Alicona FOCUSvariation, Edition 3, English

The magazine about Alicona-metrology

English edition 3, 2012/2013

TRACEABLE ROUGHNESS MEASUREMENT

HOW TO MEASURE FORM AND ROUGHNESS WITH ONLY ONE SYSTEM

OPTICAL 3D MEASUREMENT IN PRODUCTION

FAST INTUITIVE MEASUREMENT InfiniteFocusSL

InfiniteFocusSL

IF-EdgeMaster IF-Portable

IF-ToolPrecision

InfiniteFocus X-Large

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IF-SensorR25

InfiniteFocus

Dr. Stefan Scherer, Alicona CEO

Dr. Manfred Prantl, Alicona CEO

Recommended: 3D measurement technology Which measurement technology should I use? Which device and which provider are the best choice for performing my measurement task?

In the age of multimedia and information overload, it is clear that especially those suppliers who were recommended the most, are also trusted the most. Thus, every year we have our customers speak for us and have them present our measurement systems including information about applications and benefits. The latest statements are published in the new, third edition of FOCUSvariation.

Common applications in different industries give an idea of where and how to use the Focus-Variation technology.

One aspect that our customers very often associate us with, is reliability. This clearly reflects the standards that our company sets itself. A large emphasize is put on being a dependable and competent partner, offering 3D measurement devices that deliver reliable results. More than a mere determination of the "Ra" value is necessary in order to generate added value from a measurement. For this reason our measurement systems enable easy automation, area based measurements as well as simple and intuitive operation. Users gain traceable and repeatable results and benefit from multiple use at no additional cost. All Alicona measurement systems for quality assurance in research and production are based on these principles. This also applies to the new, quick InfiniteFocusSL system from the InfiniteFocus line. Come and see yourself how fast and simple 3D measurement can be!

Maybe you will be the next one to recommend us.

Yours faithfully,

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Table of content JANUARY 2012/2013

HOW TO MEASURE FORM AND ROUGHNESS WITH INFINITEFOCUS 8 – 41

InfiniteFocus

8–9

System description

8

10 – 11 What makes InfiniteFocus distinctive: Features

12 – 27 InfiniteFocus in use: References Makino SuttonTools Cassidian (an EADS group) Komatsu Seiki Kosakusho GF AgieCharmilles Rohde & Schwarz Profin Atomic 28 – 31 Measurement modules based on Focus-Variation

32

Measure from every position: Technology of “Real3D”

33

InfiniteFocus Accessoires

34 – 35 InfiniteFocus X-Large Systems

36 – 37 Technical Specification: InfiniteFocus

12-27

38 – 39 InfiniteFocusSL:

As fast and intuitve as 3D measurements can be New profiler for fast, simple and traceable 3D surface measurement

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TOOL MEASUREMENT

40

42 – 45 Measurement of drills, miller cutters, inserts etc.: IF-EdgeMaster System description, technical specification and case study 46 – 47 Measurement of hob cutters: IF-EdgeMasterHOB System description, technical specification and case study 48 – 49 Measurement of taps: IF-ToolPrecision System description

QUALITY ASSURANCE IN PRODUCTION 52 – 53 Stable 3D measurement in production: IF-SensorR25 System description, technical specification

50-55

54 – 55 Measure micro structured surfaces on large components: IF-Portable System description, technical specification

TECHNOLOGY 58 – 59 Traceable roughness measurements Focus-Variation as an ideal technique to measure roughness

59

59 – 60 Focus-Variation Function & Features

61

61

Focus-Variation from the point of view of a tool research association Heinz-Wolfgang Lahman (GFE) about Focus-Variation

62

Accessories Grips, standards and other accessories for all Alicona measurement systems

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As fast and easy as 3D measurement can be 6

alicona I Form and roughness measurement

Measure form and roughness with only system Âť InfiniteFocus Âť InfiniteFocusSL

Form and roughness measurement I alicona

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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

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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

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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.

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alicona I InfiniteFocus USPs

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. The patent pending SmartFlash technology 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 dcm2 range.

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Source: Makino

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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

What

Makino uses InfiniteFocus to verify the machining performances of its precision micromachining center iQ300

All kinds of micro precision components

ABOUT

IS MEASURED

What THE CUSTOMER STATES

Makino measures micro components that have been manufactured for further use in various industries, including tool making, automotive,

With InfiniteFocus being used in internal

die casting or aerospace industry. Regardless

testing facilities, Makino meets the re-

of industry or specific application, these usually

quirements of customers in terms of qua-

miniaturized components often have complex

lity assurance throughout high resolution

geometries with challenging forms. Both tool

3D measurement of manufactured com-

machine manufacturer and users emphasize

ponents. Both geometry and surface fi-

on verification of dimensional accuracy and

nish are verified. In addition, InfiniteFocus

achieved surface finish of machined compo-

Micro Machining Team

is increasingly used for integrated tool

nents. This is both achieved with InfiniteFocus

Makino

compensation.

Where

Toshihiko Tada Application Technology Developing Group

since the optical system combines the capabilities of a form with those of a roughness mea-

“We expect from our partners highest qua-

surement device in one system.

lity in terms of products and service, which includes high expertise as well as qualified

However, quality assurance with InfiniteFocus

and quick responses to our needs. With Ali-

WHERE INFINITEFOCUS ALSO IS USED

starts at an earlier stage than measuring the

cona we have found a reliable partner in all

final manufactured component. Makino also

fields. Our requests that we address for in-

Extension of worldwide services

offers the optical measurement system to

stance to the departments Support and Ap-

perform integrated tool compensation. Measu-

plications are followed up quickly, competent

rements with InfiniteFocus make even minimal

and friendly. This is valid for both the Euro-

In near future Makino plans to extend its

changed machining parameters clearly visible

pean headquarters and the local contact in

global services in the fields of Reverse

and transparent, which optimizes manufactu-

Japan.”

Engineering and 3D Scanning. Also,

ring and accelerates the achievement of tole-

InfiniteFocus is supposed to be offered

rances in the µm–range.

as integrated measurement technology for automated tool compensation.

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Source: Sutton Tools

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CUTTING TOOLS NEW PERSPECTIVES – NEW INSIGHTS Increased cutting speed and longer durability Sutton Tools has a clear idea of what they expect from their products. “Our goal is to fulfill and even exceed our customer’s expectations with performance and process reliability of our tools”, says the Australian manufacturer. In order to reach this goal, InfiniteFocus is used in combination with the rotation unit “Real3D”. The complete form measurement of drills, end mills and taps shows how much impact even smallest surface characteristics can have.

What

What

Complete form measurement of drills, end mills and taps

Form, roughness and contour

ABOUT

IS MEASURED

Research and development is a major

With the optional rotation unit Real3D,

focus for Sutton Tools. Being equipped

InfiniteFocus measures surface charac-

with state-of-the-art technology is

teristics such as clearance, diverse flank

part of the company’s philosophy to

angles or thread pitch. The tool’s auto-

develop and deliver advanced manu-

matic 360° rotation allows complete

facturing technology. As a result,

form measurement from all directions.

using InfiniteFocus with the Real3D

This provides significant advantages in

What THE CUSTOMER STATES

Steve Dowey Technical Manager

option is a logical step: 360° tool

tool optimization.

measurement provides completely

Further applications are wear measure-

new perspectives and insight into the

ment or the measurement of form devia-

“InfiniteFocus with Real3D is the most efficient

tool geometry, leading to more advan-

tions to a CAD dataset. Especially in tool

measurement system we know. No other device

ced products than previously thought

design Sutton Tools benefits from the

can deliver such a detailed visualization nor could

achievable.

Where

WHERE INFINITEFOCUS ALSO IS USED

To understand and make use of the relation between tool geometry, material and surface finish Regardless of the surface finish, compo-

Sutton Tools

detailed visualization including true color

it possibly measure both, geometry and surface

information. However, the system is not

quality. This makes development and manufac-

limited to the measurement of only one

ture processes run significantly faster. In addition

tool or tool type. The large vertical travel

InfiniteFocus has proved to be the ideal instrument

range enables the handling of varied tool

for strategic benchmarking within this branch. The

forms and sizes.

results of the respective comparisons help us to stay ahead of the competition as it allows us to respond quickly and directly to market requirements.

Our research confirms that we work with the most state-of-the-art technologies and procedures worldwide.”

nents are measured at every stage of manufacture and development. This provides Sutton Tools with new insights and assessment criteria in tool development.

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Source: Cassidian

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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

What

Incoming goods inspection, failure analysis and avoiding customer complaints

Titan, high strength steels and fibre composites

ABOUT

IS MEASURED

High resolution measurement of geometry and

Varying components, many of which have

surface finish is performed to verify the manufac-

complex forms are measured. The measu-

turer's information and identify defects prior to

rement of these various components include

further processing. The surface quality of compo-

radii, threads, diverse angles and roughness.

nents is determined with a numerical measure-

Since Cassidian uses InfiniteFocus, surface

ment in order to avoid unsuitable and expensive

characteristics are measured, that in the

materials in production. A thorough report that in-

past, were either difficult to access or could

cludes practically oriented visualization and mea-

not be accessed at all. These include root

surement results that are easy to read, verifies

of a thread and thread flanks of gear drives.

compliance with the agreed specifications and

Surface damage of various sizes and di-

the stipulated surface finish. Since this was intro-

mensions are measured, even on round

duced customer complaints at final inspection of

components.

aircraft are reduced to a minimum.

What THE CUSTOMER STATES

Gregor Heichler Project engineer in the area of non-destructive material testing Cassidian

"Due to its high flexibility, InfiniteFocus had paid for itself within the first year.

Initially the system had been purchased for failure analysis and for

Where

WHERE INFINITEFOCUS ALSO IS USED

measuring the depth of surface damage. However, it became apparent very soon that the measurement device can be universally used. Today we operate across

For the development of a new material in polymer technology

departments which makes both, quality assurance and development more comprehensive and at

The objective is to develop a material of appropriate strength for an optimal adhesion of surfaces. Analysis

the same time easier and more

with InfiniteFocus, using area based measurement, shows which surface treatment and/or which surface

efficient."

parameters improve strength of adhesion.

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Source: Alicona

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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

What

What

Quality assurance in stamping

Small stamped holes and tool condition

“Alicona is a very valuable and powerful

Komatsu Seiki Kosakusho manufacture high qua-

Small holes in gasoline injector nozzles

lity, small and accurate mass produced products

and its tools for production are measured.

for wrist watches and injector parts for automobile

The diameter of small holes is Ø 0.12mm

engines. High resolution and reliable measure-

and the length is 0.2mm, and these are

ments are not the only requirement for the pro-

produced by micro piercing. The whole

ducts, also the data have to be comparable

condition at entrance and exit is one of the

between the finished products and the stamping

important control criteria for the quality

tools.

and production departments. InfiniteFocus

ABOUT

IS MEASURED

THE CUSTOMER STATES

partner in both service and technical innovation with new developments that offer

Where

WHERE INFINITEFOCUS ALSO IS USED

Development of new materials in the academic area

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.”

can easily measure the hole condition without any damage, and it shows 3D analy-

Takafumi Komatsu Executive Director

tical images for both the operators and

Komatsu Seiki Kosakusho

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

For the last 10 years Komatsu Seiki Kosa-

wear process in mass production.

kusho 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.

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Source: GF AgieCharmilles

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LASERTEXTURING TEXTURING, ENGRAVING AND MICRO-STRUCTURING How to strengthen the market position as complete supplier A joint project by Alicona and GF AgieCharmilles has shown that InfiniteFocus enables the supplier of precision machines to offer a complete solution for the entire production chain in the field of laser texturing. InfiniteFocus is used to scan and digitalize natural surfaces. This texture is then applied to mold components via laser texturing by GF AC. This competitive advantage is to be extended to the business areas EDM and milling technologies.

What

What

With InfiniteFocus GF AC also offers a solution for digitalizing surfaces

Materials such as leather, silk or other surfaces

ABOUT

Having Alicona as a partner, GF AgieCharmilles is a qualified supplier for the entire production chain. This includes the digitalization of natural surfaces and quality assurance of the final machined component.

IS MEASURED

What THE CUSTOMER STATES

The 3D data of the measured surface, provided by InfiniteFocus, are transferred as Grayscales data file and finally applied to the final parts via laser. The high resolution 3D measurement is the basis of being able to produce a mold component with a surface texture that looks and feels as close as possible to the origin material, thanks to GFAC laser technology.

Jean-Paul Nicolet Head of Marketing and Sales Support for new technologies GF AgieCharmilles

“Our machines for mold and tool making are widely used for manufacturing high

Where

WHERE INFINITEFOCUS ALSO IS USED

EDM and milling technology

precision micro components. There is currently no other measurement device for our customers I can think of that is more suitable for the measurement or the quality assurance of machined workpieces. In return, measurements from InfiniteFocus

GF AgieCharmilles increasingly manufactures in the micrometer through to the nanometer range.

demonstrate the high precision and quality

With InfiniteFocus, GF AC verifies the accuracy of its precision machines through high resolution

of our machines.�

surface measurement of the machined workpieces. Both measurement of dimensional accuracy and surface roughness measurement are performed. Particularly in tool design GF AC also benefits from the ability to measure geometries with complex forms.

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Source: Rohde & Schwarz, plant Teisnach

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MICROPRECISION VERIFICATION OF TOOL AND WORKPIECE InfiniteFocus for 3D measurement in all areas of manufacturing For Rohde & Schwarz quality assurance is a value-added process. The insights in micro precision manufacturing that have been gained with InfiniteFocus, have helped to increase process reliability, safe production costs and optimize the workflow. Applications reach from tool release to the 3D measurement of turned and milled components.

What

What

Quality assurance for a real net output ratio in all areas of manufacturing

Stamping dies for tool release, micro components and workpieces with varying surface finish

InfiniteFocus is used for a wide range of

» For the production of miniature switches, Rohde &

ABOUT

IS MEASURED

applications over the whole parts spec-

Schwarz produces a stamping die which is further

trum. These applications reach from

used to engrave a defined relief onto a sheet sur-

quality assurance of dies in forming

face. Before the stamping die is used in series pro-

technology over to 3D measurement of

duction for the first time, the form of its surface is

turned and milled components. The 3D

measured. It has a pyramid-shaped structure with a

measurement device is used as an inte-

total area of 70µm x 70µm and a height of 35µm.

gral part of the process chain in the pro-

With InfiniteFocus Rohde & Schwarz verifies the

duction of mechanical components.

right distance between the individual paths by mea-

What THE CUSTOMER STATES

Gerhard Kokott Head of quality management at the Rohde & Schwarz plant Teisnach

suring pits and peaks. Also diverse angles are measured and the proper partition is determined.

Where

WHERE INFINITEFOCUS ALSO IS USED Various materials in numerous manufacturing segments These include: printed circuit boards

» Another standard application is the measurement of

“The measurement system's fle-

miniaturized components with complex forms. Often

lity are a great benefit for us. After

these components have steep flanks with functional

less than a year InfiniteFocus had

characteristics such as incisions or indentations.

already helped us to increase

InfiniteFocus measures these fine, highly precise

process reliability, optimize pro-

structures quickly, effortlessly and in high resolution.

duction processes, save produc-

» Another application is electroplating. In this proce-

tion costs and improve workflows.

xibility and its universal applicabi-

We can get into production more

dure components are being coated with e.g. gold

quickly and involve far less em-

(PCB boards), drill holes including inter-

and silver. The intelligent illumination technology of

ployees.”

nal geometries, galvanized and/or sput-

InfiniteFocus delivers high resolution results regard-

tered surfaces (e.g. components with

less of lightning conditions and varying reflective

thin film technology), height levels on ca-

properties.

libration disks, teflon coated surfaces, materials made of pure iron, nozzles from the sheet metal processing area, roughness measurements at milled components etc.

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Source: Profin

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CUTTINGEDGEPREPARATION MEASURABLE SURFACE QUALITY Micro cutting edges for smallest production tolerances Manufacturing micro cutting edges is all about highly precise contours, edges and areas. The Swiss enterprise Profin is also aware of that and therefore the expert for precise processing of cutting tools and precision components operates with InfiniteFocus which measures form but also surface quality.

What

What

Measurement of form and surface quality

Micro tools after edge preparation: indexable inserts, end mills, drills or saw bands

ABOUT

Machine tools by Profin facilitate edge

IS MEASURED

roundness in µm range plus quality im-

With InfiniteFocus Profin tests whether the tra-

provement of the cutting edge's chip

ditional requirements regarding surface finis-

and clearance surface. InfiniteFocus is

hing e.g. high precision deburring, edge

used for quality assurance of the pro-

roundness within µm range or refining proces-

cessing result and for continuous deve-

ses of polished workpiece conform to the defi-

lopment of machine tools. Area based

ned specifications. A particular emphasis is put

roughness measurement enables Profin

on the measurement of chipping, form, radius

to numerically verify the surface state of

and roughness of the tool's cutting edges.

components.

What THE CUSTOMER STATES

Dr. Peter Frank Head of Profin development

“We were looking for a 3D measurement device that would not only evaluate form but also surface. Alicona was the only provider that succeeded in presenting such a measure-

Where

WHERE INFINITEFOCUS ALSO IS USED

ment device. Every other system we evaluated featured only one functionality. The devices were either measuring form or surface but never both. With InfiniteFocus we now have

Verification of high surface quality Furthermore InfiniteFocus is used for a numerical verification of the benefits that come with the

a system for form measurement and for evaluating the surface.”

Flakkoting technology developed by Profin for cutting edge preparation. The machined tools' high surface quality clearly demonstrates the detailed visualization including true color information and the significant 3D measurements.

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INJECTION MOLDING SAFETY IN PHARMACEUTICS AND MEDICAL ENGINEERING Safe administration of medication via 3D measurement Since the surface roughness of injection molded components may influence the functionality of medical products, one of the leading pharmaceutical companies uses InfiniteFocus to perform enhanced quality assurance. The use of the high resolution form and roughness measurement system results in safer administration of medications and minimizes the risk of injury for hospital staff.

What

What

Roughness measurement of injection molding components

Polymer components which are used in devices and combination products

A surface roughness that is either too

These products offer, apart from the ad-

ABOUT

What THE CUSTOMER STATES

IS MEASURED

high or too low might affect a medical

ministration of medications, diverse

product’s proper functionality. Infinite-

safety features. Among other things they

Focus is used to verify surface finish

include syringes with an additional

of these items and thus helps to

needle protection device made of polymer.

achieve error free functionality. This

This protection is put over the syringe

enhances the patient comfort and the

after the injection in order to prevent

hospital saves money.

needlestick injuries by contaminated “In the past, roughness was traditionally measured

roughness being too low could, in the

profile based. The results were correspondingly

worst case, even lead to a leaking con-

uncertain and of no great significance since pro-

tact between needle protection and

file-based roughness measurements only deliver

needle. Protection against an infection

information about a small segment of a surface.

caused by a contaminated needle would

Due to the area based roughness measurement

no longer be provided then.

with InfiniteFocus, we now gain reliable feedback

Roughness measurement by InfiniteFocus

regarding the product's secured functionality. On

is performed in combination with form

top of that we benefit from the great user friendli-

measurement. By measuring the syrin-

ness and the intuitive handling. The easy handling

ge’s form or/and glass cone on the sy-

allows several employees to use the system in va-

ringe, the matching sealing plug’s

ried areas only shortly after a quick introduction.”

The

polymer’s

perfect fit is verified.

alicona I InfiniteFocus References

in pharmaceutical development

surface

needles.

26

Cédric Gysel Associate Scientist

TUNING OF A SKI´S RUNNING BASE AND EDGES OPTIMUM EDGE GRIP ON THE SLOPE Determine slide characteristics of skis via roughness measurement "We were looking for a suitable measurement device to measure both, edge geometry and running base roughness of our skis", Atomic states. Eventually the supplier of winter sports came across InfiniteFocus. Area based roughness measurements of the running base allow to draw conclusions about the slide characteristics of the skis.

What

What

InfiniteFocus for ensuring the proper tuning of running base and edge

Surface roughness and edge geometry

While the surface is decisive for slide

base its surface roughness. Whether a

ABOUT

IS MEASURED

What THE CUSTOMER STATES

A grinding process gives the running characteristics, the edge geometry

result is correct, is easily determined by

guarantees turning compliancy and

a “well defined surface pattern”, as Ato-

optimum edge grip. Information about

mic puts it. The result is also verified by

the exact values of the grinded running

the area based roughness measure-

base makes it possible to adapt pro-

ment. Additionally, roughness measure-

duction parameters to suit the accor-

ment allows to draw conclusions on

ding requirements even better.

Harald Scheikl Head of the test lab “Gliding” Atomic

friction and thus on the ski's glide characteristics.

“In the past, roughness and geometry of our skis

Another main focus of quality assurance

were measured separately. Not only did we have to

is the measurement of edge geometry.

face complex sample preparation but also inade-

This includes various edge angles or an-

quate results. For example, when we had to mea-

gular distribution, edge roughness and

sure larger areas, it was inevitably to do step by

the chipping at the edge’s point.

step measurements and put them together to a final area model afterwards. Today we measure both, roughness plus geometry with only one system. This helps us to even gain results of large measurement areas in an up to now not known quality!”

Source: Atomic

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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.

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alicona I InfiniteFocus measurement modules

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 25178 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

29

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.

30

alicona I InfiniteFocus measurement modules

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

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.

measures another already existing data set without any restrictions. » 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

DIFFERENCE MEASUREMENT

standard features of the tool measurement device IF-EdgeMaster. » all measurement modules have been

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.

developed by Alicona and share a consistent operation. Thus the practical application of a new module is possible immediately and intuitively.

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

31

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 360째 with a rotation unit The InfiniteFocus combined with the optional rotation unit Real3D, re-

3D. Therefore surface characteristics such as diverse flank angles,

present a genuine competitive advantage in, for example, the tool indu-

thread pitch, undercuts and clearance are accessed and measured. A

stry. Drills, milling cutters etc. are automatically rotated around 360째

number of various adapters enable the 360째 rotation of components

allowing operators to perform full form measurement of their tools in

without rotational symmetry.

32

alicona I InfiniteFocus Real3D

INFINITEFOCUS ACCESSORIES

2

1

1-2 IF-GUIDE Components are continuously equally positioned and aligned to simplify automated measurements.

4

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 3 5

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.

6

InfiniteFocus Accessories I alicona

33

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. fer in possible XY-travel ranges and a max

material is measurable as soon as there is a

adjustable and functionalities can easily be exten-

measurable weight of components. The cur-

minimum surface roughness of only a few na-

ded depending on application and measurement

rently available spectrum of InfiniteFocus X-

nometers. Typical applications are e.g. the au-

InfiniteFocus X-Large InfiniteFocus is easily

task. Its core technology, Focus-Variation, can

Large solutions includes travel ranges from

tomatic defect analysis of large measurement

be “transformed� into another hardware wit-

(mm) 200 x 200 up to 1000 x 1000 with a

fields or form measurement of laser structured

hout losing any of its variety. Area based mea-

max measurable weight of up to 20 kg. Howe-

geometries on printing plates.

surement with high measurement point

ver, on request an increased weight of com-

density, high repeatability, several options for

ponents is achievable. This flexibility is also

automation as well as high resolution measu-

valid for possible applications as each solid

rements even across large measurement volumes are key benefits that all X-Large variants of InfiniteFocus have in common. The systems dif-

34

alicona I InfiniteFocus X-Large

MEASUREMENT WITH EXTRAS Both the InfiniteFocus standard system and the X-Large series for the characterization of measurement fields larger than 10cm x 10cm are easily SPECIFICATION INFINITEFOCUS XL200

adoptable to particular environments and/or new conditions. This means that not only the hardware

Dimensions

810mm x 640mm x 780mm

Weight of system

120kg

Max. lateral travel range (x/y)

200mm x 200mm

Max. vertical travel range (z)

100mm

throughout new software modules. Instead of

Max. sample height

100mm*

purchasing a new measurement system because

Max. sample weight

20 kg

of new or additional measurement tasks which

can be changed to meet new requirements, but also the software is extendable individually

* can be extended

change former conditions to perform quality as-

SPECIFICATION INFINITEFOCUS XL 500

simple implementation of new software modules.

surance, Focus-Variation allows the quick and Dimensions

900mm x 1100mm x 800mm

This is valid for both already available software

Weight of system

300kg

modules as well as new modules on request. See

Max. lateral travel range (x/y)

500mm x 500mm

what is possible with Focus-Variation – there are

Max. vertical travel range (z)

100mm

packages on-hand for the groove measurement

Max. sample height

100mm*

Max. sample weight

10 kg**

* can be extended ** load must be centered

of golf clubs, the measurement of diamond particles, valve inspection, conrod and cams measurement etc.

SPECIFICATION INFINITEFOCUS XL 1000 Dimensions

1680mm x 785mm x 1700mm

Weight of system

1100kg

Max. lateral travel range (x/y)

1000mm x 1000mm

Max. vertical travel range (z)

100mm

Max. sample height

100mm*

Max. sample weight

200 kg

Max. sample dimensions

1100mm x 1500mm

* can be extended

InfiniteFocus X-Large I alicona

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TECHNICAL SPECIFICATION GENERAL SPECIFICATION Measurement principle

non-contact, optical, 3 dimensional, based on Focus-Variation

Measurement result

2-100mio 3D points in registered true color information (maximum is dependent on the used measurement module)

Maintenance

maintenance free

Illumination

white LED coaxial light, high power, controllable; Optional: white LED ring light, controllable, polarization

Nosepiece

6 objectives manual or motorized

Travel range

X:100mm, Y:100mm, Z:100mm

Weight

95-100kg, depending on equipment

Size measurement system WxDxH

710mm x 540mm x 628mm (up to 868mm)

Temperature range

possible: 5° - 40°C, calibrated for: 18° - 22°C (other temperature ranges can be calibrated)

Temperature gradient

less than 1° per hour

Power supply

900W;110-230V~; 50-60Hz

Size ControlUnit WxDxH

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

3.52

1.76

0.88

0.44

0.18

0.09

Min. lateral resolution

µm

58.71

23.48

11.74

8.8

6.4

4.4

Max. lateral resolution

µm

6.92

3.49

1.75

0.88

0.64

0.44

Min. repeatability (vert.)

µm

0.8

0.12

0.03

0.015

0.008

0.003

Max. scan height (approx.)

mm

8

22

16

12

9

3.2

Scan speed*

µm/s

2300

400

100

50

20

10

nm

2300

410

100

50

20

10

3400

52000

160000

250000

430000

380000

Best vertical resolution** Vertical dynamic Working distance

mm

8.8

23.5

17.5

13.0

10.1

3.5

Field of view X

µm

5716

2858

1429

715

286

143

µm

4351

2175

1088

544

218

109

Max. extended field of view Y

Field of view Y

mm²

10000

10000

10000

4500

700

150

Max. uni-directional scan extension

mm

100

100

100

100

100

100

SOFTWARE

36

Measurement modules and utilities

Standard: ProfileFormMeasurement (height, angle…), ProfileRoughnessMeasurement (Ra…), SurfaceTextureMeasurement (Sa, fractale dimension…), VolumeMeasurement, 3D-Editor, FormRemoval; Optional: 3DFormMeasurement, DifferenceMeasurement, ContourMeasurement, EdgeMeasurement;

Automation

IF Automation (built-in script editor), .NET Remoting interface

Visualization

2D-image and high resolution 3D visualization

Database

intuitive, graphical database

Import/Export

Simple export to STL and VRML, import of CAD-data with STL format, QDAS export, variety of reporting functionalities

Available in

German, English, Korean, Japanese

alicona I InfiniteFocus Specification

RANGE OF RESOLUTION AND APPLICATIONS Objectives

2,5x

5x

10x

20x

50x

Min. measurable height

nm

2300

410

100

50

20

10

Max. measurable height (approx.)

mm

8

22

16

12

9

3.2

%

-

0.05

0.05

0.05

0.05

0.05

Max. measurable area

mm²

10000

10000

10000

4500

700

150

Max. measurable profile length

mm

100

100

100

100

100

100

Min. repeatability

nm

800

120

30

15

8

3

Min. measurable roughness (Ra)*

nm

7000

1200

300

150

60

30

Min. measurable roughness (Sa)*

nm

3500

600

150

75

30

15

Min. measurable radius

µm

20

10

8

5

2

1

°

20

20

20

20

20

20

Step height accuracy (1mm height step)

Min. measurable vertical angle

100x

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

37

INFINITEFOCUSSL AS FAST AND INTUITIVE AS 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.

38

alicona I InfiniteFocusSL

GENERAL SPECIFICATION Travel range X/Y

manual option: 25x25mm motorized option: 50x50mm

Vertical travel range Z

130mm (26mm motorized)

Illumination

LED ringlight with 24 segments

Weight

15kg

Dimensions

195x316x418mm (WxDxH)

OBJECTIVES 5x

10x

20x

50x

5x SX2

10x SX2

20x SX2

50x SX2

Sampling distance

µm

2

1

0.5

0.2

2

1

0.5

0.2

Min. repeatability (vertical)

nm

120

30

15

8

180

45

25

15

Max. scan height (approx.)

mm

22

16

12

9

25

25

19

12

Best vertical resolution1

nm

410

100

50

20

510

130

70

45

Working distance

mm

23.5

17.5

13.0

10.1

34

33.5

20

13

Field of view X

µm

4000

2000

1000

400

4000

2000

1000

400

µm

4000

2000

1000

400

4000

2000

1000

400

Max. extended field of view

Field of view Y

mm²

2500

2500

2500

1100

2500

2500

2500

1100

Max. uni-directional measurement

mm

50

50

50

50

50

50

50

50

50x SX2

1) Vertical resolution can be adjusted in the IF-LaboratoryMeasurementModule 2) SX are objectives with higher working distance

RANGE OF RESOLUTION AND APPLICATIONS 5x

10x

20x

50x

5x SX2

10x SX2

20x SX2

µm

10

5

3

2

10

5

3

2

Min. measurable wedge angle

°

20

20

20

20

20

20

20

20

Min. measurable roughness (Ra)

nm

-

300

150

80

-

450

250

150

Min. measurable roughness (Sa)

nm

-

150

75

50

-

250

100

80

Min. measurable radius

InfiniteFocusSL I alicona

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Contactless cutting edge measurement in research and production

40

alicona I Tool measurement

Tool measurement » IF-EdgeMaster » IF-EdgeMasterHOB » IF-ToolPrecision

Tool measurement I alicona

41

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 patent pending 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

42

alicona I Tool measurement IF-EdgeMaster

A range of user friendly functions in hard and software supports the high measurement accuracy, high measurement speed and intuitive user guide.

» 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 XY- measurement 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 (patent pending). 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 gradients for best possible use in a production near environment

Tool measurement IF-EdgeMaster I alicona

43

GENERAL SPECIFICATION Travel range X/Y

manual option: 25x25mm, motorized option: 50x50mm

Travel range Z

130mm (26mm motorized)

llumination

LED ring light with 24 segments

Weight

15kg

Dimensions

195x316x418mm (WxDxH)

OBJECTIVE DETAILS 5x

10x

20x

50x

5x SX2

10x SX2

20x SX2

50x SX2

Sampling distance

µm

2

1

0.5

0.2

2

1

0.5

0.2

Min. repeatability (vertical)

nm

120

30

15

8

180

45

25

15

Max. scan height (approx.)

mm

22

16

12

9

25

25

19

12

Best vertical resolution1

nm

410

100

50

20

510

130

70

45

Working distance2

mm

23.5

17.5

13.0

10.1

34

33.5

20

13

Field of view X

µm

4000

2000

1000

400

4000

2000

1000

400

µm

4000

2000

1000

400

4000

2000

1000

400

Max. extended field of view

Field of view Y

mm²

2500

2500

2500

1100

2500

2500

2500

1100

Max. uni-directional measurement

mm

50

50

50

50

50

50

50

50

50x

5x SX2

10x SX2

20x SX2

50x SX2

1) 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.

RANGE OF RESOLUTION AND APPLICATIONS 5x Min. measurable radius

10x

20x

µm

10

5

3

2

10

5

3

2

Min. measurable wedge angle

°

20

20

20

20

20

20

20

20

Min. measurable roughness (Ra)

nm

-

300

150

80

-

450

250

150

Min. measurable roughness (Sa)

nm

-

150

75

50

-

250

100

80

44

alicona I Tool measurement IF-EdgeMaster

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

What

Each batch with same tool lifetime

Carbide inserts

Simtek Precision Tools develops, manu-

the measurement of very small radii on

factures and distributes high precision

carbide inserts. In addition, negative and

tools for high demands. The product

positive bevels on the inserts are mea-

range includes about 10,000 standard

sured as they decrease signs of wear

tools for Turning, Grooving, Groove

and increase durability. Negative bevels,

Milling, Broaching, Thread Whirling, Po-

for example, increase the cutting pres-

lygon Milling etc. One of the manufac-

sure and at the same time protect the

turer´s key priorities is to deliver tools

cutting edge. Detailed visualization of

that with each batch have the same

the measurements is used for transpa-

geometry and perform identically to

rent, provable quality assurance.

ABOUT

offer process reliability to their custo-

IS MEASURED

What THE CUSTOMER STATES

The IF-EdgeMaster is mainly used for

“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!”

mers. Cutting edge measurement is, amongst others, performed with the IF-EdgeMaster.

Ulrich Weber Special Tools Construction SIMTEK Precision Tools

Tool measurement IF-EdgeMaster I alicona

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IF-EDGEMASTERHOB

IF-EdgeMasterHOB…

GENERAL SPECIFICATION Travel range

66mm (26mm motorized)

… is one of Alicona´s optical 3D tool measurement systems and a mar-

Rotation table

+/- 90°

ket specific adapation of the optical cutting edge measurement device IF-

Illumination

LED ring light

EdgeMaster. Due to a patent pending illumination technology and special

Weight

18kg

vibration isolation, the system is also suitable for the use in production.

Dimensions

299x254x502mm (WxDxH)

Sample size

Diameter 25-300mm

In terms of hard- and software, the IF-EdgeMasterHOB is adjusted to measure hob cutters. Users measure the edge geometry at the tooth

OBJECTIVE DETAILS

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

10x SX2 Sampling distance

µm

Min. repeatability (vertical)

nm

40

des both chipping and traceable roughness measurement. Other typical

Max. scan height (approx.)

mm

22

applications are wear measurement or the automatic comparison to CAD

Best vertical resolution1

nm

100

data or reference geometry. A large vertical working distance allows ef-

Working distance2

mm

33.5

fortless measurement of cutting edges even in areas that are hard to ac-

Field of view X

µm

1760

Field of view Y

µm

1320

as positive and negative bevel of the edge. In addition, the system provi-

cess. Users measure hob cutters at every stage of manufacture, regardless of surface finish or coating.

1.1

1) The vertical resolution is automatically adjusted depending on the application.

2) Objectives with larger working distances.

RANGE OF RESOLUTION AND APPLICATIONS 10x SX1 Min. measurable radius Min. measurable wedge angle

46

alicona I Tool measurement IF-EdgeMasterHOB

µm

6

°

20

Uncertainty of angle

°

0.5

Max. Bevel length

µm

500

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

What

In-process measurement to produce hob cutters with equal cutting edge geometry

Form and chipping

ABOUT

Due to a new technology for cutting

IS MEASURED

What THE CUSTOMER STATES

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 ob-

edge preparation LMT Fette manufactu-

jective. High emphasize is placed on the

res hob cutters with an equal geometry.

edge measurement at the tooth flank, the

This enables the supplier to offer tools

tooth root and the tooth tip. This includes

that provide identical lifetime in produc-

parameters such as radius, wedge angle,

“Being able to measure the edge radius of both,

tion. The edge geometry of the hob cut-

basket arch form (waterfall-type and trum-

tooth tip and tooth flank over this broad range is,

ters is verified with high resolution and

pet-type) as well as bevel length. In addi-

as far as I know, not possible with any other sy-

traceable 3D measurements with the

tion, the IF-EdgeMasterHOB is used for

stem. The high resolution 3D measurements with

IF-EdgeMasterHOB. The optical 3D mea-

measure chipping.

the IF-EdgeMasterHOB enable us to offer tools

surement system delivers repeatable re-

with dimensional accuracy, optimized surface state

sults even at positions which have been

and an equal geometry for increased process re-

difficult to access before use of the

liability. Also, the system´s user friendliness and

Alicona system.

the independence from user influence are truly impressive.”

Tobias Schulz Head of quality assurance in gearing LMT Werkzeugtechnologie

Tool measurement IF-EdgeMasterHOB I alicona

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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.

48

alicona I Tool measurement IF-ToolPrecision

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

49

Stable 3D measurement in production

50

alicona I Quality assurance in production

Quality assurance in production Âť IF-SensorR25 Âť IF-Portable

Quality assurance in production I alicona

51

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 Âľm or sub-Âľm 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.

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alicona I Quality assurance in production IF-SensorR25

GENERAL SPECIFICATION Travel range Z

26mm motorized

Illumination

LED ring light with 24 segments

Weight

4kg

Dimensions

126x153x220mm (WxDxH)

OBJECTIVE DETAILS 5x

10x

20x

50x

5x SX2

10x SX2

20x SX2

50x SX2

Sampling distance

µm

2

1

0.5

0.2

2

1

0.5

0.2

Min. repeatability (vertical)

nm

120

30

15

8

180

45

25

15

Max. scan height (approx.)

mm

22

16

12

9

25

25

19

12

Best vertical resolution1

nm

410

100

50

20

510

130

70

45

Working distance2

mm

23.5

17.5

13.0

10.1

34

33.5

20

13

Field of view X

µm

4000

2000

1000

400

4000

2000

1000

400

Field of view Y

µm

4000

2000

1000

400

4000

2000

1000

400

50x SX2

1) Vertical resolution can be adjusted in IF-LaboratoryMeasurementModule.

2) SX stands for objectives with larger working distances.

RANGE OF RESOLUTION AND APPLICATIONS 5x

10x

20x

50x

5x SX2

10x SX2

20x SX2

µm

10

5

3

2

10

5

3

2

Min. measurable wedge angle

°

20

20

20

20

20

20

20

20

Min. measurable roughness (Ra)

nm

-

300

150

80

-

450

250

150

Min. measurable roughness (Sa)

nm

-

150

75

50

-

250

100

80

Min. measurable radius

Quality assurance in production IF-SensorR25 I alicona

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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) 50x50x19. 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.

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alicona I Quality assurance in production IF-Portable

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

50x50mm

Travel range Z

26mm

Illumination

LED coaxial light

Weight

9.3kg (dependent from configuration)

Dimensions

300x180x260mm (WxDxH)

OBJECTIVE DETAILS 2.5x

5x

10x

20x

50x

100x

Sampling distance

µm

4.4

2.2

1.1

0.55

0.22

0.11

Min. repeatability (vertical)

nm

610

160

40

25

25

25

Max. scan height (approx.)

mm

8

22

16

12

9

3.2

Best vertical resolution1

nm

1717

428

106

60

60

60

Working distance2

mm

8.5

23.1

17.5

13.0

10.1

3.5

Field of view X

µm

7040

3520

1760

880

352

176

Field of view Y

µm

5280

2640

1320

660

264

132

1) Vertical resolution can be adjusted in IF-LaboratoryMeasurementModule

RANGE OF RESOLUTION AND APPLICATION 2.5x

5x

10x

20x

50x

100x

Max. measurable area

mm²

2500

2500

2500

2500

1000

210

Min. measurable angle

°

20

20

20

20

20

20

Min. measurable roughness (Ra)

nm

5200

1300

320

180

180

180

Min. measurable roughness (Sa)

nm

2600

650

160

90

90

90

Quality assurance in production IF-Portable I alicona

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alicona I Technology & Accessories

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

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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 25178. 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, ….)

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alicona I Technology

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 100

100nm

103nm

Roughness standard 500

503.5nm

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 SmartFlash 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

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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. » Various light sources minimize the impact of light. » InfiniteFocus delivers an estimation of the measurement uncertainty for every 3D-point.

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alicona I Technology

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.

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 FocusVariation 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 FocusVariation 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 pri-

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 InfiniteFocus 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.

marily 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.

Heinz-Wolfgang Lahmann Society for Production Engineering and Development (GFE e.V.), Schmalkalden/Germany

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ACCESSORIES Alicona offers a range of accessoires which increase usability and minimize user influence. A selection of standards ensures traceability of the measurements performed.

1 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

2 ADVANCED-INSERT-GRIP

2

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

1

3 ROTATION-GRIP Clamping device, for horizontal mounting of components such as drills or milling cutters enabling it to be rotated into the desired position. Also cutting edges are measured easily.

Usable for: IF-EdgeMaster, InfiniteFocus, InfiniteFocusSL

3

4 CLAMPING-SET 4

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

5 ROUGHNESS-STANDARD 6 5

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

6 CALIBRATION TOOL 7

Standard, traceable to the PTB, for verifying the vertical and lateral accuracy of InfiniteFocus. It provides a height step (1000Âľm) for the vertical check and various chess patterns for the verification of lateral results.

Usable for: All Alicona 3D measurement systems

7 VERIFICATION-TOOL 62

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 alicona I Accessoires

SELECTED CUSTOMERS

Bass

Ceratizit

EDM

ETH

Fette

FZG

Fraunhofer Vision

Fraunhofer IPA

Heidelberg

Inspire

NFI

NPL

oerlikon

PTB

PTS

SIMTEK

TU Hamburg Harburg

Vollmer

VW

KomatsuSeiki

Vargus

IFAS

Makino

Profin

Atomic

LMT Fette

Rohde & Schwarz

GF AgieCharmilles

GFE

Cassidian

Sutton Tools

Selected customers who have contributed to the magazine series FOCUSvariation.

University of Wisconsin

Selected customers I alicona

63

Alicona headquarters Alicona Imaging GmbH Dr.-Auner-Straße 21a 8074 Raaba/Grambach Austria phone +43 316 403010 700 fax +43 316 403010 711 info@alicona.com

Alicona Asia Alicona Korea Pacific Co. Ltd. 104-1606, 16th Floor, Hangangno Byucksan Megatrium 2-8 Hangangno 2-ga Yongsan-gu 140-780 Seoul phone +82 2795 5045 fax +82 2795 5044 sales.asia@alicona.com

Alicona Germany Alicona GmbH Buchenötz 2 83471 Schönau Germany phone +49 8652 6553901 fax +49 8652 6553902 info@alicona.de

Alicona UK Alicona UK Ltd. Lime Tree House 15 Lime Tree Walk Sevenoaks Kent TN13 1YH UK phone +44 1732 746262 fax +44 1732 465500 sales.uk@alicona.com

Germany South/West Daniel Soares phone +49 151 1214 3339 daniel.soares@alicona.com

Germany North Ingo Böhm phone +49 175 2932223 ingo.boehm@alicona.com

Germany South/East Matthias Strößner phone +49 151 23530254 matthias.stroessner@alicona.com

IF-IF-20102011-3.1

Technical data, images, descriptions without obligations. We reserve the right to modify content. ®alicona and ®InfiniteFocus are registered trademarks, ©copyright by alicona

Alicona France Alicona SARL Rue de Savoie 11 91940 Les Ulis France phone +33 169 86 9137 fax +33 169 86 9137 sales.fr@alicona.com Alicona US Alicona Corporation 1261 Humbracht Circle Suite G, Bartlett IL 60103 USA phone 630 372 9900 fax 630 372 9965 sales.us@alicona.com