments Fixed Datum

Stylus Instruments Surface Datum

Light Sectioning

Con-focal Microscope

Scanned Surface by Confocal Microscope

Phase shift Interferometry

Atomic Force Microscope

Digital Measurements
Linear Measurements Angular Measurements Other Measurements

Digital readouts

Optical Scales

Moir`e Fringes

Digital Linear Measurements

Incremental Scales

Resolver

Magnetic Scale

Inductosyn

Angular Measurements

Laser Scanner

What is Coordinate Metrology?

Any point in space can be specified by 3 coordinates Knowing the coordinates of two points in space the distance between them can be computed. This can be extended to other curves, planes and surfaces.

Thus the digital data on a number of points on a part can be used for measuring many parameters like length, diameter, flatness, parallelism etc. This approach of measurement is known as coordinate metrology.

What is a Coordinate Measuring Machine? [CMM]

CMM is a machine with a frame work for accessing a point on the surface of a part and give the coordinate of that point in x, y and z coordinates. The frame work provides displacements in the three axis. A appropriate probe fixed to the CMM registers the coordinates.

Coordinate Metrology

CMM

CMM- Cantilever Type

CMM- Gantry Type

CMM- Bridge Type

Advantage of Co-ordinate measurement

Elements of a CMM
Measurement frame work - CMM configuration Measuring Scales Digital scale Measuring Probe Discrete or continuous Contact or noncontact Provision for probe change Measurement software Provision for calibration

CMM Probes
Touch trigger probes Scanning probes Non-contact probes

Touch Trigger Probe

Scanning Probe

Piezoelectric Probe

Combination Probe

Triangulation Probe

Laser Triangulation Probe

CMM Software Substitute Elements

Substitute Elements

Substitute Elements

Substitute Elements Probing Points needed

Errors in axis movement

Digitization of free form surface

Types of CMMs

Horizontal Arm CMMs

Portable Arm CMM

Micro system CMM

Nano-CMM

Molecular Measuring Machine

Optical CMM

Metrotomography
Measurement Technology of the Future

Laser Tracker

Laser Tracker
Polar coordination One length, two angles Low accuracy Accuracy is degraded when the target is far due to limited resolution of the rotary encoder.

d0

Laser Tracker

Laser Tracking
Laser trackers are based on the combination of two techniques: 1. A laser interferometer to measure relative distance, 2. Optical encoders to measure azimuth and elevation of the 3. Beam tracking

Principle of tracking

Laser Tracking

Principle of tracking

Laser Tracker

Three length measurement

Three length measurement

At the beginning of the measurement, all lasers are locked to the target.

After that, all trackers automatically chase the target.