Marrying the power of X-RAY/CT with Certified METROLOGY Nikon Metrology introduced the, offering absolute accuracy for inside geometry. This new ‘absolute-accuracy’ Metrology-CT (MCT) system measures all internal and external geometry efficiently in a single non-destructive process. Since you visited our booth, we hope you were able to experience this newest product from Nikon Metrology’s broad range of Metrology Solutions. SCANNING ELECTRON MICROSCOPY AS EASY TO USE AS A DIGITAL CAMERA The a powerful benchtop Scanning Electron Microscope that is a high resolution SEM, producing images with a large depth of field at magnifications ranging from 10X – 60,000X.
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It combines the familiar look and feel of today’s smart phones and tablets with simple operation, enhanced low vacuum capability, and New Imaging Capabilities. And it is compact, lightweight, and energy efficient! THE METROLOGY SOLUTIONS DON’T STOP THERE! Nikon Metrology also featured our VMA-2520 Vision Measuring System, the Digital Handheld Microscope, the, our for large volume applications, Coordinate Measuring Machines with our newest digital laser scanning and touch probe technology and if you toured our booth, you also noticed our newest Portable Metrology Arm, the MCAx! Visit for more details!
By Bill Kennedy, as seen in Accurately machining and measuring a part requires it to be located and clamped with precision that matches or exceeds specified final tolerances. Generally, a shop can combine good machine tools, vises and tooling to get a good result.
But when working with micron-level tolerances, good is not good enough. Beyond assembling high-accuracy workholding components, it is crucial to control how they relate to each other as an integrated system, and assure they are applied in a repeatable, systematic manner. Zero-point palletizing, or referencing systems, can maximize precision in machining operations. In these systems, workholding pallets feature a centrally located drawbar or stud drawn into a machine-mounted chuck to provide consistent positioning. “In the case of developing or validating a process with small tools or small features, at some stage you have to remove the part and take it to a dedicated metrology device to inspect your results,” said John Bradford, micromachining R&D team leader for Makino Inc., Mason, Ohio. “You then put it back in the machine, make adjustments to your process and continue machining. You must be able to remove, check and replace the part without repeating the whole setup process.” A micromold machined at Plastic Design is positioned on a Hermann Schmidt magnetic chuck mounted on a unit of System 3R’s Nano reference system.
Image courtesy Plastic Design. Microcavity challenges Plastic Design Corp. (PDC), Scottsdale, Ariz., deals with those challenges every day. The company manufactures molds and uses them to produce small medical devices, microfluidic circuits and in-vitro labware. “We are cutting true microcavities,” said PDC President Mark Kinder.
“Typically, we are doing one- and two-cavity tools; a luxury for us is a four-cavity mold. In the case of microfluidic devices, he said, “the X-Y of the cavity may be pretty big—3″ × 5″—but we are cutting features in the 30µm to 50µm range.” Machining features as small as 10µm, he said, “is no big deal.” However, there are many variables that affect the shop’s ability to consistently generate those tolerances. For example, all rotary chip-removal systems feature some degree of spindle whip. “When you bring the machine up to speed, the centerline shifts subtly,” said Kinder. “It’s a centripetal phenomenon.
The better the spindle, the less there is, but it occurs. We’ve mapped all of our machines.
We can predict it, but it is never an exact thing. It’s subtle—tenths (10-thousandths of an inch) or microns.” In consideration of that and other variables, Kinder regularly checks part dimensions while machining. The parts are taken from a VMC or EDM to a, inspected and returned for re-machining, if necessary. The actual steps followed are dictated by a shop’s familiarity with, and confidence in, a specific operation, as well as the tolerances of the part being machined.
“If we have a high level of confidence, we will make the cut and check the part just for verification,” Kinder said. If the part is out of specification, it’s either scrapped or, if possible, refixtured for further machining.
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The Nano reference system is a “tweaked and finessed version” of System 3R’s standard Macro chuck system. Chuck components are ground and lapped to maximize accuracy and produce repeatability better than 1µm, according to the company. Image courtesy System 3R. On the other hand, if tolerances are especially tight, Kinder said he takes a different approach.
The initial CAM program is written to cut the part to slightly larger-than-final dimensions. Then the part is inspected, the program is adjusted and the part is refixtured for machining to final tolerances. For that reprogramming and remachin-ing to be accurate, the part must be positioned identically for measurement and machining. About 2 years ago, PDC was having trouble repositioning work after removing it for inspection. “When you get down to splitting tenths, measuring the part is difficult enough,” Kinder said. “But getting it back into a location where we could take a 0.00004″ (1µm) cut is where we were really struggling.
We were spending 2 hours on a good day, and 4 to 5 hours, on average, getting the block trammed back into the machine.” A palletizing system might eliminate much of the time spent repositioning the molds, Kinder observed, but standard systems didn’t provide accuracy high enough for his needs. Then he saw a demonstration of the Nano referencing chuck system from System 3R USA, Elk Grove Village, Ill. “Repeatability was basically unmeasurable,” Kinder said. “It was something on the order of magnitude of 0.000010″.” Tweaked and finessed Jack Sebzda Jr., System 3R Northeast regional manager, said the Nano system is a “tweaked and finessed version” of System 3R’s standard Macro chuck system. “We take standard chucks out of the production line and basically balance and blueprint them, sort of like they do to an automobile engine to improve its performance,” Sebzda said. “The chuck is hand-lapped and hand-measured; everything is done with the goal of making it as accurate as possible.” For example, he said, instead of being simply rough-milled and tumbled, the locking surfaces of the pallet drawbar are ground so those dimensions are consistent drawbar to drawbar.
“It’s overkill for what you might normally expect, but we want the same exact pull force to be exerted on the pallets every time,” Sebzda explained. The result is repeatability better than 1µm, he said. Pallets in the System 3R Nano referencing system can be removed and replaced with repeatability at levels less than 0.5µm (500nm), according to the company. Image courtesy Plastic Design. Kinder enlisted his workholding supplier, Hermann Schmidt Co., South Windsor, Conn., to integrate Schmidt’s workpiece-holding chucks with the System 3R palletizing system. PDC required precision vises and different styles of magnetic chucks for its machining center and EDM, said Peter Schmidt, president of Hermann Schmidt.
The company provided 6″ × 6″ magnetic chucks ground to better than 0.00005″ square. When mounting the magnetic chucks to the System 3R pallet chucks, Schmidt said, “we indicated the rail around the outside of the magnetic chuck (against which the part rests) from the centerline of the System 3R reference chuck, so that in multiple chucks the work offset is within 0.00003″ square and parallel from the center location.” A step higher Palletizing is a long-established technology and most suppliers will guarantee their products to repeat within 2µm. However, while 2µm repeatability is good enough for most applications, “Mark Kinder’s world is a whole other step higher,” Schmidt said. “Mark wanted to take a pallet out of one machine, put it in another machine, and repeat to 1µm or better.
We are talking about going from 0.00008″ repeatability in one machine down to 0.00004″ repeatability machine-to-machine. Hermann Schmidt takes the prefinished chuck and bolts it to the referencing system. When two objects are bolted, they are stressed, so at some point in the process one of the surfaces is lightly machined to qualify it.
For example, the flat plate on the back of a magnetic chuck will be requalified via grinding and lapping. PDC just had to mount the chucks and tram them in. 213 the hard way album download zip. “It has become our standard workholding system,” Kinder said. The pallets are installed on PDC’s VMC, sinker EDM and CMM. Some hold magnetic chucks, some grinding vises and some System 3R electrode holders. After initial machine setup, no further setup is required. Such precision is not inexpensive, Kinder noted.
“We put as much money into that system as we would a machine tool,” he said. “Originally, when we priced the system out, I had an ROI of 3 years on it, based on the shortened setup time after measurement.” However, because of the system’s positive effect on constraint management at PDC (see sidebar below), the payback period was 9 months. Systematic approach required Peter Schmidt stressed that this kind of precision workholding system is not a set-and-forget proposition. “It requires a systematic approach not only in how we build it, but in how they use it,” he said.
“If they don’t use it the same way every time, if they change that procedure, they are not going to hold tolerance.” Jack Sebzda agreed. “That last 10-millionths is an expensive and difficult thing to get at,” he said. “Maintenance, cleanliness and consistency are critical. You can put the best chuck in the world in a shop and you’ll fail miserably if the machines are not maintained properly, or the operators don’t handle things with care.” Some variables, inconsequential in macro applications, become significant in micromanufacturing. For example, System 3R specifies that even the air pressure used to actuate the chucks be tightly controlled. “If we want the reaction of this chuck to be identical every time, the procedure for opening and closing the chuck must be as accurate as everything else,” Sebzda said. While System 3R recommends air pressure in the range of 5 to 7 bar (about 70 to 100 psi) to operate its standard chucks, it recommends air pressure for the Nano should always be 6 bar.
One manufacturing challenge is that advances in machine tool accuracy may limit the usefulness of some palletizing systems, according to Makino’s Bradford. He cited machines such as Makino’s Hyper 2J VMC that features 0.000000020″ (0.5nm) scale feedback with guaranteed positioning accuracy of ±0.3µm (±0.000012″) and repeatability accuracy of ±0.2µm (±0.000008″). A System 3R Nano reference system unit fitted with a Hermann Schmidt vise. Image courtesy Hermann Schmidt. In actual applications, he noted, the machine has provided positioning accuracy and reliability on the level of ±30nm (0.030µm).
When machining parts or features that take advantage of those machine capabilities, removing the part from the machine for measurement may not be an option since part tolerance might only be a few microns. As the machines are introduced with repeatability in the 70nm to 80nm range, more accurate workholding systems are a must, he added. “If your tooling only gives you repeatability of 700nm to 800nm, you are losing the benefit of the machine’s accuracy and stability.” In those cases, he said, machine tools will offer increasingly sophisticated on-board measuring systems that permit inspection without removing the part.
However, according to Sebzda, advanced palletizing systems are already in the same tiny ballpark as the machines Bradford described. System 3R’s Nano referencing system can repeat at levels under 0.5µm (500nm), but the problem has been how to prove it, he said.
“By placing optical sensors on both the pallet and reference surface of the chuck, we are able to monitor and confirm system performance.” Testing of the system has taken place in the optical grinding industry, he said, including work with the Fraunhofer USA Applied Research Institute. A micromold positioned in a referencing system is machined on a Makino Hyper 2J vertical machining center. Image courtesy Makino.
The whole package To remain competitive, shops must continually seek out and apply new technology. Regarding workholding systems, Schmidt said there are micromanufacturers who struggle because they are unaware of new equipment and integration services that enable high precision. To those who struggle, Schmidt says, “You can buy it.
There are people who understand what you are talking about and your problems.” Sebzda said all machining elements must be included in the upgrade. “I can put the most expensive tires possible on a Yugo, and it’s still a Yugo,” he said. “The whole package has to be there. Sometimes that package has to be chosen from a variety of suppliers. It all has to be researched and constantly reviewed because there is always a better way to do it.
“What is coming down the pike must be understood, accepted and embraced,” Sebzda continued. “Unless you move with the changes, you are going to be behind the times. We are coming to the point where our industry is doing the elite work; the no-brainer mold work, the blow molds, cheap toys and things like that are all gone. What’s left are the upper-level, tip-of-the-pyramid processes that only a few can truly achieve.”. Nikon Metrology offers a complete range of examination and measurement services for the inspection of medical devices and components. These include,.
Accurate inspection of small medical components With medical devices, failure is not an option. Reproducible examination and measurement of key components and specified tolerances play a key role in ensuring the reliable and repeatable performance needed for items such as simple, single-use catheters right through to the most advanced drug delivery systems. In order to avoid the rejection of rogue batches, examination and measurement methods also need to be able to verify the quality of purchased materials prior to release from inventory, and provide a complete audit trail for regulatory purposes. Is a key tool in the examination of medical devices and components as it provides the means to produce the high-contrast images needed to spot small imperfections on and below the surface of samples such as catheters and surgical blades.
It can also prove beneficial in examining failures, to assess whether they are due to a manufacturing error or misuse. Provides an accurate means to assess prototypes, check the performance of new injection-molding tools and perform lower-volume quality control checks. Allows multiple measurements to be reliably made on large numbers of small and complex components at a rate that can keep pace with demanding production schedules.
With the correct illumination settings, and repeatable and reproducible edge detection, even the edges on dark and clear parts can be correctly refracted, detected and reproducibly measured. Non-contact video measurement can also be used to compare CAD versus actual data and perform real-time SPC. For some components, like knee, hip or dental implants and hearing aids, the as-built shape of the component is crucial for fast patient recovery and maximum comfort. State-of-the art create high-accuracy, high-density 3D digital copies of the part with a minimum of effort. These point clouds can be used for the inspection of the surface geometry. Color diagrams instantly highlight deviations and facilitate the communication with the production department. Alternatively, these copies can be used to create CAD surface models from components that have been tuned manually or where no CAD file is available.
Medical devices are highly complex components where critical parts can’t be reached by touch probes or seen by video and laser systems; think about the dimensions of an inhaler chamber or any other drug delivery system. Of course, you want to be sure that all components in a pacemaker are connected properly before it is implanted. In this case is the ideal solution. CT is a non-destructive technique that creates full 3D copies of the test specimen that not only allows dimensional inspection but also fault detection, failure analysis and the assembly inspection of complex mechanisms. Nikon Metrology offers a wide range of CT solutions that all feature in-house-built X-ray sources that give very sharp, high-resolution images. Real-time radiography enables interactive visual inspection, but automation capabilities are available for the inspection of larger batches.
Nikon Metrology Grand Opening in Irvine, California just announced the opening of its new Western regional sales office in Irvine, California. The facility will serve as a sales and demonstration center for current and potential Nikon Metrology customers in California, Arizona, New Mexico, Utah, Colorado, Nevada, Idaho, Wyoming, and Texas. “We are always looking for ways to support our customers’ needs, and this new regional sales office exemplifies these efforts,” says Robert Wasilesky, senior vice president of sales and marketing, for Nikon Metrology, Inc.
“It’s exciting to open this facility for our West Coast customers and ensure we are providing them the top level of service possible.” A celebration for the grand opening of the facility was held October 20-21, 2010 with a ribbon cutting ceremony and a catered lunch. Nikon Metrology technical experts demonstrated a wide range of different products from the company’s diverse product line, including, and. The office will be home to nearly a dozen Nikon Metrology employees who will provide customer support and sales demonstrations for customers. Assembling advanced optics is subject to tight-tolerance inspection. Since the optical path of larger instruments is relatively long, is ideally suited to perform measurements on these systems.
In many space-related applications, there is no other sensor capable of meeting the metrology requirements. Laser Radar operates with a graphical software interface supporting both manual and automatic use by a single operator. As part of an ongoing space telescope program, the measures mirror features and large mechanical structures holding sensitive flight hardware without touching the specimens. This metrology system automatically verifies optical component alignment because distance limits can be established for near and far focus by managing the focus of its measurement beam. Thanks to its ability to sample both specular and diffuse material surfaces, Laser Radar can determine mirror alignment directly. For accurate inspection of smaller parts and assemblies, are deployed and equipped with tactile and laser sensors, such as the and. Alternatively, individual parts can be measured using CNC video measuring systems, such as and systems, and industrial or measuring microcopes.
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Nice Nikon Nexiv VMR-3020 3D Coordinate Measuring System with CCD and Laser Auto-focus. Approx 4 years old, unit is in perfect working condition and comes as pictured with Dell CPU, 24' monitor APC Backup, HP Printer, manuals and accessories. Computer has Nexiv VMR AutoMeasure Version 2.11a software installed. Delivery available. This is an ideal general purpose 3D coordinate measuring system with 300 x 200 x 150mm stage travel, the NEXIV-3020 handles a variety of measurement tasks including those for mechanical parts, molded parts, stamped parts and various other workpieces. Features an 8-segment LED illumination system and through-the-lens laser auto-focus, allowing for ultra-accurate detection of measurement points. Comes in four models with 5 step zoom magnification to cover different fields of view and resolution requirements.
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