Advances

in

METROLOGY
By

V.P Singh
Head mechanical
Division
CSIO,

24th March 2009

What is Metrology ?
Metrology is the study of measurements
Measurements are quantitative observations &
numerically
descriptive. It has larger responsibility to serve as
Legal
Deterministic metrology
We often take measurements for granted, but
measurements
must be good and authenticated
Then what is good ?

Good measurement
Good measurement is a precise science that
measures the physical quantity in close tolerances,
minimizing uncertainty.
All want good measurements that can be trusted
Awareness of measuring equipments and its
appropriate usage
Accuracy follows random and systematic measurement
Minimizing, Uncertainty in measurements
Evaluate % age error and RMS values
Calibration, traceability of equipments with Certifying
Agencies
Up-keep & Maintenance of equipments before and
after use

Metrology
Metrology

Scientific

Industrial

Testing
Measureme
nt
Quality
( Each level of
competency and
traceability )

Mass
Electricity
Length
Time
Frequency
Thermometry
Ionization
Radiation
Radioactivity
Photometry
Acoustics

Need of
Metrology ..??

Accuracy & Interchangeability

Repeatability & quality assurance

Flexibility in Manufacturing
Implementation of Just In Time
Lowering Down Machining time & Expense
Multiple Setup(s) and updated machining
methodologies
Customers Need & Requirements for
measurements

Elements of Metrology

Measurement
(Precision &
accuracy)

Comparison
with
Standards

Traceability

Calibration

Uncertainty
measuremen
ts

% age error

Calibratio
n
Calibration is the basic tool in ensuring
traceability of measurements just to
Ensure consistency in reading the
instrument
determining accuracy
Establishing reliability for trust
Facts are

Calibration strengthen the accuracy basic

machine geometry
Calibration identifies the machine error and
sources
Its possible
Major contribution to process control
measurements & quality
Provides opportunities for better machining
methodology

Errors
An Error is the difference between a measured value and the
true value
Three types of error:
Gross error :- it arises from human mistake
Reading the instrument before it has reached its
steady state
Not eliminating parallax
Mistake in reading data
Misuse of instrument
Random Error
Small variation in position setting
Transit fluctuation - scale and pointer
Systematic
Instrument not calibrated
Reading uncertainty in presence of nose

Uncertainty
Uncertainty is a quantitative measure of quality of
a measure result, comparable to other standard/
reference

Estimate of the inaccuracy of a measurement that

includes both the random and systematic components

An estimate of the range within which the true value for a

measurement lies, with a given probability level

Not surprisingly, it is difficult to state, with certainty, how

much uncertainty there is in a measurement value.

But metrologists keep on trying .

Traceability
BIPM

National
Metr.

Definition of Unit

Foreign
standar
ds

National
standar
ds

Calibration
Labs

Reference
standards

Enterprises

Industrial standards

End users

Measurements

Accuracy & Precision

Accuracy

Accuracy is how close an individual value is to

the true or accepted value

Precision

Precision is the consistency of a series of

measurements

High Precision
Low Accuracy

High Accuracy
Low Precision

Core Strength in Metrology (CSIO)

3D Optical Profiler (Non

contact)

Talysurf

Zygo GPI
Interferometer

Core Strength in Metrology (CSIO)

3D Coordinate Measuring
Machine

Universal Measuring
Equipment

Laser
Interferometer

Thank You

Confidence level

INNOVATIVE METROLOGY
SOLUTIONS

Gautam Doshi
Productivity & Quality Improvement Services
Adviser, IMTMA

OBJECTIVES OF METROLOGY

Required measuring accuracy at min. cost

Newly designed components within process
& measuring instrument capability
Determine measuring instrument capability
Minimise cost of Inspection
Standardising measuring methods
Maintain accuracy of measurement
Solve shop floor measurement problems

WHY ARE YOU ATTENDING

THIS SEMINAR?

Awareness
New Technology
New methods
Cost Effectiveness of metrology
Overall cost effectiveness in manufacturing
Speed of inspection
To impove quality of products
To improve productivity
Networking
To have a good time
Increase automation in metrology

WHY METROLOGY?

What you cannot quantify you cannot

measure!
What you cannot measure you
cannot monitor!
What you cannot monitor you cannot
control!
Finally what you cannot control you
cannot assure!
And if you cannot assure you cannot
sell & continue to be in business!

BASIC ELEMENTS OF METROLOGY

Standards
Workpiece
Measuring Instrument
Person
Environment

DOES METROLOGY ADD

VALUE TO A PROCESS?

Feedback
Assure customer
Reduce customer end rejections
Controls process & quality cost
Reduces subjectivity
Time delay
Process methodology can be
evaluated
Reduce wastage

AGENDA

Innovative Solutions in Metrology

Metrology of Machine Tools
3D Measuring machines & Scanning
Case study on cost effective metrology

PRODUCTION METROLOGY

Machining &
metrology in
one close loop
control
Active tools
compensate
wear in boring,
automatically
tools supplied
by Komet

ON MACHINE MEASURING
TECHNOLOGY

Source: Blum-Novotest

Not dependent on
machine accuracy
Measuring time 0.5
sec
Measuring tool stored
in ATC of m/c; no post
process measuring
station required
Resolution 0.15m
Opto-electric sensor
used with battery life
of 150,000
measurements

MEASUREMENTS CAN BE FOR DIA

OR PROFILE & POSITION

Floating Principle

Multiple Sensor Principle

SQC BUILT INTO SYSTEM TO GIVE ZERO DEFECT

Wear compensation

Tool breakage

TOOL CHANGING ERRORS ARE DETECTED WITHIN

A FEW SECONDS

Unacceptable runout
on multi-edge tools
results in

Vibration
Reduced tool life
Non uniform cutting
load dimensional
deviation
Poor surface finish

Dynamic runout to be
detected with spindle
running
Proximity sensors can
sense gap of 0.03 mm

RUN OUT SENSOR USING LASER

LIGHT BARRIER

Radius measuring
values not considered
absolutely but relative
Measured tool radius
compared with virtual
concentricity measuring
value
Deviations considered
in relation to previous
measurement
Possible to detect
runout of few microns
under production
conditions
Measuring time 1 sec approx.

TURNING TOOLS - LASER

MEASURED

Measurement of high
point, L1 & L2
Detection of cutting
edge breakage
Measurement of
corner radius
Wear detection at any
position
Scanning of the
complete cutting edge
geometry

CCL routine determines not only the precise cutting edge radius but also
its center point.

Parallel beam

In contrast to a probe, Blum

LaserControl detects cutting
edge breakage resp. wear at any
position of the tool cutting edge
by continuous scanning

Focused beam

Influence of the laser beam

diameter on the measuring result

MANUFACTURERS OF GEARS, STEERING

SYSTEMS, TURBO CHARGERS OR
HYDRAULIC VALVES

Operated at up
to 10 m/min
measuring
speed
Repeatability
below 1 micron

Pulling /pushing
measurement with TC51-20

METROLOGY FOR PLASTIC

PARTS

Gauges made out

of high strength
anodised
aluminum.
Good wear
resistance.
Visual check of
fitment
dimensions.
Other measuring
equipment not
Source: Witte
necessary.

Acceptance Gauges

IN LINE PROCESS CONTROL

3 sides open CMM

GageMax
Can be integrated
into production line
Heat, dust &
temperature
variation does not
affect
Quill made of
carbon fibre
Cast mineral base
Operates between
15C - 32C
Source: Carl Zeiss

TWO IN ONE SURFACE FINISH

& CONTOUR MEASUREMENT

Dual measuring
instruments capable of
capturing surface &
contour values with
single measuring run
Uses linear motor for
tracer driver
Low wear & tear
Available with probing
range of 2.5mm &
6.5mm

MEASUREMENT OF MICRO MACHINED

COMPONENTS

Micro test
workpiece to check
3axis interpolation
of machine and
2axis on head
F 25 from Carl
Zeiss as reference
measuring
machine, resolution
of 0.25 nanometers

100% TUBE INSPECTION IN

VOLUME PRODUCTION

Optical 3D tube
measurement for
100% production
Determines set-up &
correction data &
transmits to bending
machines
Inspection in less than
60 sec, no mechanical
gauges
SPC control is available
AICON TubeInspect

COORDINATE MEASURING MACHINE

WITH X-RAY TOMOGRAPHY

Werth Messtechnik
GmbH TomoScope
HV used on highdensity components
made of aluminum,
steel, titanium,
composite materials,
ceramics, and glassfiber reinforced plastics
Non destructive
inspection of metal &
non metal parts

ENHANCING TOOL PRESETTERS WITH VISION SYSTEM

& SOFTWARE

Cutting edge contour of form tools consists

of lines and arcs
Vision system on the presetter records the
contour & compares with CAD
Form testing/ OP & CMM eliminated
Software takes care of straight & fluted tools
Microsoft compatible; measurement program
can be stored, records generated
www.kelch.de

LEICA GEOSYSTEMS ARMLESS AND WIRELESS

T-PROBE PORTABLE MEASUREMENT SYSTEM

Measurements accurate up to 0.1 mm in

measurement volume equivalent to full-size car
T-Scan can easily digitise all objects with virtually no
set-up time, can be combined with the T-Probe to
create new all-in-one solution for industrial
measurement purposes.
New technology based on camera embedded at top of
tracker (T-Cam), which allows user to measure
precisely orientation of object in space, while tracker
simultaneously determines its position.

T-PROBE
Just walk around with a hand held CMM Probe
and take 3D -measurements wherever
needed

Walk-Around
CMM

BALL ENDMILL VISION MEASURING

SYSTEM

Vision measuring system for ball

endmill
Chuck holds endmill, allowing it
to rotate
Digital angle counter indicates
positions of endmill cutting edge
as it is rotated
Mitutoyo QSPAK software
compares actual and nominal
values to determine edge wear
Checking for abrasion wear of
ball endmill R-contour to help
forecast when to re-grind &
improve process stability
CCD camera accurately detects
position reduces focus time &
avoids focusing error

www.mitutoyo.com

QUICK VISION STREAM CNC VISION SYSTEMS

MEASURE ON-THE-FLY FOR 5X FASTER

Progressive camera
with stroboscopic
illumination bundled
with powerful QVPak
software to enable m/c
to capture
measurements while
the camera-head is in
motion

Molded plastic or metal parts & PCB assembly

SURFTEST SV-3000 SUPPORTS EASY

INTEGRATION OF CNC SURFACE ROUGHNESS
TESTING, AND AUTOMATION

Integrate CNC
surface roughness
measurement into
automated material
handling and
downstream
machining and
assembly
processes.
Surface roughness
measurement of
transmission gears
and connecting rods

COMBINATION VISION/ULTRASONIC PROBE

SYSTEM MEASURES MICRO HOLES & FEATURES

Hair-like ultrasonic probe

Vision system used to position tiny
probe (20m dia) for insertion into
holes or other miniature features
Probe activated ultrasonically &
measurement data taken according to
wave-form changes when in contact.
Probe tip, of carbide/glass, 2mm in
length, & thin enough to measure dias
of fuel injection nozzles, optical
ferrules, ink jet printer nozzles & other
tiny holes

COOLANT PROOF DIGIMATIC CALIPER

PROTECTED TO IP67 AND IMMERSIBLE

IP (Ingress Protection) 67 certification means dust

proof, chip proof, coolant-proof & virtually immune
to toughest conditions found on production floor
0.01mm resolution with 0.02mm accuracy for 6
and 8 models
Absolute linear encoded measuring scale
Expected battery life of three years

SUMMARISING METROLOGY

Close loop metrology

Built in SQC solutions
Measurement sensors for process
errors
Fine tuning tool/ part measurement on
m/c
Robust shop floor metrology

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MEASURING TECHNOLOGIES FOR CNC MACHINE TOOLS

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NEED FOR METROLOGY IN MACHINING

To introduce Quality checks during machining process

To identify non conforming parts there by avoiding further

machining process

To eliminate errors in Fixture, Job & Tool set up

To reduce material movement from the machine to the

standards room

53

END RESULT

Consistency in producing Quality parts

Increase in Productivity

Effective Man Power & Machine Utilisation

Less worry of rejection

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SOLUTIONS:
BLUM MEASURING SYSTEMS FOR CNC MACHINES

Touch Probe

Bore Gage
Laser System

Z-Probe

Form Control Software

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PROBE SERIES TC
Universal Touch Probe TC50
Universal Touch Probe
Multidirectional
- precise non-lobing touch
characteristics
- robust design
- optoelectronicmeasurement
- extended battery life
- compatible with BLUM bore
gauge
BG40 and adjustable boring bar

56

PROBE SERIES TC
Function principle probe TC50
Optoelectronic measurement

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PROBE SERIES TC
Probe TC51
Bi-directional Touch Probe
Designed for fast part and fixture
loca-tion on production machining
centers
- extremely fast acceleration and
measuring speed
- no wear optoelectronic
measure- ment
super precision
- touch proof even with coolant
- compatible with BLUM bore gauge
BG40 and adjustable boring bar

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PROBE SERIES TC
Function principle probe TC51

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PROBE SERIES TC
Function principle probe TC51-20

Design to measure
grooves, recessed
diameter slots and
shoulders with
additional Z+ approach
direction

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INFRARED CONTROLLER IC55

Infrared Controller
Transmission and Receiving
Technology of the Latest Generation
- reliable, interference-free
infrared
data transmission
- robust design, IP68
- no additional interface
necessary
- easy installation
- ideal integration of the air
nozzle

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INFRARED CONTROLLER IC55

Modes
A standard for all products

- switch ON/OFF via IR flash

- signal transmission for TC series
- 16 Bit measuring value transmission for bore gauge BG
series
- 16 Bit measuring value transmission for temperature,
compression and roughness
and more sensors
- control of active tools

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INFRARED CONTROLLER IC55

Air nozzle

Signal transmission without

interference and wear

63

Software
FormControl

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IDENTIFICATION OF MEASURING POINTS

Content

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CALCULATION AND DISPLAY OF PROBE PATHS

Content

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SOFTWARE FORMCONTROL

ADIF Automatic Data Interface

entire measuring sequence executed with one

mouse command

automatic import of measuring results

no manual generation and transmission of NC
programs

67

START MEASURING WITH ONE MOUSE COMMAND

Content

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IMPORT OF MEASURING RESULTS

Content

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SOFTWARE FORMCONTROL

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RESULT

Content

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RESULT VIA NEEDLES

Content

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SOFTWARE FORMCONTROL

Early Problem Identification:

incorrect cutting parameters
wrong tool dimensions
incorrect tool orientation
tool wear

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BLUM LASER CONTROL

Laser System for tool setting

and breakage detection
within the machine tool

75

SYSTEM BLUM LASER CONTROL

Content

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SYSTEM FUNCTIONS

Tool breakage detection

Tool length and radius setting
Run-out control
Single edge cutter control
Form control
Temperature compensation

at nominal spindle
speed

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SCOPE OF SUPPLY

Transmitter - Classification

Laser class II, Power 1 mW,

IP68

Receiver

Monitors laser light and

generates
skip signal to machine control,
IP68

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SCOPE OF SUPPLY
BLUM shutter system

Protects against coolant and

chips,
with shutter mechanism and
barrier air

BLUM Software Cycles

Proven subroutines for all

controls

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APPLICATION

Software developed by
experts for easy use
Most measurement
applications
can be realized with
Blum-Standard- Software
Qualified support for custom
specific measurement tasks

Content

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YOUR BENEFITS

Increased machine accuracy

Increased machine uptime

higher manufacturing quality

higher Productivity and Profitability

Unmanned operation

Less scrap

Reduced collision risk

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BORE GAUGE SERIES BG

Designed to address the following problems:

Shortage of skilled measuring engineers

Air micro meter is difficult to maintain
Air micro meter needs frequent calibration
Air micro meter is unstable
Air micro meter needs long measuring time
Errors due to operator fatigue

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BORE GAUGE SERIES BG

Bore Gauge BG40

- high precision Bore Gauge for the

mass production of parts with the
same bore diameter
- extremely fast measuring cycle
- machine-independent measuring
system
- on-machine measuring
- reliable process control
- replaces postprocess measuring
station

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BORE GAUGE SERIES BG

BG40 designed with floating measuring

system for diameter measurement only
diameter measurement
- economical solution
- float principle provides accurate diameter even
when machine is not perfectly positioned in
bore center
- self-contained, machine independent, measuring
principle

BG41 designed with multiple sensors to

measure:
Diameter, position, cylindricity, roundness
- customized solution to provide complete bore
quality characteristics
- self-contained, machine independent, measuring
principle

84
APPLICATIONS BORE GAUGE BG40:
CYLINDER BLOCKS

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APPLICATIONS BORE GAUGE BG40:
ADJUSTABLE TOOLS CONTROLLED VIA IC55

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APPLICATIONS BORE GAUGE BG40:
HYDRAULIC VALVE BODY

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APPLICATIONS BORE GAUGE BG40:
MAIN BORE OF BRAKE CYLINDER

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APPLICATIONS BORE GAUGE BG40:

CRANK JOURNAL BORE MEASURING

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BORE GAUGE SERIES BG

Measuring Heads

- Measuring heads
exchangeable
- Measuring range from
+/- 50mm up to +/- 200mm
- different standard lengthes
available
- Linearity +/- 1m

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CLOSED LOOP PROCESS

Quality oriented

Move into target tolerance

Process Control
Best Quality
Less Scrap

Process compensation

Tool breakage

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OLD METHOD(COMPLEX)
MEASURING
STATION

BORING STATION
WORK PIECE
TRANSFER

FINE BORING

MEASURING
DATA
CALCULATION

TOOL COMPENSATE

MEASURING AND RATING DATA

FEED BACK
SIMPLIFIED
BLUM METHOD
BORING STATION
FINE BORING
MEASURING
DATA CALCULATION &
TOOL COMPENSATION

TIME SAVING WITH QUALITY!

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COMPANY HISTORY

1968: Gnther Blum founds the Company

Seventies: Automation and engineering
Eighties: Lead- in production measurement metrology
1982 First electronic BLUM Workpiece Touch Probe
1985 First BLUM Measuring Machine
1987 BLUM First Development of a Laser System for
tool breakage detection in machining centers

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COMPANY HISTORY

1994 NOVOTEST becomes part of the group

1996 Innovation Award for BLUM Laser System at
MACH96 in Birmingham
2002 BLUM introduces intelligent and patented
generation of laser systems Laser Control NT

next

2003/2004: completion of product line for machining

centers with the probe serie TC and Bore Gauge BG
2005 BLUM introduces LaserControl Hybrid

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BLUM OVERVIEW

Over 35 Years Experience

More than 35,000 Laser Installations Worldwide
Proven Design
Proven Software
Your Competent Partner in Measuring Technology

BLUM -- SETTING THE WORLD STANDARD

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Thank You for your time

Sandeep Engineers
Blum System Integrators