MEASURE FASTER. Form and. in one system. 3D Profiler Traceable. Optical 3D micro-coordinate measurement. roughness

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1 E n g l i s h e d i t i o n 4, / T h e m a g a z i n e a b o u t A l i c o n a - m e t r o l o g y Optical 3D micro-coordinate measurement Form and roughness in one system 3D Profiler Traceable roughness measurement MEASURE FASTER

2 IF-Profiler IF-EdgeMaster IF-Portable InfiniteFocusSL IF-ToolPrecision InfiniteFocus X-Large IF-SensorR25 2 alicona

3 InfiniteFocus Dr. Stefan Scherer, Alicona CEO Dr. Manfred Prantl, Alicona CEO Measure faster with Alicona! Alicona s corporate mission is to continuously improve and drive forward optical metrology throughout our products and measures. Just in time with the 4th edition of FOCUSvariation, we further advance optical metrology by providing high resolution 3D measurement solutions with a measurement speed that has been increased up to ten times. By using 4m measuring points in two seconds, there is to our knowledge currently no alternative that enables measurements in this high resolution and, at the same time, in this speed. This not only boosts our customer s economical advantage, it also strengthens our motivation to further enhance applications, increase user benefits and improve industrial compatibility of optical measurement solutions. Users confirm that Alicona stands out as a highly user oriented supplier with a high application expertise. As in former editions of FOCUSvariation, customers introduce how they solve their measurement tasks, talk about their first impression when meeting Alicona and share their benefits by applying Focus-Variation. Another novelty is the introduction of IF-Profiler, a 3D measurement system to traceably measure roughness both profile and areal based. It is the recent addition to our product range for high resolution form and roughness measurement in research and production. See for yourself how much faster you can be with Alicona! Yours faithfully, alicona 3

4 Table of content EDITION 4, 2013/2014 High resolution optical 3D measurement in research and production 4 5 Table of content 8 9 InfiniteFocus: How to measure form and roughness with one system What makes InfiniteFocus distinctive: Unique benefits InfiniteFocus in use: References and user case stories Roush Yates (USA) Makino (Japan) Jarvis Cutting Tools (USA) Cassidian (Germany) Komatsu Seiki (Japan) Otec (Germany) Shanghai Cheng Qin Tools (China) Measurement modules based on Focus-Variation 30 Full form measurement of components Micro coordinate measurement with Multi-Measurement and Focus-Variation accessories Technical Specification of InfiniteFocus InfiniteFocus X-Large Systems InfiniteFocusSL: As fast and easy as a 3D profiler can be alicona

5 TOOL MEASUREMENT IF-EdgeMaster: How to measure cutting edges optically and repeatable also in production Measurement modules and user case story: SIMTEK (Germany) IF-EdgeMasterHob: 3D measurement of hob cutters and user case story, LMT Fette (Germany) IF-ToolPrecision: Automatic 3D measurement of taps InfiniteFocusSL in use: 3D measurement of dental implants at Alpha Bio (Israel) IF-Profiler: Alicona s profilometry to traceably measure roughness HIGH RESOLUTION 3D MEASUREMENT IN PRODUCTION IF-SensorR25: Stable 3D measurement in production IF-Portable: Form and roughness measurement on larger components How to achieve traceable roughness measurement Focus-Variation: Technical principle 63 Focus-Variation from a point of view of a tool research association: Heinz Wolfgang Lahmann (GFE) about Focus-Variation Grips, standards and 3D measurement accessories alicona 5

6 As fast and easy as 3D measurement can be 6 alicona I Form and roughness measurement

7 Measure form and roughness with only system» InfiniteFocus» InfiniteFocusSL» IF-Profiler Form and roughness measurement I alicona 7

8 INFINITEFOCUS HOW TO MEASURE FORM AND ROUGHNESS IN ONE SYSTEM THE SYSTEM InfiniteFocus is an optical 3D measurement device that is universal, flexible and applicable in many industries. It combines the functionalities of a surface measurement system and a micro coordinate system in one measurement device. Even when measuring complex forms and large measurement areas, operators achieve a vertical resolution of up to 10 nm. THE BENEFITS Users perform high resolution measurements of even complex components with steep flanks and varying material properties. This also applies to polished components or forms with small radii and angles. Every measurement provides color information registered to the 3D data. THE APPLICATION Typical applications are the cutting edge measurement of drills, milling cutters etc. as well as quality assurance of micro precision components in the automotive industry, aerospace industry, medical technology or micro die casting industry. Other applications are paper and print industry, micro electronics and forensics. THE EXPERIENCE We use InfiniteFocus to measure micro end mills. Here, the option of full form measurement is a key benefit. In our view Alicona has no competition in this field! Also, the system is remarkably easy to use and extremely robust from my point, InfiniteFocus is an unbreakable device. Frank E. Pfefferkorn, Ph.D. Associate Professor, Mechanical Engineering University of Wisconsin-Madison 8 alicona I InfiniteFocus

9 InfiniteFocus stands out with high flexibility and universal use. Users from various industries and various applications and/or inhomogeneous material benefit from a robust measurement device with high usability, high measurement speed, registered color information and traceability.» High vertical resolution that remains constant even across a large vertical scanning range (Z)» Technology that delivers a measurement point density of over 100 mil measure points including an estimation of measurement uncertainty for every 3D point» Automatic deviation from target geometry» Options for automation and offline licenses for an optimal and resource-friendly use» Complete form measurement of drills, mills etc. with the Real3D rotation unit» Ability to change objectives without calibration, upon request also automatically» Various standards and calibration tools to verify traceability» High degree of robustness without wear or maintenance InfiniteFocus I alicona 9

10 WHAT MAKES INFINITEFOCUS DISTINCTIVE Form and roughness measurement with only one system Usually, when measuring roughness a surface measurement system is used whereas for dimensional accuracy or verifying tolerances a coordinate measurement system is used. InfiniteFocus offers the functionalities of both device types combined into one system. Consequently quality assurance becomes more cost-effective, is easier to execute and delivers results more efficiently. Measure small radii and angles even across large measurement volumes More than 100 mil measurement points ensure a meticulously detailed measurement. This is how components and tolerances within the µm or sub-µm range are measured. The high measurement point density of Focus-Variation enables operators to gain a consistently high lateral and vertical resolution even across large measurement areas. Traceable measurement is also provided of small radii, angles and roughness which are often difficult to access. Measure steep flanks In contrast to other techniques, light coming from different directions is used to positively influence a measurement. In addition, the measurement of the maximum flank angle is not restricted by the numerical aperture. Depending on the surface users measure flanks of up to approximately 90. This is achieved via add-ons such as optional ring light or polarization to support the measurement of complex geometries. 10 alicona I InfiniteFocus USPs

11 A technology that measures form and roughness. A flexibility that allows almost unlimited application. A resolution that remains constant over the whole measurement range. And an ease of handling that makes InfiniteFocus a popular measurement device that is widely used. Measure components with varying surface finishes or coating InfiniteFocus is based on an intelligent lighting technology. SmartFlash also allows quick and intuitive measurement of materials with varying surface characteristics or reflection patterns. Modulated light provides optimal illumination throughout the whole measurement area. Operators measure glossy, ground, rough, reflective and diffuse components. Full form measurement with the Real3D technology Meaningful quality assurance requires area based measurements. Due to various hard and software modules, the Real3D technology enables full form measurement of components. Individual measurements from various directions are automatically reassembled for a complete 3D view. This way operators also measure complex contours and surfaces that can hardly be measured optically in the conventional way. Measure even large and heavy components The robust technology of Focus-Variation combined with the vibration isolation frame of InfiniteFocus allows the measurement of roughness plus form on heavy and large components. The spectrum of measurable surfaces goes hand in hand with the respective weight classes up to the dcm 2 range. InfiniteFocus USPs I alicona 11

12 12 alicona I InfiniteFocus References Source: Roush Yates

13 AUTOMOTIVE HIGH PERFORMANCE RACING ENGINE Failure analysis and in-depth surface finish inspection With NASCAR Sprint Cup, Roush Yates is well known for its powerful and reliable racing engines. Here, failure analysis is the key to understand the durability of engine components. To increase performance, Roush Yates was looking for a system with high depth of field to do more extensive surface finish inspection. Today, the work with InfiniteFocus has led to improved processes and maintained quality control. What ABOUT What IS MEASURED What THE CUSTOMER STATES Durability of engine components Failure analysis is a critical task in Roush Yates continuing development. It is the key to understand the durability of engine components as they are being developed and implemented in production. InfiniteFocus is mainly used to measure the geography of fracture sights which normally would not be possible with other systems, as the racing engine builder says. The system enables measurement, documentation and understanding of both dimensions and surface of critical components. Where WHERE INFINITEFOCUS ALSO IS USED Various metals Fracture analysis Typically, crankshafts, camshafts, pistons, connecting rods, valves, valves springs, and rocker arms are measured. Most of the components are reflective with a high contrast ratio and steep, uneven surfaces. The high vertical resolution of InfiniteFocus enables the measurement of also micro cracks over large measurement areas. In addition, color information allows seeing differences in surface characteristics, which in turn helps to understand foreign materials and debris. The majority of material measured is metals, specifically steel, cast iron, aluminum, titanium, and copper. In addition to failure analysis of NASCAR Sprint Cups engines InfiniteFocus is in use for other engine programs as well. Brett Manwill Reliability / Design Engineer Roush Yates Engines We are now able to analyze surfaces very fast and make quick decisions about components without the long lead times of off-site analysis. Alicona surface roughness measurements allow us to determine if a component s surface is inconsistent or is outside of the quality controls desired range over a large surface area. Prior to purchasing InfiniteFocus we did not have any system that had the depth of field to inspect an entire fracture surface. InfiniteFocus References I alicona 13

14 14 alicona I InfiniteFocus References Source: Makino

15 MACHINE TOOL MANUFACTURE VISIBLE PRECISION One system useable by both manufacturer and his customers Makino is well known as a leading supplier of vertical and horizontal machining centers. Our machines are in use whenever highest precision is required, states the manufacturer. InfiniteFocus is used to verify how precise and accurate the machining centers manufacture. Users of Makino apply the optical 3D measurement system to verifiy surface finish and machining results of produced workpieces. What ABOUT Makino uses InfiniteFocus to verify the machining performances of its precision micromachining center iq300 With InfiniteFocus being used in internal testing facilities, Makino meets the requirements of customers in terms of quality assurance throughout high resolution 3D measurement of manufactured components. Both geometry and surface finish are verified. In addition, InfiniteFocus is increasingly used for integrated tool compensation. Where WHERE INFINITEFOCUS ALSO IS USED Extension of worldwide services In near future Makino plans to extend its global services in the fields of Reverse Engineering and 3D Scanning. Also, InfiniteFocus is supposed to be offered as integrated measurement technology for automated tool compensation. What IS MEASURED All kinds of micro precision components Makino measures micro components that have been manufactured for further use in various industries, including tool making, automotive, die casting or aerospace industry. Regardless of industry or specific application, these usually miniaturized components often have complex geometries with challenging forms. Both tool machine manufacturer and users emphasize on verification of dimensional accuracy and achieved surface finish of machined components. This is both achieved with InfiniteFocus since the optical system combines the capabilities of a form with those of a roughness measurement device in one system. However, quality assurance with InfiniteFocus starts at an earlier stage than measuring the final manufactured component. Makino also offers the optical measurement system to perform integrated tool compensation. Measurements with InfiniteFocus make even minimal changed machining parameters clearly visible and transparent, which optimizes manufacturing and accelerates the achievement of tolerances in the µm range. What THE CUSTOMER STATES Toshihiko Tada Application Technology Developing Group Micro Machining Team Makino We expect from our partners highest quality in terms of products and service, which includes high expertise as well as qualified and quick responses to our needs. With Alicona we have found a reliable partner in all fields. Our requests that we address for instance to the departments Support and Applications are followed up quickly, competent and friendly. This is valid for both the European headquarters and the local contact in Japan. InfiniteFocus References I alicona 15

16 16 alicona I InfiniteFocus References Source: Jarvis Cutting Tools

17 CUTTING TOOLS EDGE RADII AND SURFACE FINISH Full form measurement of taps Jarvis Cutting Tools was looking at a number of 3D measurement systems to measure edge radii and surface finish. The high variety of measurable tool types together with the efficiency of quality assurance was the decisive factor to go for InfiniteFocus. The manufacturer of customized tools with very specific geometry requests performs full form measurement in only one system. What ABOUT Manufacturing of customized tools with specific geometries Jarvis Cutting Tools stands for the manufacturing of application specific HSS (high speed steel) and carbide taps. Understanding how only little nuances of surface finish affect the performance of a tool at the customer opens up new possibilities to achieve customized requests for different geometries, gauging requirements and tool life. The tool manufacturer is now able to perform fast and easy quality assurance of a number of different tool types and sizes. Analysis and testing loops are verified within the same day. Also, the development of new standardized ways to measure various processes, e.g. grinding, increases productivity and quality. Where WHERE INFINITEFOCUS ALSO IS USED Cam inspection InfiniteFocus is also used on the maintenance of equipment. Roundness measurement is used for e.g. cam inspection, achieved by the measurement of the outer diameter to verify the shape of the cam. What IS MEASURED Edge radii and surface finish InfiniteFocus is used in combination with the rotation unit Real 3D. Users at Jarvis Cutting Tools perform full form measurement of taps with steep flanks and different coatings. In particular, thread and flute of taps are traceably and repeatably measured. Measurable parameters include e.g. various diameters, radii, roughness, diverse angles and pitch reliefs. Instead of measuring each edge individually the full tap with all relevant edges is captured in only one measurement. What THE CUSTOMER STATES Costikyan Jarvis Chief of Operations Jarvis Cutting Tools Before the use of InfiniteFocus, we were quite ignorant about surface finish. We defined it into rough and smooth, not being aware of how many nuances there can be which affect the performance of the tool at the customer. So when we started working with Alicona, a total new world opened up. We now understand the link between the measurements and the quality of our products. InfiniteFocus References I alicona 17

18 18 alicona I InfiniteFocus References Source: Cassidian

19 AEROSPACE AND AERONAUTICS ERROR ANALYSIS Reduction of material and labor costs Initially Cassidian intended to purchase a measurement device for failure analysis. It did not take the areospace and defence enterprise long to realize the great potential InfiniteFocus has to offer in different areas and today this potential is fully exploited. Typical applications other than failure analysis are incoming goods inspection and the verification of high surface quality for customers. What ABOUT Incoming goods inspection, failure analysis and avoiding customer complaints What IS MEASURED Titan, high strength steels and fibre composites What THE CUSTOMER STATES High resolution measurement of geometry and surface finish is performed to verify the manufacturer's information and identify defects prior to further processing. The surface quality of components is determined with a numerical measurement in order to avoid unsuitable and expensive materials in production. A thorough report that includes practically oriented visualization and measurement results that are easy to read, verifies compliance with the agreed specifications and the stipulated surface finish. Since this was introduced customer complaints at final inspection of aircraft are reduced to a minimum. Where WHERE INFINITEFOCUS ALSO IS USED For the development of a new material in polymer technology Varying components, many of which have complex forms are measured. The measurement of these various components include radii, threads, diverse angles and roughness. Since Cassidian uses InfiniteFocus, surface characteristics are measured, that in the past, were either difficult to access or could not be accessed at all. These include root of a thread and thread flanks of gear drives. Surface damage of various sizes and dimensions are measured, even on round components. The objective is to develop a material of appropriate strength for an optimal adhesion of surfaces. Analysis with InfiniteFocus, using area based measurement, shows which surface treatment and/or which surface parameters improve strength of adhesion. Gregor Heichler Project engineer in the area of non-destructive material testing Cassidian "Due to its high flexibility, Infinite- Focus had paid for itself within the first year. Initially the system had been purchased for failure analysis and for measuring the depth of surface damage. However, it became apparent very soon that the measurement device can be universally used. Today we operate across departments which makes both, quality assurance and development more comprehensive and at the same time easier and more efficient." InfiniteFocus References I alicona 19

20 20 alicona I InfiniteFocus References Source: Alicona

21 MICRO PRECISION STAMPING HIGH PRECISION IN LARGE VOLUME PRODUCTION Injector nozzles which provide best possible combustion Komatsu Seiki Kosakusho manufactures micro precision tools and products for the automobile, electronics, and medical device industries. High emphasis is placed on high quality components even with a monthly production rate of more than 1,000,000 units. The measurement of stamping tools is the first business area where the Alicona InfiniteFocus is used. The high repeatability and resolution of the flexible 3D measurement system is very suitable for the precise and accurate manufacturing. This provides innovation to maintain competitive advantage. What ABOUT Quality assurance in stamping Komatsu Seiki Kosakusho manufacture high quality, small and accurate mass produced products for wrist watches and injector parts for automobile engines. High resolution and reliable measurements are not the only requirement for the products, also the data have to be comparable between the finished products and the stamping tools. Where WHERE INFINITEFOCUS ALSO IS USED Development of new materials in the academic area For the last 10 years Komatsu Seiki Kosakusho has been working on the development of grain size controlled material to provide stable stamping and cutting conditions for micro and nano scale products. The micro or nano structured geometry needs to be measured by non-contact methods, and in high resolution, without any damage on the limited number of development samples. Also, the data created by InfiniteFocus is used for academic papers, books, and presentations in seminars and education. What IS MEASURED Small stamped holes and tool condition Small holes in gasoline injector nozzles and its tools for production are measured. The diameter of small holes is Ø 0.12mm and the length is 0.2mm, and these are produced by micro piercing. The whole condition at entrance and exit is one of the important control criteria for the quality and production departments. InfiniteFocus can easily measure the hole condition without any damage, and it shows 3D analytical images for both the operators and managers. Also we are able to establish a correlation between tool life and product quality. This allows us to develop competitive cost analysis and continuous improvement by measuring tool wear and the wear process in mass production. What THE CUSTOMER STATES Alicona is a very valuable and powerful partner in both service and technical innovation with new developments that offer benefits. It provides benefits and trust between our customers and us. New software-developments increase the range of possible applications into micro and nano scale. I am, thus, very confident with InfiniteFocus and Alicona. Takafumi Komatsu Executive Director Komatsu Seiki Kosakusho InfiniteFocus References I alicona 21

22 22 alicona I InfiniteFocus References Source: Alicona

23 TOOLMAKING PROCESS RELIABILITY IN CUTTING EDGE PREPARATION 3D measurement of the real edge contour OTEC offers innovative drag finishing machines for high precision surface finish. Perfect surfaces, as the supplier states, are achieved quickly and cost-effectively. Customers benefit from optimal machining results with precise edge rounding. For cutting edge measurement, OTEC obtains high resolution surface measurement with Alicona. 3D measurement of chipping, edge radius and traceable roughness measurement provide the supplier with competitive advantages. In sample processing, excellent service is provided. What ABOUT Deburring, grinding, smoothing and polishing By using OTEC machines, cutting edges can be rounded down to 1µm. In order to verify geometries in this detail and accuracy, a 3D measurement system that provides a high resolution is required. This is why OTEC has decided to go for Alicona. Instead of utilizing only common radiusfit, the high resolution of InfiniteFocus enables traceable and repeatable measurement of the real edge contour including its elliptical form. Where WHERE INFINITEFOCUS ALSO IS USED Measurable surface quality OTEC uses InfiniteFocus to numerically verify and illustrate the benefits that apply when using its drag finishing machines. Advanced 3D visualization of machined surfaces including registered 3D color information provides a clear understanding of the advantages that are achievable by using OTEC machines. What IS MEASURED Complex and highly contoured surfaces Complex geometries of deburred, ground, smoothed and polished components are measured. InfiniteFocus is used to verify defined tolerances in terms of cutting edge preparation. In addition to the measurement of edge radius and various edge angles, OTEC also achieves the measurement of chipping along the cutting edge. For test purposes, InfiniteFocus is also used to measure stamped components, turned parts and milled work pieces. In process engineering, OTEC applies high resolution 3D measurement for process monitoring. What THE CUSTOMER STATES Soran Jota Managing Director Otec Präzisionsfinish GmbH, Germany In order to produce a defined edge shape in the µm-range, a highly precise 3D measurement technique is required. The high measurement quality offered by Focus-Variation was the decisive factor for us to continue cutting edge measurement with using Alicona systems. Today, we achieve a higher resolution and higher accuracy. Also, we are now able to measure more tool geometries and types than before. In addition, we appreciate Alicona as a very user-oriented supplier. The intuitive handling of the systems clearly shows an in depth understanding of the users requirements. In our opinion, there is currently no better way to do it. InfiniteFocus References I alicona 23

24 24 alicona I InfiniteFocus References Source: Shanghai Cheng Qin Tools

25 CUTTING TOOLS DEVELOPMENT AND APPLICATION OF CNC TOOLS Improved cutting tool design The use of InfiniteFocus enables the service provider Shanghai Cheng Qin Tools to significantly extend its services in tool design and measurement capability. The ability to perform and visualize full form measurement of complex geometries strengthens the supplier s standing as an experienced expert in the field of high precision cutting tools. What ABOUT Tool design, tool measuring and tool material analysis The main application is the edge measurement of drills, reamers, screw taps, micro end mills and various kind of inserts, e.g. cemented carbide insert, CBN and PCD. Comprehensive measurement functionalities combined with high measurement speed and high repeatability allow the 3D measurement of a wide range of various tools. For Shanghai Cheng Qin Tools this enables significant advantages in tool design and efficient trouble shooting. Where WHERE INFINITEFOCUS ALSO IS USED Design of tool holder Shanghai Cheng Qin Tools also designs tool holders according to customer requests. InfiniteFocus is used to verify the correct match between the tool and the holder. In addition, Reverse Engineering is performed. What IS MEASURED Full form measurement of cutting tools The tool s automatic 360 rotation with the Real3D rotation unit allows complete form measurement from all perspectives. In particular, Shanghai Cheng Qin Tools focuses on the edge symmetry (K, a, b), edge radius, chipping angle, clearance angle, wedge angle and rake angle. Also, measurements of form deviation or reference geometry are performed. Detailed 3D visualization with registered color information illustrates high accuracy and high quality of the cutting tool s surface state. What THE CUSTOMER STATES Lu Hong Bo Manager Shanghai Cheng Qin Tools Co., Ltd. Before we used Alicona, we were not able to perform measurements in this detail. We now are able to conveniently measure a wide range of different tools with high vertical resolution, enabling us to analyze surface details we could not verify before. Also, with InfiniteFocus we achieved the best results in terms of speed, traceability and repeatability during our evaluation of optical measurement systems. What we also like about Alicona is the excellent service, know-how and friendliness of the staff. InfiniteFocus References I alicona 25

26 MEASUREMENT MODULES BASED ON FOCUS-VARIATION All measurement modules installed in InfiniteFocus provide in-depth information of the measured objects geometry s coordinate system. In addition, a variety of form removal utilities are available for form and roughness measurement. This allows simple, accurate and repeatable surface measurement on simple and complex components. All measurement modules are designed by Alicona and are optimally tailored to each other, ensuring user friendly operation. PROFILE-FORM MEASUREMENT Form measurement along a user defined profile Radii, angles, height steps and normal distances are measured automatically or manually. In addition, the profile-form measurement enables the verification of surface parameters such as circum-circle and in-circle plus a series of further thread parameters. Cutting edge measurement can also be performed and users measure radius, basket arch form both waterfall and trumpet type wedge angle and bevel lengths. ROUGHNESS MEASUREMENT Classic profile-based measurement of Ra, Rq, Rz conforming to ISO 4287, 4288 Roughness is measured with comprehensive parameter evaluation of roughness, waviness and frequency. Statistical evaluations and the bearing ratio curve or spectral analysis are graphically visualized. 26 alicona I InfiniteFocus measurement modules

27 A simple to use tab-windows system guide a user through the application and the 3D measurement of various surface parameters. Advanced graphic visualization, including registered color information, enhances the options to characterize surfaces and a series of export functions increase user friendliness. Also complex parameters are visualized and measured from different perspectives. AREAL SURFACE TEXTURE MEASUREMENT Surface measurement according to ISO Surface roughness, in this module, is measured area based instead of profile based. Statistics include bearing area curve, fractal dimension, autocorrelation, gradient distribution, local homogeneity and spectral distribution. A specially designed filter allows form removal to verify roughness on large measurement fields. VOLUME MEASUREMENT Quantification of pits and peaks The volume of features are measured according to a user defined border. The easy positioning of cutting layers or cutting surfaces provide a universal tool. InfiniteFocus measurement modules I alicona 27

28 MEASUREMENT MODULES BASED ON FOCUS-VARIATION 2D IMAGE MEASUREMENT Evaluation of 2D geometries In the 2D view of the measured surface features such as circles, straight lines, angles, parallel lines, distances, ellipses, rectangles etc. can be measured. AUTOMATION Programmable solution for repeating measurement tasks InfiniteFocus measurement applications are programmable, from a simple profile form measurement to more complex hardware control. 28 alicona I InfiniteFocus measurement modules

29 Modular software design The Alicona software design for 3D surface measurement is based on a modular concept which provides a wide range of benefits.» the generation of a 3D data set and the 3D measurement of another already existing data set, are performed independently of one another. Meaning, while one component's 3D data set is created, the operator simultaneously measures another already existing data set without any restrictions. CONTOUR MEASUREMENT Users measure angles, distances, circles, incircles, circumcircles, thread pitch etc. from every position. In addition, the contour measurement module includes roundness measurement. Even complex profiles of e.g. along a helix are measured.» the software modules can be supplemented as required. All Alicona measurement systems are based on the principle of individually adding further application specific modules. This way, operators have the possibility of e.g. adding modules for edge measurement to InfiniteFocus. These modules are standard features of the tool measurement device IF-EdgeMaster.» measurement modules have been developed by Alicona and share a consistent operation. Thus the practical application of a new module is possible immediately and intuitively. DIFFERENCE MEASUREMENT Difference measurement is used to numerically compare two different geometries. A typical application is the measurement of wear before and after use of a cutting tool. Also, users measure form deviations to a CAD-dataset or reference geometry. The module is also used in the field of Reverse Engineering.» the modular software design further enables e.g. customized measurement reports, automation and GD&T measurements. FORM MEASUREMENT Operators measure regular geometries and curved surfaces. Automatic fitting of spheres, cones and cylinders allow the visualization and form measurement of tools and other components. Also, deviation from target geometry becomes clear. InfiniteFocus measurement modules I alicona 29

30 MEASURE FROM EVERY POSITION The Real3D technology automatically merges individual measurements from various directions into a complete 3D data set. InfiniteFocus is not limited to a view from one perspective when performing measurement. If required, a component is measured in 3D from different perspectives. This can either be achieved manually by the operator positioning the respective part or automatically by using the appropriate hardware add-ons. In both cases the individual measurements from various positions are automatically merged into a complete 3D data set. The "Real3D" technology allows the component's visualization from different angles plus a measurement of contour, difference and form. This way, surface parameters that are normally difficult to access are measured quickly and effortlessly. Measuring with the Real3D technology is essentially more user friendly and more accurate than it can be achieved with conventional stitching techniques on the basis of mechanical rotation or transmission Measure components around 360 with a rotation unit The InfiniteFocus combined with the optional rotation unit Real3D, represent a genuine competitive advantage in, for example, the tool industry. Drills, milling cutters etc. are automatically rotated around 360 allowing operators to perform full form measurement of their tools in 3D. Therefore surface characteristics such as diverse flank angles, thread pitch, undercuts and clearance are accessed and measured. A number of various adapters enable the 360 rotation of components without rotational symmetry. 30 alicona I InfiniteFocus Real3D

31 MULTI-MEASUREMENT INFINITEFOCUS ACCESSORIES Fully automatically and in a high resolution - in various positions, from various sides By using the so called Multi-Measurement functionality, different surface features of components are measured from various positions and perspectives. In addition, single measurement fields in the referring measurement volume are captured in the exact geometric relation. Herewith, Alicona performs high resolution optical 3D coordinate measurement. In addition, rotation and tilting of components is achieved with accordant accessories. This enables users to measure further surface details at various positions, which are then optionally merged into a complete 3D dataset. When measuring e.g. a drill, not only the shaft of the tool is captured, but also the tool tip. Multi-Measurement also significantly increases the efficiency of repeatable measurement tasks as serial measurements are performed fully automatically. 1-2 IF-GUIDE Components are continuously equally positioned and aligned to simplify automated measurements. 3 VACUUM-PLATE Used to vacuum clamp the specimen when measuring. Especially useful for thin-walled or sensitive material, e.g. sheets, paper or rubber. 4 SPACER-PLATE Heigth extension for the X/Y stage. Especially for roughness measurements a stable positioning can be ensured. The Spacer-Plate is available in two different heights: 17.5mm and 35mm. 5 RINGLIGHT Additional light source for improved illumination. Especially useful on very complex surfaces. 6 ROTATION-TABLE Hardware for aligning components along X or Y axis of the system. Ideal for the measurement of horizontal or vertical grooves. 5 6 InfiniteFocus Accessories I alicona 31

32 TECHNICAL SPECIFICATION GENERAL SPECIFICATION Measurement principle Measurement result Maintenance Illumination Nosepiece Travel range Weight Size measurement system WxDxH Temperature range Temperature gradient Power supply Size ControlUnit WxDxH non-contact, optical, 3 dimensional, based on Focus-Variation 2-100mio 3D points in registered true color information (maximum is dependent on the used measurement module) maintenance free white LED coaxial light, high power, controllable; Optional: white LED ring light, controllable, polarization 6 objectives manual or motorized X:100mm, Y:100mm, Z:100mm kg, depending on equipment 710mm x 540mm x 628mm (up to 868mm) possible: 5-40 C, calibrated for: C (other temperature ranges can be calibrated) less than 1 per hour 900W; V~; 50-60Hz 540mm x 682mm x 360mm SPECIMEN Specimen surface texture surface topography Ra above 10-15nm with a Lc of 2µm, surface structure dependent Max. height of specimen 100mm up to 240mm Max. weight of specimen 35kg, more on inquiry Maximum slope angle up to 85 Sample preparation none OBJECTIVES Objectives 2,5x 5x 10x 20x 50x 100x Lateral sampling distance µm Min. lateral resolution µm Max. lateral resolution µm Min. repeatability (vert.) µm Max. scan height (approx.) mm Scan speed* µm/s Best vertical resolution** nm Vertical dynamic Working distance mm Field of view X µm Field of view Y µm Max. extended field of view Y mm² Max. uni-directional scan extension mm SOFTWARE Measurement modules and utilities Automation Visualization Database Import/Export Available in Standard: ProfileFormMeasurement (height, angle ), ProfileRoughnessMeasurement (Ra ), SurfaceTextureMeasurement (Sa, fractale dimension ), VolumeMeasurement, 3D-Editor, FormRemoval; Optional: 3DFormMeasurement, DifferenceMeasurement, ContourMeasurement, EdgeMeasurement; IF Automation (built-in script editor),.net Remoting interface 2D-image and high resolution 3D visualization intuitive, graphical database Simple export to STL and VRML, import of CAD-data with STL format, QDAS export, variety of reporting functionalities German, English, Korean, Japanese 32 alicona I InfiniteFocus Specification

33 RANGE OF RESOLUTION AND APPLICATIONS Objectives 2,5x 5x 10x 20x 50x 100x Min. measurable height nm Max. measurable height (approx.) mm Step height accuracy (1mm height step) % Max. measurable area mm² Max. measurable profile length mm Min. repeatability nm Min. measurable roughness (Ra)* nm Min. measurable roughness (Sa)* nm Min. measurable radius µm Min. measurable vertical angle The entries in the table are traceable values. *) The minimum measurable values are dependent on the structure of the specimen. ACCURACY Roughness Measurement U = 25nm at Ra =100nm U = 40nm at Ra = 500nm Height Measurement MPE z = 300nm at z = 10µm MPE z = 400nm at z = 100µm MPE z = 500nm at z = 1000µm Information about measurement conditions is given by request (1) Sensor head and stiffened sensor ribs (2) passive vibration damping and x-/y-stage (3) manual nosepiece (4) motorized nosepiece (5) 2.5x, 5x, 10x, 20x, 50x and 100x objective (6) ring light (7) polarization disc for ring light (8) polarization for coaxial light source (9) height extension* for larger specimens (10) ClampingSet (11) InsertGrip (12) AdvancedInsertGrip (13) RotationTable (14) RotationGrip (15) Real3DRotationUnit *) can only be changed by certified Alicona service engineers InfiniteFocus Specification I alicona 33

34 CUSTOMIZED MEASUREMENTS WITH INFINITEFOCUS X-LARGE Special measurement tasks need special measurement solutions. This is why Alicona offers the X-Large series of InfiniteFocus to characterize surfaces that are not suitable for the standard measurement system due to shape, size or weight of components to be measured. X-Large devices have a different look but offer the same benefits as the standard system: high vertical resolution of even complex forms with steep flanks, measurement of surfaces with varying material and reflection properties and registered color information with each measurement. InfiniteFocus X-Large InfiniteFocus is easily adjustable and functionalities can easily be extended depending on application and measurement task. Its core technology, Focus-Variation, can be transformed into another hardware without losing any of its variety. Area based measurement with high measurement point density, high repeatability, several options for automation as well as high resolution measurements even across large measurement volumes are key benefits that all X-Large variants of InfiniteFocus have in common. The systems dif- fer in possible XY-travel ranges and a max measurable weight of components. The currently available spectrum of InfiniteFocus X- Large solutions includes travel ranges from (mm) 200 x 200 up to 1000 x 1000 with a max measurable weight of up to 20 kg. However, on request an increased weight of components is achievable. This flexibility is also valid for possible applications as each solid material is measurable as soon as there is a minimum surface roughness of only a few nanometers. Typical applications are e.g. the automatic defect analysis of large measurement fields or form measurement of laser structured geometries on printing plates. 34 alicona I InfiniteFocus X-Large

35 MEASUREMENT WITH EXTRAS SPECIFICATION INFINITEFOCUS XL200 Dimensions Weight of system Max. lateral travel range (x/y) Max. vertical travel range (z) Max. sample height Max. sample weight * can be extended Dimensions Weight of system Max. lateral travel range (x/y) Max. vertical travel range (z) Max. sample height Max. sample weight 810mm x 640mm x 780mm 120kg 200mm x 200mm 100mm 100mm* 20 kg SPECIFICATION INFINITEFOCUS XL 500 * can be extended ** load must be centered 900mm x 1100mm x 800mm 300kg 500mm x 500mm 100mm 100mm* 10 kg** Both the InfiniteFocus standard system and the X-Large series for the characterization of measurement fields larger than 10cm x 10cm are easily adoptable to particular environments and/or new conditions. This means that not only the hardware can be changed to meet new requirements, but also the software is extendable individually throughout new software modules. Instead of purchasing a new measurement system because of new or additional measurement tasks which change former conditions to perform quality assurance, Focus-Variation allows the quick and simple implementation of new software modules. This is valid for both already available software modules as well as new modules on request. See what is possible with Focus-Variation there are packages on-hand for the groove measurement of golf clubs, the measurement of diamond particles, valve inspection, conrod and cams measurement etc. SPECIFICATION INFINITEFOCUS XL 1000 Dimensions Weight of system Max. lateral travel range (x/y) Max. vertical travel range (z) Max. sample height Max. sample weight Max. sample dimensions 1680mm x 785mm x 1700mm 1100kg 1000mm x 1000mm 100mm 100mm* 200 kg 1100mm x 1500mm * can be extended InfiniteFocus X-Large I alicona 35

36 INFINITEFOCUSSL AS FAST AND INTUITIVE AS A 3D SURFACE PROFILER CAN BE THE SYSTEM InfiniteFocusSL is a cost efficient optical 3D profile measurement system for easy, fast and traceable 3D measurement of form and finish on micro structured surfaces. Users are able to measure form and roughness of components with only one system. In addition, color images with high contrast and depth of focus are achieved. The robust frame and the intelligent illumination technology provide fast and high resolution measurement in laboratory and production near environment. THE BENEFITS InfiniteFocusSL is particularly attractive due to its cost effectiveness, measurement speed and usability. The long working distance of up to 33mm in combination with the above average measurement field of 50x50mm allows a wide range of applications. Measurements are achieved within seconds, and features, such as a coaxial laser for quick and easy focusing enhance its usability. THE APPLICATIONS Applications range from cutting edge measurement in tool industry to quality assurance and surface finish measurement of micro components and features on surfaces. InfiniteFocusSL is used in the automotive, aerospace, mold and medical device industries. Users also measure difficult to access surface positions including steep flanks or the roughness on, for example, the tooth root of a gear. 36 alicona I InfiniteFocusSL

37 GENERAL SPECIFICATION Travel range X/Y Vertical travel range Z Illumination Weight Dimensions manual option: 25x25mm motorized option: 50x50mm 130mm (26mm motorized) LED ringlight with 24 segments 15kg 195x316x418mm (WxDxH) OBJECTIVES 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Sampling distance µm Min. repeatability (vertical) nm Max. scan height (approx.) mm Best vertical resolution 1 nm Working distance 2 mm Field of view X µm Field of view Y µm Max. extended field of view mm² Max. uni-directional measurement mm ) Vertical resolution can be adjusted in the IF-LaboratoryMeasurementModule 2) SX are objectives with higher working distance RANGE OF RESOLUTION AND APPLICATIONS 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Min. measurable radius µm Min. measurable wedge angle Min. measurable roughness (Ra) nm Min. measurable roughness (Sa) nm InfiniteFocusSL I alicona 37

38 38 alicona I InfiniteFocusSL References Source: Alpha Bio Tec

39 DENTAL IMPLANTS FORM AND ROUGHNESS FOR SAFE SEALING 3D measurement of implant and abutment Alpha Bio targets the ongoing improvement of measurements during development, production and final inspection of both dental implants and accessories. InfiniteFocusSL is used in all stages of the manufacturing process and enables accurate, reliable and repeatable measurements, says Alpha Bio. Both form and surface finish measurements even across large measurement fields are performed in only one system. What ABOUT Innovation in development, production and final inspection What IS MEASURED Internal conical connection and surface finish What THE CUSTOMER STATES Quality engineering at Alpha Bio focuses on measurement systems that are more precise, more accurate and more reliable in terms of repeatability and reproducibility. With InfiniteFocusSL, the leading manufacturer of advanced implantology and prosthetics solutions is now able to perform both roughness and form measurements with only one system. In particular, form measurement has opened up new measures in quality assurance, as it allows the measurement of the internal conical connection of implants. In combination with roughness measurement, this ensures the safe sealing of implant and abutment. Where WHERE INFINITEFOCUS ALSO IS USED Volume measurement InfiniteFocusSL is used to measure form and roughness. Among other geometries, form measurement includes the verification of a cone s open conical angle, its roundness as well as different radii and other geometry requirements. In addition to form, also surface finish measurements are achieved. Both, internal and external roughness even at the thread flank is measured. When measuring the external roughness of an implant, areal measurements (Sa, Sq, Sz ) lead to more significant results to verify the surface state. In addition to surface finish and form, volume measurements are performed. Registered 3D color information enables comfortable alignment. Josef Meisler Quality Engineering Alpha Bio Tec My first impression about Alicona was the high expertise and professionalism of its people. I immediately felt that I can rely on a strong partnership and continuous support as well as on the accurate and repeatable measurements achieved by the system. With InfiniteFocusSL I now measure parameters that I have never been able to inspect before. The Alicona 3D measurement system significantly upgrades Alpha Bio s quality engineering metrology lab. InfiniteFocusSL References I alicona 39

40 IF-PROFILER HOW TO MEASURE ROUGHNESS AND SURFACE FINISH THE SYSTEM Optical surface profilometry to measure roughness and form The IF-Profiler is a handheld 3D measurement system for high resolution measurement of surface finish including form. Users measure roughness and form of both, flat and curved components with only one system. The lightweight IF-Profiler consists of a 3D measurement sensor and a robust, at the same time handy framework. The ergonomic design combines ease of use and requested mechanical rigidity. THE BENEFITS Flexible and easy to use The IF-Profiler achieves flexible measurements and applications at high measurement speed. Various positions and measurement fields are traceably and intuitively measured. Depending on the application, users gain results within 3 seconds. The working distance of up to 34mm in combination with a measurement field of up to 10mm x 10mm enables a high range of measurable components. Roughness is measured based on the extraction of a linear profile (ISO 4287/88). In addition, users benefit from areal measurements (ISO 25178) enabling the verification of local roughness and real surface state. THE APPLICATIONS Quality assurance of car bodies, steel plates, print rolls, etc. Amongst other applications the IF-Profiler is used to measure surface finish and form even of large and heavy components. Fields of use are the measurement of e.g. turbine or rotor blades, steel and body type surfaces. Traceable measurements are achieved in high repeatability. 40 alicona I IF-Profiler

41 GENERAL SPECIFICATION Travel range Z Illumination Weight Dimensions 25mm motorized LED ring light with 24 segments 6.5kg 157x300x344mm (WxDxH) OBJECTIVE DETAILS 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Sampling distance µm Min. repeatability (vertical) nm Max. scan height (approx.) mm Best vertical resolution 1 nm Working distance mm Field of view X µm Field of view Y µm RANGE OF RESOLUTION AND APPLICATION 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Min. measurable radius µm Min. measurable angle Min. measurable roughness (Ra) 1 nm Min. measurable roughness (Sa) 1 nm ) Vertical resolution and min. measurable roughness are adjusted automatically, dependent on application and environment (vibrations ) 2) SX stands for objectives with larger working distances IF-Profiler I alicona 41

42 Contactless cutting edge measurement in research and production 42 alicona I Tool measurement

43 Tool measurement» IF-EdgeMaster» IF-EdgeMasterHOB» IF-ToolPrecision Tool measurement I alicona 43

44 IF-EDGEMASTER HOW TO MEASURE CUTTING EDGES OPTICALLY AND REPEATABLE ALSO IN PRODUCTION THE SYSTEM The IF-EdgeMaster is an optical 3D measurement device to automatically measure cutting tools. Typically, the system is used to measure cutting edges regardless of type, size, material or surface finish of the tool. Users measure radii > 2µm as well as rake, wedge and clearance angle of cutting edges. Both waterfall-type and trumpet-type are precisely measured. The robust technology of Focus-Variation delivers stable and traceable measurements also in a production near environment. THE BENEFITS The IF-EdgeMaster delivers fully automatic measurements and stable results even with external vibration and external light. The system provides user friendly operation with high measurement speed. High vertical resolution enables chipping measurement and, in addition, traceable roughness measurements at the rake face of an edge. A specially designed illumination technology enables optimized illumination of surfaces with short exposure times, leading to fast measurements. THE APPLICATION Users benefit from high resolution measurements during the whole manufacturing process. The IF-EdgeMaster is used to measure the green part of a tool as well as the highly polished component in its final stage. Typically, the measurement system is used to measure inserts, drills, millers etc. Advanced visualization including registered true color information allows transparent and provable quality assurance. THE EXPERIENCE In addition to the large variety of measurement possibilities, it was the user friendly operation of the system that convinced us in the first place. These characteristics combined with the high measurement accuracy make this device an ideal tool for our production! Ulrich Weber Special Tools Construction, SIMTEK 44 alicona I Tool measurement IF-EdgeMaster

45 GENERAL SPECIFICATION Travel range X/Y Travel range Z llumination Weight Dimensions manual option: 25x25mm, motorized option: 50x50mm 130mm (26mm motorized) LED ring light with 24 segments 15kg 195x316x418mm (WxDxH) OBJECTIVE DETAILS RANGE OF RESOLUTION AND APPLICATIONS 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Sampling distance µm Min. repeatability (vertical) nm Max. scan height (approx.) mm Best vertical resolution 1 nm Working distance 2 mm Field of view X µm Field of view Y µm Max. extended field of view mm² Max. uni-directional measurement mm ) The vertical resolution is automatically adjusted depending on the application. 2) Objectives with larger working distances are available (5x objective: 34mm, 10x objective: 33.5mm, 20x objective: 20mm, 50x objective: 13mm). For detailed specifications please contact sales@alicona.com. 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Min. measurable radius µm Min. measurable wedge angle Min. measurable roughness (Ra) nm Min. measurable roughness (Sa) nm Tool measurement IF-EdgeMaster I alicona 45

46 TRACEABLE 3D MEASUREMENT OF VARIOUS TOOL TYPES AND SIZES Fully automatic cutting edge measurement of inserts, micro end mills, drills, taps, etc. Users measure radii, shapes, chipping and roughness regardless of type, size, material or surface finish. Straight and curved edges and edges with or without bevels are measured. A range of user friendly functions in hard and software supports the high measurement accuracy, high measurement speed and intuitive user guide. RADIUS AND FORM MEASUREMENT Users measure e.g. radius, clearance angle (α), wedge angle (β), rake/ chipping angle (ɣ), edge symmetry (K) as well as negative and positive bevel lengths. Measurements include projected bevel length, true bevel length and bevel angles. CHIPPING MEASUREMENT High resolution enables the measurement of ISO 4287 conform parameters (Ra, Rq, Rz, Rp, Rv ) along the edge, making e.g. edge defects measurable and visible. TRUE EDGE CONTOUR THROUGH ELLIPTIC FIT Inserts with both waterfall and trumpet shapes are measured. A fit of elliptic shapes into the edge region describes the shape by two radial parameters. The edge can also be compared to user-defined basket arch files of arbitrary shape.» a coaxial laser, which enables best possible positioning and focusing of a component» a robust coarse drive for a quick start of the measurement and an effortless change of specimen» an optional motorized XYmeasurement stage with integrated axis control for the accurate measurement of various components and geometries» a ring light with individually controllable segments based on a concentrator optics. This provides an optimal surface illumination with high contrast and short exposure times» a polarizer which is activated by motorization supports the measurement of highly polished components or other surfaces with high reflective properties» a compact, lightweight control unit with integrated power supply for mobile and handy use» a robust, compact and specially designed Z-axis with integrated 5nm resolution linear scale for maximum measurement accuracy, planarity and straightness» a vibration-isolating frame including sensors to monitor vibrations, temperature and temperature gra dients for best possible use in a production near environment FORM DEVIATION WITH DIFFERENCE MEASUREMENT 3D measurements are automatically compared to an imported 3D data set or reference geometry. Measurable parameters are e.g. min./max./mean deviation to reference surface. Also, form deviations are clearly visible by advanced color coded visualization. 46 alicona I Tool measurement IF-EdgeMaster

47 CUTTING TOOL INSERTS RADIUS AND BEVEL MEASUREMENT Exact cutting edge geometry for higher process reliability in production Practical 3D measurement in production has to be precise, quick and simple. The IF-EdgeMaster not only offers repeatable and traceable measurements within a few seconds but also a very simple and intuitive user interface. Simtek Precision Tools uses these benefits for high resolution edge measurement and provable quality assurance. What ABOUT Each batch with same tool lifetime Simtek Precision Tools develops, manufactures and distributes high precision tools for high demands. The product range includes about 10,000 standard tools for Turning, Grooving, Groove Milling, Broaching, Thread Whirling, Polygon Milling etc. One of the manufacturer s key priorities is to deliver tools that with each batch have the same geometry and perform identically to offer process reliability to their customers. Cutting edge measurement is, amongst others, performed with the IF-EdgeMaster. What IS MEASURED Carbide inserts The IF-EdgeMaster is mainly used for the measurement of very small radii on carbide inserts. In addition, negative and positive bevels on the inserts are measured as they decrease signs of wear and increase durability. Negative bevels, for example, increase the cutting pressure and at the same time protect the cutting edge. Detailed visualization of the measurements is used for transparent, provable quality assurance. What THE CUSTOMER STATES In addition to the large variety of measurement possibilities, it was the user friendly operation of the system that convinced us. The IF-EdgeMaster has an extremely intuitive user interface and is very easy to operate. These characteristics combined with the high measurement accuracy make the device ideal for our production! Ulrich Weber Special Tools Construction SIMTEK Precision Tools Tool measurement IF-EdgeMaster I alicona 47

48 IF-EDGEMASTERHOB IF-EdgeMasterHOB is one of Alicona s optical 3D tool measurement systems and a market specific adapation of the optical cutting edge measurement device IF- EdgeMaster. Due to a patent pending illumination technology and special vibration isolation, the system is also suitable for the use in production. In terms of hard- and software, the IF-EdgeMasterHOB is adjusted to measure hob cutters. Users measure the edge geometry at the tooth flank, the tooth root and tooth tip. This includes parameters such as radii, wedge angle, basket arch form ( waterfall and/or trumpet type) as well as positive and negative bevel of the edge. In addition, the system provides both chipping and traceable roughness measurement. Other typical applications are wear measurement or the automatic comparison to CAD data or reference geometry. A large vertical working distance allows effortless measurement of cutting edges even in areas that are hard to access. Users measure hob cutters at every stage of manufacture, regardless of surface finish or coating. GENERAL SPECIFICATION Travel range Rotation table +/- 90 Illumination Weight Dimensions Sample size OBJECTIVE DETAILS 66mm (26mm motorized) LED ring light 18kg 299x254x502mm (WxDxH) Diameter mm 10x SX 2 Sampling distance µm 1.1 Min. repeatability (vertical) nm 40 Max. scan height (approx.) mm 22 Best vertical resolution 1 nm 100 Working distance 2 mm 33.5 Field of view X µm 1760 Field of view Y µm ) The vertical resolution is automatically adjusted depending on the application. 2) Objectives with larger working distances. RANGE OF RESOLUTION AND APPLICATIONS 10x SX 1 Min. measurable radius µm 6 Min. measurable wedge angle 20 Uncertainty of angle 0.5 Max. Bevel length µm alicona I Tool measurement IF-EdgeMasterHOB

49 HOB CUTTERS EDGE MEASUREMENT AT TOOTH FLANK, TOOTH ROOT AND TOOTH TIP Optimized cutting edge geometry for controlled tool lifetime in operation When LMT Fette introduced a new blasting technology for cutting edge preparation of hob cutters, a quick and reliable measurement system to support this process was necessary. In selecting the IF-EdgeMasterHOB, the manufacturer of precision tools chose another one of Alicona s 3D measurement systems. Quality assurance with the IF-EdgeMasterHOB enables the production of hob cutters with optimized geometry and identical tool-lifetime in operation. What ABOUT In-process measurement to produce hob cutters with equal cutting edge geometry Due to a new technology for cutting edge preparation LMT Fette manufactures hob cutters with an equal geometry. This enables the supplier to offer tools that provide identical lifetime in production. The edge geometry of the hob cutters is verified with high resolution and traceable 3D measurements with the IF-EdgeMasterHOB. The optical 3D measurement system delivers repeatable results even at positions which have been difficult to access before use of the Alicona system. What IS MEASURED Form and chipping The IF-EdgeMasterHOB is used for hob cutters in the model range 1-7. This means that LMT Fette is able to measure tooth sizes of up to 11mm with one objective. High emphasize is placed on the edge measurement at the tooth flank, the tooth root and the tooth tip. This includes parameters such as radius, wedge angle, basket arch form (waterfall-type and trumpet-type) as well as bevel length. In addition, the IF-EdgeMasterHOB is used for measure chipping. What THE CUSTOMER STATES Being able to measure the edge radius of both, tooth tip and tooth flank over this broad range is, as far as I know, not possible with any other system. The high resolution 3D measurements with the IF-EdgeMasterHOB enable us to offer tools with dimensional accuracy, optimized surface state and an equal geometry for increased process reliability. Also, the system s user friendliness and the independence from user influence are truly impressive. Tobias Schulz Head of quality assurance in gearing LMT Werkzeugtechnologie Tool measurement IF-EdgeMasterHOB I alicona 49

50 IF-TOOLPRECISION AUTOMATIC 3D MEASUREMENT OF TAPS THE SYSTEM The IF-ToolPrecision is a non contact, automatic 3D tool measurement system for areal based and high resolution measurement of shank-tools. The system is optimized to measure taps. It combines all the functionalities of a coordinate measurement machine, a surface measurement device and a contour plus roundness measurement system. Users measure relevant parameters in the chamfer area, the flute and in the thread. THE BENEFITS The IF-ToolPrecision measures with a high measurement point density at high user friendliness. This is valid for the use in both research and single handed operation. There are no time consuming calibration routines necessary as the insertion of the tool is very simple with auto calibration included. This both reduces measurement times and increases accuracy. Measurement reports include OK/NOT OK status, tolerances and visualization in registered true color information. THE APPLICATIONS The IF-ToolPrecision measures with a high measurement point density. Users benefit from a detailed and dense visualization which makes the system to an ideal tool in both tool design and reverse engineering. The 3D measurement system is used for both, 3D digitalization of the tool and automatic comparison with CAD data. 50 alicona I Tool measurement IF-ToolPrecision

51 THE EXPERIENCE Before IF-ToolPrecision, there worldwide was no comparable system available neither in function nor in precision. Michael Ackermann Bass GmbH & Co.KG Tool measurement IF-ToolPrecision I alicona 51

52 Stable 3D measurement in production 52 alicona I Quality assurance in production

53 Quality assurance in production» IF-SensorR25» IF-Portable Quality assurance in production I alicona 53

54 IF-SENSORR25 HOW TO ACHIEVE STABLE 3D MEASUREMENT IN PRODUCTION THE SYSTEM Optical 3D measurement sensor IF-SensorR25 is a solid optical 3D measurement instrument for automated form and roughness measurement in production. The sensor is integrated into a production line and delivers high resolution, repeatable and traceable results when measuring surface characteristics in the µm or sub-µm range. This resolution can hardly be achieved by conventional 2D solutions or tactile techniques. THE BENEFITS A measurement procedure from development to production The robust technology of Focus-Variation delivers high resolution results with high repeatability in research and production. Therefore IF-SensorR25 is a platform that enables the use of the same measurement process both in-line and in the lab. Standardized interfaces (QDAS) support an easy and quick integration into production allowing comparable in-line and lab measurements. THE APPLICATION Measurement of surface quality and finest form tolerances IF-SensorR25 is a measurement system for quality assurance in serial production. It is suitable for numerous materials including composite materials. Applications range from tool to automotive industry, die casting industry and any form of precision manufacturing. The modular design allows arbitrary extensions of hard- and software for new and/or complex measurement tasks. 54 alicona I Quality assurance in production IF-SensorR25

55 OBJECTIVE DETAILS GENERAL SPECIFICATION Travel range Z Illumination Weight Dimensions 26mm motorized LED ring light with 24 segments 4kg 126x153x220mm (WxDxH) 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Sampling distance µm Min. repeatability (vertical) nm Max. scan height (approx.) mm Best vertical resolution 1 nm Working distance 2 mm Field od view X µm Field of view Y µm Max. extended field of view mm² Max. uni-directional measurement mm ) Vertical resolution can be adjusted in IF-LaboratoryMeasurementModule. 2) SX stands for objectives with larger working distances. RANGE OF RESOLUTION AND APPLICATIONS 10x 20x 50x 2x SX 2 5x SX 2 10x SX 2 20x SX 2 50x SX 2 Min. measurable radius µm Min. measurable wedge angle Min. measurable roughness (Ra) nm Min. measurable roughness (Sa) nm Quality assurance in production IF-SensorR25 I alicona 55

56 IF-PORTABLE HOW TO MEASURE MICRO STRUCTURED SURFACES ON LARGER COMPONENTS THE SYSTEM The IF-Portable is an optical 3D measurement device to measure form and roughness on also larger components. The standard configuration allows the high resolution measurement of surface fields of up to (mm) 50x50x26. Typically, the system is used for near and or in production quality assurance. As an easy to handle and portable system it is a flexible measurement station which can be used wherever it is needed. THE BENEFITS A key feature is the integrated revolving nosepiece to change objectives and measurement resolution. This increases measurement precision as each objective is pre-calibrated, avoiding error-prone readjustment or recalibration processes. Also, easy automation of measurements increases process reliability, production efficiency and usability. THE APPLICATIONS A large vertical scanning range enables the measurement of various geometry types and forms. Amongst others, a key application is platen inspection in print industry. Further fields of use are the measurement of turbine or rotor blades, steel and body type surfaces. Users achieve traceable measurements in high repeatability. 56 alicona I Quality assurance in production IF-Portable

57 THE EXPERIENCE The form of a laser structured surface geometry is a crucial challenge when it comes to measure a platen. With the IF-Portable system we have found a solution which really delivers precise results. Andreas Tillmann project management Heidelberger Druck GENERAL SPECIFICATION Travel range X/Y Travel range Z Illumination Weight Dimensions 50x50mm 26mm LED coaxial light 9.3kg (dependent from configuration) 300x180x260mm (WxDxH) OBJECTIVE DETAILS 2.5x 5x 10x 20x 50x 100x Sampling distance µm Min. repeatability (vertical) nm Max. scan height (approx.) mm Best vertical resolution 1 nm Working distance mm Field od view X µm Field of view Y µm Max. uni-directional measurement mm ) Vertical resolution can be adjusted in IF-LaboratoryMeasurementModule RANGE OF RESOLUTION AND APPLICATION 2.5x 5x 10x 20x 50x 100x Max. measurable area mm² Min. measurable angle Min. measurable roughness (Ra) nm Min. measurable roughness (Sa) nm Quality assurance in production IF-Portable I alicona 57

58 58 alicona I Technology & Accessories

59 Technology & Accessories» Principle of Focus-Variation» Traceable roughness measurement» Focus-Variation from the perspective of a tool research association: A guest editorial Technology & Accessories I alicona 59

60 RELIABLE ROUGHNESS MEASUREMENT MEANS TRACEABLE ROUGHNESS MEASUREMENT Based on the Focus-Variation technology, InfiniteFocus offers a high measurement system capability for measuring surface roughness. Roughness is measured profile based according to ISO 4287/88 and area based according to ISO Due to unique technology and system specific characteristics, operators perform repeatable and traceable roughness measurements down to 0.05 µm. A high vertical and lateral resolution enables measurements of components with low roughness but also of highly textured surfaces. This measurement performance is supported by the flexible lighting technology which allows the measurement of steep flanks and materials with varying surface characteristics. The large vertical travel range with a long working distance makes it possible to measure varied component forms and types. Using standards of the PTB (Physikalisch Technische Bundesanstalt, Braunschweig, the national metrology institute providing scientific and technical services) and the DKD (Deutscher Kalibrierdienst) for calibration and adjustment guarantee traceable results. The high vertical and lateral resolution of InfiniteFocus is based on:» a robust measurement sensor with integrated granite» a glass scale with a 2nm resolution» specially developed lens» a high quality and high resolution CCD sensor» an optical vibration isolation Area based surface parameters conforming to ISO 25178» Height parameter (Sa, Sq,..)» Lateral parameter (Sdq, Sdr,..)» Functional parameter (Sk, volume parameter...)» Features (Sda,.) 60 alicona I Technology

61 PROVABLE PRECISION OPTICAL ROUGHNESS MEASUREMENT WITH INFINITEFOCUS Due to the Alicona roughness standard the optical roughness measurement of InfiniteFocus guarantees traceable precision:» The standard that is traceable to the PTB is applicable for all optical techniques included in EN ISO.» This roughness standard is suitable for optical as well as for tactile scanning and thus enables comparison to tactile roughness measurements.» Available roughness values: Ra 100nm, 500nm and 3000nm Average roughness value Ra Tactile measurement Optical measurement with InfiniteFocus Roughness standard nm 103nm Roughness standard nm 501.3nm How Focus-Variation works The specimen is placed onto the stage and is illuminated with modulated light. This light is transmitted through the optic and focused through a beam splitter onto the specimen. Coaxial illumination is created. The light is reflected by the specimen and projected on to a digital sensor in the precision optic. Depending on the objective selected various lateral and vertical resolutions can be achieved. As the distance between specimen and objective is varied the change of sharpness is measured. Depending on the 3-dimensional structure of the specimen some areas are depicted sharp or not, the sharp data is used to construct the 3D dataset. Essential to the measurement result is the correct interaction of modulated illumination with continuous vertical movement and the quality of the sensor measurement. This process is achieved with the Smart- Flash technology developed by Alicona. For every position on the object the sharp regions are measured. The variation of the sharpness values is used for the measurement of the 3D-postion. This is how dense 3D-datasets are created. Technology I alicona 61

62 TECHNOLOGY: FOCUS-VARIATION InfiniteFocus is based on the principle of Focus-Variation. It is a robust technology with a high measurement point density including information about measurement uncertainty. Focus-Variation is applied in both research and production. MEASUREMENT POINT DENSITY AND REPEATABILITY A large number of dense measurement points, also on larger areas, provides highly repeatable measurements. Alicona also automatically provides an estimation of the repeatability of every single measurement value analyzing the variance of each measurement point in the Z-direction. This repeatability measure helps to evaluate the quality of individual measurement points. This again allows measurement results that are easy to interpret. In addition it shows if and to which extend vibrations occurred during the measurement. InfiniteFocus provides high resolution and reproducible measurement results in both the lab and in rougher manufacturing environments.» The technology works reliably and is not affected by environmental influences such as temperature or ambient light. This is due to the large amount of data that is used for measuring every single z-value.» InfiniteFocus is a high quality measurement device and generally insensitive to external influences. The system includes a vibration absorption construction and is therefore vibration resistant. INFINITEFOCUS: Dr. Manfred Prantl, Alicona R&D CEO Security and reliability are the cornerstones in each development. We develop with high investment in R&D, ensuring that we can tackle the needs required in industry and science.» All Alicona measurement systems guarantee versatility and precision.» The use of the measurement systems is easy to understand even though a variety of different settings is provided.» All measurement results are traceable back to the PTB as well as to NPL. Additionally we have developed our own standard that allows the verification of the accuracy of optical roughness measurements.» Various light sources minimize the impact of light.» InfiniteFocus delivers an estimation of the measurement uncertainty for every 3D-point. 62 alicona I Technology

63 FOCUS-VARIATION FROM THE PERSPECTIVE OF A TOOL RESEARCH ASSOCIATION A GUEST EDITORIAL BY HEINZ-WOLFGANG LAHMANN Heinz-Wolfgang Lahmann from the Society for Production Engineering and Development (GFE e.v.) Schmalkalden/Germany is an expert in the application of optical measurement procedures for the evaluation of precision tools. Among other subjects, he specializes in the metrological characterization of a tool's micro geometry and is familiar with the developments in measurement and test engineering. For basic research on cutting edge characterization he also uses Focus-Variation. From the traceable edge measurement with InfiniteFocus he expects significant progress, which he describes as follows. There is still a huge need in the research on the problem, what impact typical parameters of a cutting edge produce on the processing result. During industry for quality assurance is mainly focused on the measurement of a radius, chipping, wear and micro cracks, research however is dealing with a problem, which additional surface parameters can be used for a functional description of a cutting edge. Recent developments in metrology help us to move forward with relevant activities. This is why, among other factors, the impact of a form of the cutting edge and its roughness is examined as to their influence on the results of processing. Here the Focus-Variation turns to be increasingly establishing itself as an appropriate technology. The area based, high resolution measurements that can be achieved by Focus- Variation open new possibilities for research, and, consequently, new insights into cutting edge characterization which was not possible in such a form until now. One of the most significant benefits for us is the fact that we are now able to perform traceable measurements of both geometry and roughness of various edge types. "One of the greatest advantages, besides the high vertical resolution, is the fact that with Focus- Variation we are able to perform traceable measurements of geometry and roughness of different edge forms." The main subject of our current studies is dealing with possible effects that the cutting edge form might produce on the processing result in addition to the edge radius. Therefore every common edge form, ranging from simple edge roundness to a more complex, elliptic form has to be completely measured. At GFE we perform these measurements primarily by means of InfiniteFocus optical measuring system. Due to a lateral resolution in the submicrometer range and a vertical resolution in nanometer range, the device is ideal for defining necessary roughness parameters. With the 3D measurement device by Alicona we also measure additional parameters such as the roughness on the clearance and chip surface. These parameters analyze the impact of roughness on the machining process, workpiece quality, durability and chip flow. Another subject of research is the correlation between a tool and a workpiece. The study examines effects of the material, a tool has been made of, on the machined workpiece or vice versa, how the material of a workpiece affects the tools as for its wear and the like. Here, we benefit from the flexibility of Infinite- Focus as we use the system for the measurement of a tool and a workpiece. For a research association, visualization plays an important role as well. It delivers an additional evaluation possibility for a better analysis of a tool. The visualization in true color information with InfiniteFocus also allows us to detect coated areas quickly and without much effort. Heinz-Wolfgang Lahmann Society for Production Engineering and Development (GFE e.v.), Schmalkalden/Germany Technology I alicona 63

64 ACCESSORIES Alicona offers a range of accessories which increases usability and minimize user influence. A selection of standards ensures traceability of the measurements performed TOOL-GRIP Grip for user-friendly and repeatable clamping of shaft tools. Tools with diameters of up to 30mm and lengths of up to 250mm are measurable. Usable for: IF-EdgeMaster, InfiniteFocusSL, InfiniteFocus 5 INSERT-GRIP A tool for placing small components in an exact 45 position. This minimizes sources of error and increases repeatability. Usable for: IF-EdgeMaster, InfiniteFocus, InfiniteFocusSL, IF-Profiler 2 ADVANCED REAL3D ROTATION UNIT Grip including automatic motorized tilt axis for full form measurement of components. Its special design allows the use of the same clamping system that is applied in production. Users avoid the inefficient achievement to remove a tool from the clamping system used in manufacturing to then fix it in a different tool holder to perform 3D measurements. Usable for: InfiniteFocus, InfiniteFocusXL200 3 COLLET CHUCK Extension of the Real3D rotation unit to clamp tools with shaft diameters down to 1mm. In total, a set of four different chucks (1mm, 1.5mm, 2mm, 2.5mm) is offered. Usable for: InfiniteFocus 4 NANO GRIP Sample holder to fix components with a smooth contact surface in XY. Usable for: InfiniteFocus, InfiniteFocusSL, IF-EdgeMaster, IF-Profiler 64 alicona I Accessories 6 ADVANCED-INSERT-GRIP Grip for the measurement of small objects in variable oblique positions. This grip can be adjusted to most specimens and also locked in the desired position. Measurement comfort and repeatability are increased. Usable for: IF-EdgeMaster, InfiniteFocus, InfiniteFocusSL 7 ROTATION GRIP Clamping device for horizontal mounting of components such as drills or milling cutters. Tools are rotated into the desired position to also easily measure cutting edges. Usable for: InfiniteFocus, InfiniteFocusSL, IF-EdgeMaster 8 CLAMPING-SET A set of different clamping bars for mounting and securing specimens in a certain position: A flexible solution for flat, steep and round components. Usable for: IF-EdgeMaster, InfiniteFocus, InfiniteFocusSL 9 45 MIRROR Optical 45 mirror to also measure the inner geometry of components. Usable for: InfiniteFocus

65 IF-TRAVELLER Case for the flexible transport of Alicona s InfiniteFocusSL, IF-EdgeMaster and IF-Profiler. It is designed to easy pack and unpack the systems for 3D measurements independent from a defined location. Usable for: InfiniteFocusSL, IF-EdgeMaster, IF-Profiler Accessories I alicona 65

66 STANDARDS 1 1 VERIFICATION TOOL Standard, traceable to the PTB, with miscellaneous form artifacts such as steep slopes, angles and cylinder sizes. Used for verifying the accuracy of form measurements. Usable for: All Alicona 3D measurement systems 2 ROUGHNESS STANDARD Roughness standard for optical and tactile measurements traceable to the PTB. With this tool, the accuracy of optical roughness measurements is verified. All ISO optical measurement techniques are validated. Usable for: All Alicona 3D measurement systems 2 3 CALIBRATION TOOL Standard, traceable to the PTB, for verifying the vertical and lateral accuracy. It provides a height step (1000µm) for the vertical check and various chess patterns for the verification of lateral results. Usable for: All Alicona 3D measurement systems 3 4 AREAL ROUGHNESS STANDARD Standard, traceable to NPL, for verifying optical roughness measurements. It provides the calibration of areal roughness parameters such as Sa, Sq or Sz in compliance with ISO Usable for: All Alicona 3D measurement systems 4 5 DEPTH MEASUREMENT STANDARD Standard, traceable to national metrology institutes, for the verification of small scale height measurements. Height steps from 0.24µm to 75µm are provided. Usable for: All Alicona 3D measurement systems 6 EDGE CALIBRATION TOOL Standard, traceable to national metrology institutes, for the verification of edge measurements. It shows radii from 1µm to 20µm. Usable for: All Alicona 3D measurement systems alicona I Standards

67 SELECTED CUSTOMERS Bass Ceratizit EDM ETH Fette FZG Fraunhofer Vision Fraunhofer IPA Heidelberg Inspire NFI NPL Thyssen Krupp PTB PTS SIMTEK TU Hamburg Harburg Vollmer VW University of Wisconsin KomatsuSeiki Vargus IFAS Makino Profin Atomic LMT Fette Rohde & Schwarz GF AgieCharmilles GFE Cassidian Sutton Tools Intai Jarvis Roush Yates Shanghai Cheng Qin Tools Selected customers who have contributed to the magazine series FOCUSvariation. Alpha Bio Tec OTEC Diehl Metall Selected customers I alicona 67

68 Alicona headquarters Alicona Imaging GmbH Dr.-Auner-Straße 21a 8074 Raaba/Grambach Austria phone fax Alicona Asia Alicona Korea Pacific Co. Ltd , 16th Floor, Hangangno Byucksan Megatrium 2-8 Hangangno 2-ga Yongsan-gu Seoul phone fax Alicona UK Alicona UK Ltd. Lime Tree House 15 Lime Tree Walk Sevenoaks Kent TN13 1YH UK phone fax Alicona France Alicona SARL Rue de Savoie Les Ulis France phone fax Alicona Germany Alicona GmbH Buchenötz Schönau Germany phone fax sales@alicona.com Germany South/West phone sales.de@alicona.com Alicona US Alicona Corporation 1261 Humbracht Circle Suite G, Bartlett IL USA phone fax sales.us@alicona.com Germany North phone sales.de@alicona.com Germany South/East phone sales.de@alicona.com IF Technical data, images, descriptions without obligations. We reserve the right to modify content. alicona and InfiniteFocus are registered trademarks, copyright by alicona