Alicona FOCUSvariation, Edition 5, English

The magazine about Alicona-metrology

English edition 5

The 5th generation is looking forward to you!

INFINITEFOCUS Form and roughness in one system

OPTICAL 3D micro coordinate measurement

IF-Profiler InfiniteFocusSL

IF-Portable IF-EdgeMaster IF-ToolPrecision

InfiniteFocus X-Large IF-SensorR25

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InfiniteFocus

Dr. Manfred Prantl, Alicona CEO

We Welcome You!

Dr. Stefan Scherer, Alicona CEO

Alicona means innovation and evergrowing leadership in high-resolution optical 3D metrology. Through our recently intensive and market-based development efforts, we are proud to announce the release of the latest generation of measuring devices in conjunction with the 5th edition of FOCUSvariation, the magazine devoted to Alicona measurement technologies.

The 5th generation of InfiniteFocus form and roughness measuring devices places Alicona measurement systems in an elite category among the fastest optical sensors available. This new generation continuously meets traceability, repeatability and accuracy demands as well as satisfies measurement speed requirements as mandated by the industry. This impressive combination of speed and reliability allows for deep implementation of the Focus-Variation technique into production processes.

With this edition of FOCUSvariation, you´ll also find our answer to Smart Manufacturing. At Control show 2014 we revealed a closed loop manufacturing machine, a high-precision eroding machine with integrated optical 3D metrology. This state-of-the-art technology has the potential to revolutionize manufacturing as it reduces production time and increases process accuracy by up to 400%!

Would you like to verify it yourself?

We are ready and waiting for you!

Enjoy your time with Alicona measurement technologies.

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Table of content EDITION 5

HIGH RESOLUTION OPTICAL 3D MEASUREMENT IN RESEARCH AND PRODUCTION 4–5

Table of content

6–9

Key markets and applications An overview

10 – 17 Alicona metrology What makes Alicona metrology distinctive: Benefits and form and roughness measurement modules

PRODUCTS

6-9 10-17 24-31

18 – 21 InfiniteFocus Micro coordinate measurement and surface roughness measurement system in one system 22 – 23 InfiniteFocus X-Large 3D measurement of larger, heavier components 24 – 25 InfiniteFocusSL As fast and easy as 3D measurement can be 26 – 27 IF-Portable 3D measurement on large components 28 – 29 IF-Profiler Automatic roughness measurement 30 – 31 IF-SensorR25 Robust 3D measurement in production 32 – 33 Closed-Loop Manufacturing EDM machining with integrated optical 3D measurement 34

IF-ToolPrecision Optimized 3D measurement of taps

35

IF-EdgeMasterHOB 3D measurement of hob cutters

36 – 37 IF-EdgeMaster Cutting edge measurement also in production

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32-33

TECHNOLOGY 42

Focus-Variation

43

Focus-Variation from the point of view of a tool research association Heinz-Wolfgang Lahmann (GFE) about the use of Alicona in tool research

44 – 45 Traceable roughness measurement How to achieve traceable roughness measurement with Focus-Variation

18-21

43

TOOL MEASUREMENT 38 – 41 Measurement of tools and cutting edge measurement

REFERENCES AND USER CASE STORIES 48 – 49 Machine tools: Makino 50 – 51 Cutting edge preparation: Otec

38-41

52 – 53 Aerospace and aeronautics: Cassidian 54 – 55 Tooth implants: Alpha Bio 56 – 57 Automotive: Roush Yates 58 – 59 Micro precision manufacturing: Intai 60 – 61 Cutting tools: Jarvis

66

62 – 63 Tool measurement: Shanghai Cheng Qin Tools 64 – 65 Forensics: John Jay College of Criminal Justice

ACCESSORIES

67-69

66

Full form and roughness measurement Advanced Real3D RotationUnit

67 – 69 Grips and Standards alicona

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MARKETS KEY MARKETS AND APPLICATIONS Alicona technology is often utilized in fields where the production of functional surfaces with high finish quality and complex geometries is crucial. Therefore, the application range of Alicona’s optical 3D measurement systems is designed to be as diverse as the manufacturing industry and its various products.

Alicona provides its customers with a number of advantages as acknowledged by users worldwide. These users span a vast array of industries and utilize Alicona in many varied applications.

» An Alicona measurement system can pay for itself in as little as 1 year. » Measurements are fast, traceable and repeatable with high accuracy. Each measurement also includes an estimation of measurement uncertainty. » Users benefit from easily legible measurement results with extensive documentation and export options including customized reporting. » Long working distance and a wide measuring range ensure an above-average number of application varieties. For example, Alicona can be used in different ways by several departments within one company. This makes quality assurance more comprehensive and at the same time easier, more profitable and more efficient. » A high level of automation possibilities along with simple operation ensure sustainable use of resources. » Measurement accuracy is clearly and easily observed by the customers on their own production. » Automatic target/actual comparison-namely, fully automatic measurement of shape and position tolerances verifies compliance of defined tolerances. » Independence from external service providers increases the economic efficiency of one’s own value chain.

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alicona I Markets

TOOL INDUSTRY

MICRO PRECISION MANUFACTURING

» Non-contact, repeatable and traceable 3D measurement, also

» Measurement of complex shapes with smallest radii and angles

in production » Measurement of actual edges’ shapes through ellipse fitting method in addition to limited radiusfit approach » Measurement of chipping, roughness and wear

» High resolution measurements of tools’ green parts as well as of components that are highly polished and/or have different coatings » Quality assurance of cutting edge preparation and rounding » Complete measurement of a tool´s geometry with Real3D - technology » Optimization and quality assurance of coating and grinding processes » Complete reverse engineering

“We are convinced; it can’t be realized much better at present!”

Soran Jota, Managing Director, Otec Präzisionsfinish

even at high measurement volumes » Determination of shape and roughness via large lateral and vertical scanning areas within one single measurement process » Checking and verification of dimensional accuracy and finish quality » Measurement of composites with various material and reflectivity properties » Failure analysis, incoming goods inspection and integrated tools compensation » Increase of reliability and optimization of a process by means of high level of standardization » High reproducibility

» 3D measurement of dies, quality assurance in stamping and forming technologies “We mainly use Alicona’s option of full form measurement. And we believe that Alicona has no competition in this field.“ Frank E. Pfefferkorn, Associate Professor, Mechanical Engineering, University of Wisconsin-Madison

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MARKETS KEY MARKETS AND APPLICATIONS MEDICAL TECHNOLOGY

INJECTION MOULDING

AND PHARMACEUTICS

» Quality assurance of micro injection moulds and micro

» High resolution measurement of dental implants’ roughness, including those on thread roots » Quality assurance of orthodontic brackets

» Complete form measurement of surgical drills, milling cutters, etc. » High resolution measurements of knee, hip or spinal disc implants » Establishing a measurable correlation between surface quality and biological behavior of implants » Simple and visible verification against imitations (e.g. tablets)

» Quality assurance of blister packaging lines, needle protection

injection-moulded parts » Can be applied for components produced by means of plastic injection moulding and metal casting » Process optimization, e.g. optimized separation behaviour, prevention from sink marks and joint lines » Production of surfaces with homogeneous appearance and invariable gloss index » Complete miniaturized components for telecommunication, IT, electronics, design and packaging, interior (e.g. interior outfit and decoration in automotive and aviation industry), medical devices (e.g. hearing aids)

for syringes, fusion tubes and other materials produced by means of plastic injection molding “I can rely on Alicona regarding not only precise measurement but expert application knowledge as well!”

Josef Meisler, Quality Engineering, Alpha Bio Tec

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alicona I Markets

“Area-based measurements of roughness allow us to draw firm conclusions on reliability of the product’s functionality.”

Cédric Gysel, Pharmaceutical Development

AUTOMOTIVE INDUSTRY

AEROSPACE AND AERONAUTICS

» 3D measurement of fuel injection nozzles, measurement of valves,

» Failure analysis and incoming goods inspection

condors and envelopes » Automatic cams inspection

» Failure analysis and development of materials for engine and transmission components (e.g. corrosion, analysis of breakdown, measurement of spinning in angular gearbox, gearing damage, 3D measurement of multi-plate clutches and synchronizers) » Quality assurance on pumping systems (based on oil and water) » Material optimization during the development of drive and

» Verification of surface quality » Research of materials » Process optimization

» Measurement of various materials and geometries (thread, bearing parts, engine and transmission components, sealing, shafts, etc.) » Quality assurance of engines

» Measurement of tolerances and free-form surfaces

axle systems “With Alicona we know if a component is okay and if it lies within specified tolerances, and a wide measuring range makes each of our components measurable.”

“Alicona has paid off within approximately one year as a result of its high flexibility.”

Gregor Heichler, Non Destructive Materials Testing, Cassidian

Brett Manwill, Reliability/Design Engineer, Roush Yates Engines

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ALICONA METROLOGY FEATURES AND MEASUREMENT MODULES FOR 3D SURFACE ROUGHNESS AND FORM MEASUREMENT

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alicona I Alicona features

Alicona measurement solutions are used to measure form and roughness.

Even at surfaces with steep flanks and varying reflection properties users achieve traceable results in high resolution and high repeatability.

All measurement modules 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 geometries. Measurement modules are designed by Alicona and are optimally tailored to each other, ensuring user friendly operation.

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 option to characterize surfaces. A series of export functions increase user friendliness. Also complex parameters are visualized and measured from different perspectives.

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WHAT MAKES ALICONA METROLOGY DISTINCTIVE Form and roughness measurement with only one system Traditionally, a surface measurement system is used for measuring roughness whereas a coordinate measurement system is used for dimensional measurement or verifying tolerances. Alicona measurement systems offer the functionalities of both device types combined into one system. As a result, 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 Up to 500 million measurement points ensure a meticulously detailed measurement. This is how components and tolerances in the Âľm or sub-Âľm 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 measurements of small and often hard to access radii, angles and roughness are also provided.

Measure steep flanks 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 can measure up to 87°. Add-ons such as polarization or a ring light also support the measurement of complex geometries.

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alicona I Alicona features

A technology that measures form and roughness within one system.

A flexibility that allows almost unlimited application.

A resolution that remains constant over the whole measurement range.

And an ease of handling that makes Alicona a popular and widely used measurement solution.

Measure components with varying surface finishes or coating Alicona measurement solutions are based on an intelligent lightning technology. Smart Flash 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 Real3D Meaningful quality assurance requires area based measurements. Alicona’s Real3D technology enables full form measurement of components. This is achieved by a range of accessories with motorized rotation and tilt axes. Individual measurements from various directions are automatically reassembled into a full 3D data set. This way, users 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 frames of Alicona measurement systems allows the measurement of roughness plus form on heavy and large components. The spectrum of measurable surfaces goes hand in hand with respective weight classes up the dcm2 range.

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MEASUREMENT MODULES BASED ON FOCUS-VARIATION

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

AREAL SURFACE TEXTURE MEASUREMENT

Classic profile based measurement of Ra, Rq, Rz conforming to ISO 4287/4288

Surface measurement according to ISO 25178

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 Measurement modules

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.

CONTOUR MEASUREMENT Analysis of even complex profiles 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.

DIFFERENCE MEASUREMENT Verification of form deviation 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.

3D FORM MEASUREMENT Measurement of flat and curved components 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.

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MEASUREMENT MODULES PROFESSIONAL SURFACE CHARACTERIZATION

FUSION MEASUREMENT Individual measurements are merged into a full 3D data set Individual measurements from various positions are automatically merged into a 3D data set. The Real3D technology allows the component´s visualization from different angles plus a measurement of contour, difference and form.

MULTI-MEASUREMENT Automatic measurements Users define any set of measurements that are carried out automatically and are optionally merged. All settings are saved, which enables the fully automatic measurement of the same or similar measurement object.

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alicona I Measurement modules

ALICONA INSPECT Measurement of surface geometries and GD&T The 3D inspection software enables users to evaluate surface geometries and to automate measurement processes. Surfaces are analyzed by using sections, surface comparisons or GD&T in accordance with ISO 1101 and ASME Y14.5. Users benefit from individually designed measurement reports.

2D IMAGE MEASUREMENT

AUTOMATION

VOLUME MEASUREMENT

Evaluation of 2D geometries

Programmable solution for repeating measurement tasks

Quantification of pits and peaks

In the 2D view of the measured surface features such as circles, straight lines, angles, parallel lines, distances, ellipses, rectangles etc. can be measured.

All Alicona measurement applications are programmable in an easy script-language. Already existing solutions are e.g. Automatic Surface Defects Analysis, Valve Inspection, Cam Inspection etc.

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.

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INFINITEFOCUS OPTICAL MICRO COORDINATE MEASUREMENT AND SURFACE FINISH MEASUREMENT IN ONE SYSTEM

Only one sensor

InfiniteFocus combines all functionalities of a 3D micro coordinate measurement system and a surface roughness measurement device.

Universal highly efficient

The range of measurable surfaces is nearly unlimited, supported by the use of a LED ring light.

THE SYSTEM

InfiniteFocus is a highly accurate, extremely fast and highly flexible optical 3D measurement system. Users benefit from a 3D micro coordinate measurement machine and surface roughness measurement device in only one system. The range of measurable surfaces is almost unlimited, enabled by the use of coaxial lighting and an optimized LED ring light. In addition, all axes of InfiniteFocus are equipped with highly accurate encoders ensuring highly precise stage movement. Users achieve traceable measurements that combine high resolution, high repeatability and high accuracy.

high repeatability traceable

Users achieve a vertical resolution of up to 10 nm even at complex forms and surfaces.

speed

InfiniteFocus processes 1.7 mio measure points per second.

THE BENEFITS

All relevant surface features are measured with only one multi-functional measurement sensor. Mostly, the optimal setting of measurement parameters is provided automatically.

This allows multiple users in different groups or departments with different materials to use the system with ease and confidence. InfiniteFocus is almost maintenance free, easy to install and does not require controlled environments to operate.

Modular

THE APPLICATIONS automatable

In tool- and mold making, quality assurance with InfiniteFocus is a worldwide standard.

Quality assurance and in-production measurement include cutting edge measurement as well as full form and roughness measurement of drills, millers, inserts etc. With InfiniteFocus in both material and process optimization manufacturer maximize turn over in micro manufacturing, automotive industry, medical device development and pharmaceutical industry, injection molding, aerospace industry, electronics and forensics.

Optimized performance against

New functionalities are easy to integrate via additional measurement modules.

Measurements including change of objectives are easy to automate.

» up to 20 times faster » automated settings » extended range of measurable surfaces and material » more robust, more dense measurements » more accurate measurements, particularly when measuring large measurment fields

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TECHNICAL SPECIFICATION INFINITEFOCUS GENERAL SPECIFICATION Measurement principle

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

Measurement result

3.3-500 mio 3D points in registered true color information (maximum is dependent on the used measurement module)

Maintenance

maintenance free

Coaxial illumination

white LED coaxial light, high power, electronically controllable

Ring light illumination (optional)

white LED high power ring light, 24 segments, wireless, snap-on system

Objectives

2.5x – 100x on motorized nose piece

Temperature range

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

Temperature gradient

less than 1° per hour

System monitoring

automatic self-diagnosis via 8x temperature sensor, vibration sensor internal current - and voltage monitoring

Travel range X/Y/Z

100 mm x 100 mm x 100 mm

Weight

105-120 kg, depending on set up

Dimensions WxDxH

810 mm x 640 mm x 700 mm (up to 945 mm)

CONTROL SERVER Power supply

100-230V~; 50-60Hz

Power consumption

950 W

CPU

12-Core, 3.1 GHz

RAM

32 GB

HDD memory

1 TB

Dimensions WxDxH

190 mm x 500 mm x 450 mm

Weight

20 kg

Operating system

Windows 7 Ultimate 64 bit

Monitor

27“ Full HD LED Monitor with integrated USB Hub

OBJECT Surface texture

Surface topography Ra above 9 nm with Lc 2 µm, dependent on surface structure

Max. height

100 mm to 345 mm

Max. weight

30 kg, more on request

Sample preparation

none

OBJECTIVES 2.5x

5x

10x

20x

50x

Lateral sampling distance

µm

3.52

1.76

0.88

0.44

0.18

0.09

Finest lateral resolution

µm

7.04

3.52

1.76

0.88

0.64

0.44

Best repeatability (vertical)

nm

800

120

30

10

3

1

Best vertical resolution

nm

2300

410

100

50

20

10 400000

Vertical dynamic

100x

3400

55000

165000

360000

500000

Max. scan height (approx.)

mm

8

22.5

16.5

18

10

4

Working distance

mm

8.8

23.5

17.5

19.0

11

4.5

Measurement field X x Y

mm

5.63 x 5.63

2.82 x 2.82

1.62 x 1.62

0.81 x 0.81

0.32 x 0.32

0.16 x 0.16

Max. extended field of view

mm²

10000

10000

10000

10000

3940

985

Max. uni-directional scan extension

mm

100

100

100

100

100

100

2.5x

5x

10x

20x

50x

100x

Vertical scan speed

µm/s

3000

3000

1000-3000

500-3000

200-2000

100-1000

Measurement speed

1.7 mio measure points/seconds

MEASUREMENT SPEED

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alicona I Technical specification InfiniteFocus

RESOLUTION AND APPLICATION LIMITS 2.5x

5x

10x

20x

50x

100x

Min. measurable height

µm

2.3

0.41

0.1

0.05

0.02

0.01

Max. measurable height (approx.)

mm

8

22.5

16.5

18

10

4

%

-

0.05

0.05

0.05

0.05

0.05 985

Height step accuracy (1mm height step) Max. measurable area

mm²

10000

10000

10000

10000

3940

Max. measurable profile length

mm

100

100

100

100

100

100

Min. repeatability

µm

0.8

0.12

0.03

0.01

0.003

0.001

Min. measurable roughness (Ra)

µm

7

1.2

0.3

0.15

0.06

0.03

Min. measurable roughness (Sa)

µm

3.5

0.6

0.15

0.075

0.03

0.015

Min. measurable radius

µm

20

10

8

5

2

1

Min. measurable vertical angle

°

20

20

20

20

20

20

Max. measureable slope angle

°

ACCURACY Ra = 100 nm

Profile roughness

Ra = 500 nm Sa = 100 nm

Areal roughness

Sa = 500 nm

Flatness

1 mm x 1 mm with 10x objective z = 10000 µm z = 1000 µm

Height measurement

z = 100 µm z = 10 µm z = 1 µm xy up to 1 mm

Distance measurement

Edge radius

U = 25 nm, σ = 2 nm

U = 40 nm, σ = 2 nm U = 20 nm, σ = 2 nm U = 30 nm, σ = 2 nm U = 0.1 µm

EUni:St:ODS,MPE = 800 nm, σ = 0.4 µm EUni:St:ODS,MPE = 500 nm, σ = 0.1 µm

EUni:St:ODS,MPE = 400 nm, σ = 0.05 µm

EUni:St:ODS,MPE = 300 nm, σ = 0.025 µm EUni:St:ODS,MPE = 150 nm, σ = 0.01 µm EBi:Tr:ODS,MPE = 0.7 µm

xy up to 10 mm

EBi:Tr:ODS,MPE= 1.0 µm

xy up to 20 mm

EBi:Tr:ODS,MPE = 2.0 µm

R = 5 µm – 20 µm

U = 1.5 µm, σ = 0.15 µm

β = 70…110°

Edge angle

up to 87

R > 20 µm

EUni:St:ODS,MPE & EBi:Tr:ODS,MPE conform to ISO 10360-8

U = 0.15°, σ = 0.02°

U = 2 µm, σ = 0.3 µm

SOFTWARE Measurement modules

Standard: 3D data capturing, profile form, profile roughness (Ra, Rq, Rz...), surface texture (Sa, Sq, Sz...), volume, 2D, automation, AliconaInspect (3D inspection including GD&T) Optional: Automatic multi-measurement; fusion; form/contour/difference; various application specific measurement modules; Edge Measurement Package (edge radius/form/contour; edge break measurement; chipping/roughness; difference measurement; flash measurement); AliconaInspectProfessional (macros for GD&T)

Automation

Integrated 3D Script Editor, Labview Framework und Remoting

Visualization Database

High resolution 3D visualization Intuitive, graphical database

Import/Export

Standard: 3D data sets (e.g. AL3D, STL, G3D, IGES, STP); common image formats (e.g. BMP, JPG, PNG); simple export of results (CSV, 2D, 3D, QDAS export) and reporting functionalities

Languages

Optional: AliconaInspectProfessional (CATIA, UG, Pro/E) German, English, French, Japanese, Chinese

OPTIONS Grips & Accessories

Ring light; IF-ToolGrip, IF-InsertGrip, IF-AdvancedInsertGrip, IF-NanoGrip, IF-ClampingSet, IF-Guide, IF-RotationGrip, IF-VacuumPlate, IF-RotationTable; SpacerPlate; IF-Real3DRotationUnit, IF-AdvancedReal3DRotationUnit;

Calibration Standards

IF-CalibrationTool, IF-RoughnessTool, IF-VerificationTool, IF-RightAngleTool, IF-EdgeCalibrationTool

All given data are provable and traceable.

Technical specification InfiniteFocus I alicona

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CUSTOMIZED MEASUREMENTS WITH INFINITEFOCUS X-LARGE Special measurement tasks need special measurement solutions. This is why Alicona offers the X-Large series of InfiniteFocus to characterize surfaces that are not suitable for the standard measurement system due to shape, size or weight of components to be measured. X-Large devices have a different look but offer the same benefits as the standard system: high vertical resolution of even complex forms with steep flanks, measurement of surfaces with varying material and reflection properties and registered color information with each measurement.

InfiniteFocus X-Large InfiniteFocus is easily

X-Large variants of InfiniteFocus have in common.

as each solid material is measurable as soon as

adjustable and functionalities can easily be extended

The systems differ in possible XY-travel ranges and

there is a minimum surface roughness of only a

depending on application and measurement task. Its

a max measurable weight of components. The cur-

few nanometers. Typical applications are e.g. the

core technology, Focus-Variation, can be “trans-

rently available spectrum of InfiniteFocus X-Large

automatic defect analysis of large measurement

formed� into another hardware without losing any

solutions includes travel ranges from (mm) 200

fields or form measurement of laser structured

of its variety. Area based measurement with high

x 200 up to 1000 x 1000 with a max measurable

geometries on printing plates.

measurement point density, high repeatability,

weight of up to 20 kg. However, on request an

several options for automation as well as high re-

increased weight of components is achievable.

solution measurements even across large mea-

This flexibility is also valid for possible applications

surement volumes are key benefits that all

SPECIFICATION INFINITEFOCUS XL1000

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alicona I InfiniteFocus X-Large

Dimensions

1680 mm x 785 mm x 1700 mm

Weight

1100 kg

Max. lateral travel range (X/Y)

1000 mm x 1000 mm

Max. vertical travel range (Z)

100 mm

Max. sample height

100 mm, more on request

Max. sample weight

200 kg

Max. sample size

1100 mm x 1500 mm

SPECIFICATION INFINITEFOCUS XL 200 Dimensions

810 mm x 640 mm x 700 mm (up to 945 mm)

Weight

110-125 kg, depending on configuration

Max. lateral travel range (X/Y)

200 mm x 200 mm

Max. vertical travel range (Z)

100 mm

Max. sample height

345 mm

Max. sample weight

30 kg, more on request

Max. extended field of view

40000 mm²

Max. uni-directional scan extension

200 mm

SPECIFICATION INFINITEFOCUS XL 500 Dimensions

900 mm x 1100 mm x 800 mm

Weight

300 kg

Max. lateral travel range (X/Y)

500 mm x 500 mm

Max. vertical travel range (Z)

100 mm

Max. sample height

100 mm

Max. sample weight

10 kg, more on request

MEASUREMENT WITH EXTRAS Both the InfiniteFocus standard system and the X-Large series for the cha-

quality assurance, Focus-Variation allows the quick and simple implemen-

racterization of measurement fields larger than 10 cm x 10 cm are easily

tation of new software modules. This is valid for both already available soft-

adoptable to particular environments and/or new conditions. This means

ware modules as well as new modules on request. See what is possible

that not only the hardware can be changed to meet new requirements, but

with Focus-Variation – there are packages on-hand for the groove measu-

also the software is extendable individually throughout new software mo-

rement of golf clubs, the measurement of diamond particles, valve

dules. Instead of purchasing a new measurement system because of new

inspection, conrod and cams measurement etc.

or additional measurement tasks which change former conditions to perform

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INFINITEFOCUSSL AS FAST AND INTUITIVE AS 3D SURFACE MEASUREMENT 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 the laboratory and a 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 33 mm in combination with the above average measurement field of 50 mm x 50 mm 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 Robust design for universal use 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.

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alicona I InfiniteFocusSL

GENERAL SPECIFICATION Travel range X/Y Travel range Z Illumination

50 mm x 50 mm (motorized) 130 mm (26 mm motorized) LED ring light with 24 segments

Weight

15 kg

Dimensions

195 mm x 316 mm x 418 mm (W x D x H)

OBJECTIVES 10x

20x

50x

2x SX

5x SX

10x SX

20x SX

50x SX

Sampling distance

µm

1

0.5

0.2

5

2

1

0.5

0.2

Min. repeatability (vertical)

nm

40

20

10

1240

180

45

25

15

Best vertical resolution Max. scan height (approx.)

Working distance

nm mm mm

100 16 17.5

50 12 13

20 9 10.1

3500 25 34

510 25 34

130 25 33.5

70 19 20

45 12 13

Measurement field X x Y

mm

2x2

1x1

0.4 x 0.4

10 x 10

4x4

2x2

1x1

0.4 x 0.4

Max. extended field of view Max. uni-directional measurement

mm² mm

2500 50

2500 50

1100 50

2500 50

2500 50

2500 50

2500 50

1100 50

50x SX

RANGE OF RESOLUTION AND APPLICATIONS 10x

20x

50x

2x SX

5x SX

10x SX

20x SX

Min. measurable radius

µm

5

3

2

20

10

5

3

2

Min. measurable wedge angle Min. measurable roughness (Ra)

° nm

20 300

20 150

20 80

20 -

20 -

20 450

20 250

20 150

Min. measurable roughness (Sa)

nm

150

75

50

-

-

250

100

80

Max. measurable slope angle

°

ACCURACY

up to 87

Profile roughness

Ra = 500 nm

Areal roughness

Sa = 500 nm

U = 40 nm, σ = 2 nm

Flatness

2 mm x 2 mm, 10x objective

U = 0.1µm

z = 1000 µm Height measurement

z = 100 µm z = 10 µm z = 1 µm

Distance measurement

xy up to 2 mm (10x objective)

EUni:St:ODS,MPE & EBi:Tr:ODS,MPE conform to ISO 10360-8

U = 30 nm, σ = 2 nm

EUni:St:ODS,MPE = 1000 nm, σ = 0.1 µm EUni:St:ODS,MPE = 400 nm, σ = 0.05 µm EUni:St:ODS,MPE = 300 nm, σ = 0.025 µm EUni:St:ODS,MPE = 150 nm, σ = 0.01 µm EBi:Tr:ODS,MPE = 0.8 µm

SOFTWARE

Measurement modules

Standard: 3D data capturing, profile form, profile roughness (Ra, Rq, Rz...), surface texture (Sa, Sq, Sz...), volume, 2D, automation; AliconaInspect (3D surface inspection including GD&T)

Automation

Optional: Automatic multi-measurement; fusion; form/contour/difference; various application specific measurement modules; Edge Measurement Package (edge radius/form/contour; edge break measurement; chipping/roughness; difference measurement; flash measurement); AliconaInspectProfessional (macros for GD&T) Integrated 3D Script Editor, Labview Framework and Remoting

Import/ Export

Standard: 3D data sets (e.g. AL3D, STL, G3D, IGES, STP); common image formats (e.g. BMP, JPG, PNG); simple export of results (CSV, 2D, 3D, QDAS export) and reporting functionalities Optional: AliconaInspectProfessional (CATIA, UG, Pro/E)

Languages

German, English, French, Japanese, Chinese

MEASUREMENT OBJECT Texture Max. height

Surface topography Ra above 9 nm with Lc 2 µm, dependent on surface structure 155 mm

Max. weight

4 kg

Sample preparation

none

InfiniteFocusSL I alicona

25

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 of also larger components.

The standard configuration allows the high resolution measurement of surface fields of up to (mm) 50x50x26. Typically, the system is used for near and or in production quality assurance. As an easy to handle and portable system it is a flexible measurement station which can be used wherever it is needed.

THE BENEFITS High measurement accuracy via automation A key feature is the integrated revolving nose piece 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.

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

26

alicona I IF-Portable

GENERAL SPECIFICATION Travel range X/Y

50 mm x 50 mm

Travel range Z

26 mm

Illumination

LED coaxial light

Weight

9.3 kg (dependent from configuration)

Dimensionen

300 mm x 180 mm x 260 mm (W x D x H)

OBJECTIVES Sampling distance Min. repeatability (vertical) Max. scan height (approx.)

Best vertical resolution Working distance Measurement field X x Y Max. extended measurement field Max. uni-directional measurement

µm nm mm nm mm mm mm² mm

2.5x 4.4 645 8 1800 8.5 7.04 x 5.28 2500 50

5x 2.2 160 22 450 23.5 3.52 x 2.64 2500 50

10x 1.1 40 16 110 17.5 1.76 x 1.32 2500 50

20x 0.55 25 18 60 19 0.88 x 0.66 2500 50

50x 0.22 25 10.5 60 11 0.35 x 0.26 700 50

100x 0.11 25 4 60 4.5 0.17 x 0.13 150 50

2.5x 2500 20 5400 2700

5x 2500 20 1350 680

10x 2500 20 335 170

20x 2500 20 180 90

50x 1000 20 180 90

100x 210 20 180 90

RANGE OF RESOLUTION AND APPLICATIONS Max. measurable area Min. measurable angle Min. measurable roughness (Ra) Min. measurable roughness (Sa) Max. measurable slope angle

mm² ° nm nm °

up to 87

SOFTWARE Standard: 3D data capturing, profile form, profile roughness (Ra, Rq, Rz....), surface texture (Sa, Sq, Sz…), volume, 2D, automation, AliconaInspect (3D inspection software including GD&T)

Measurement modules

Automation

Optional: Automatic multi-measurement, fusion; form/contour/difference; various application specific measurement modules; Edge Measurement Package (edge radius/form/contour; edge break measurement, chipping/roughness; difference measurement; flash measurement); AliconaInspectProfessional (macros for GD&T) Integrated 3D Script Editor, Labview Framework and Remoting

Import/Export

Standard: 3D data sets (e.g. AL3D, STL, G3D, IGES, STP); common image formats (e.g. BMP, JPG, PNG); simple export of results (CSV, 2D, 3D, QDAS export) and reporting functionalities Optional: AliconaInspectProfessional (CATIA, UG, Pro/E)

Languages

German, English, French, Japanese, Chinese

MEASUREMENT OBJECT Surface texture Sample preparation

Surface topography Ra above 9 nm with Lc 2 µm, dependent on surface structure none IF-Portable I alicona

27

IF-PROFILER HOW TO MEASURE ROUGHNESS AND SURFACE FINISH

THE SYSTEM Optical surface profilometry to measure roughness IF-Profiler is a handheld 3D roughness measurement system for high resolution measurement of surface finish.

Users measure roughness of flat and curved components with only one system. Measurements are performed both profile based (ISO 4287) and areal based (ISO 25178). The lightweight IF-Profiler consists of a 3D measurement sensor and a robust, at the same time handy framework. The ergonomic design combines ease of use and requested mechanical rigidity.

THE BENEFITS Flexible and easy to use IF-Profiler achieves flexible measurements and applications at high measurement speed. Various positions and measurement fields are traceably and intuitively measured. The roughness measurement system is also used to measure geometries with steep flanks and various coatings. A note book, used as Control Server, enables a flexible usage.

28

alicona I IF-Profiler

THE APPLICATION Quality assurance of car bodies, steel plates, print rolls, etc.

Amongst other applications the IF-Profiler is used to measure surface finish even of large and heavy components. Fields of use are the measurement of e.g. turbine or rotor blades, steel and body type surfaces. Traceable measurements are achieved in high repeatability.

GENERAL SPECIFICATION Travel range Z

26 mm (motorized)

Illumination

LED ring light with 24 segments

Weight

6.5 kg

Dimensions

157 mm x 300 mm x 344 mm (W x D x H)

Control Server

Notebook (IF-ControlServerL)

OBJECTIVES 10x

20x

50x

Sampling distance

µm

1

0.5

0.2

Min. repeatability (vertical)

nm

40

30

25

Max. scan height (approx.)

mm

16

12

9

Best vertical resolution

nm

100

80

60

Working distance

mm

17.5

13

10.1

Measurement field X x Y

mm

2x2

1x1

0.4 x 0.4

50x

RANGE OF RESOLUTION AND APPLICATIONS 10x

20x

µm

5

3

2

Min. measurable wedge angle

°

20

20

20

Min. measurable roughness (Ra)

nm

300

240

180

Min. measurable roughness (Sa)

nm

150

120

90

Min. measurable radius

Max. measurable slope angle

°

up to 87

SOFTWARE Measurement modules

3D data capturing, automated measurement of surface texture (ISO 25178) and profile roughness (ISO 4287)

Import/Export

3D data sets (e.g. AL3D, STL, G3D, IGES, STP); common image formats (e.g. BMP, JPG, PNG); simple export of results (CSV, 2D, 3D, QDAS export) and printing functionalities

Languages

German, English, French, Japanese, Chinese

MEASUREMENT OBJECT Surface texture

Surface topography Ra above 9 nm with Lc 2 µm, dependent on surface structure

Max. diameter

100mm - ∞

Sample preparation

none

IF-Profiler I alicona

29

IF-SENSORR25 HOW TO ACHIEVE STABLE 3D MEASUREMENT IN PRODUCTION

THE SYSTEM Optical 3D measurement sensor IF-SensorR25 is a solid optical 3D measurement instrument for automated form and roughness measurement in production. The sensor is integrated into a production line and delivers high resolution, repeatable and traceable results when measuring surface characteristics in the µm or sub-µm range. This resolution can hardly be achieved by conventional 2D solutions or tactile techniques.

THE BENEFITS A measurement procedure from development to production The robust technology of Focus-Variation delivers high resolution results with high repeatability in research and production. Therefore IF-SensorR25 is a platform that enables the use of the same measurement process both in-line and in the lab. Standardized interfaces (QDAS) support an easy and quick integration into production allowing comparable in-line and lab measurements.

THE APPLICATION Measurement of surface quality and finest form tolerances IF-SensorR25 is a measurement system for quality assurance in serial production. It is suitable for numerous materials including composite materials. The modular design allows arbitrary extensions of hard- and software for new and/or complex measurement tasks. In the field of EDM, the sensor can be implemented directly in a Makino machining center to perform in-machine measurement. This “closed loop manufacturing” production concept enables 3D measurement of components directly in the machine, enabling up to a fourfold increase in machining accuracy.

30

alicona I IF-SensorR25

GENERAL SPECIFICATION Travel range Z

26 mm (motorized)

Illumination

LED ring light with 24 segments

Weight

4 kg

Dimensions

126 mm x 153 mm x 202 mm (W x D x H)

OBJECTIVES 10x

20x

50x

2x SX

5x SX

10x SX

20x SX

50x SX

Sampling distance

µm

1

0.5

0.2

5

2

1

0.5

0.2

Min. repeatability (vertical)

nm

40

20

10

1240

180

45

25

15

Max. scan height (approx.)

mm

16

12

9

25

25

25

19

12

Best vertical resolution

nm

100

50

20

3500

510

130

70

45

Working distance

mm

17.5

13

10.1

34

34

33.5

20

13

Measurement field X x Y

mm

2x2

1x1

0.4 x 0.4

10 x 10

4x4

2x2

1x1

0.4 x 0.4

50x SX

RANGE OF RESOLUTION AND APPLICATIONS 10x

20x

50x

2x SX

5x SX

10x SX

20x SX

µm

5

3

2

20

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

Max. measurable slope angle

°

up to 87

SOFTWARE Measurement modules

Standard: 3D data capturing; Automation; Remoting; AliconaInspect (3D inspection software including GD&T) Optional: Profile form, profile roughness (Ra, Rq, Rz...), surface texture (Sa, Sq, Sz...), volume, 2D; automatic multi-measurement; fusion; form/contour/difference; various application specific measurement modules; Edge Measurement Package (edge radius/form/contour; edge break measurement; chipping/roughness; difference measurement; flash measurement); AliconaInspectProfessional (macros for GD&T)

Automation

Integrated 3D Script Editor, Labview Framework and Remoting

Import/Export

Standard: 3D data sets (e.g. AL3D, STL, G3D, IGES, STP); common image formats (e.g. BMP, JPG, PNG); simple export of results (CSV, 2D, 3D, QDAS export) and reporting functionalities Optional: AliconaInspectProfessional (CATIA, UG, Pro/E)

Languages

German, English, French, Japanese, Chinese

MEASUREMENT OBJECT Surface texture Sample preparation

Surface topography Ra above 9 nm with Lc 2 µm, dependent on surface structure none

IF-SensorR25 I alicona

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CLOSED-LOOP MANUFACTURING High precision EDM machine with integrated optical 3D measurement sensor by Alicona With the newest generation of electrical discharge machines Alicona Manufacturing has set an example for smart manufacturing: The innovative Makino machining center combined with an optical 3D measurement sensor enables self-optimized performance. This new processing method eliminates clamping errors and increases machining accuracy up to fourfold.

Four times higher machining accuracy The closed-loop technology allows miniaturized

of the benefits include: up to a fourfold increase in

EDM components with complex geometries to be

machining accuracy; elimination of clamping errors;

manufactured using continuous high resolution

automated quality assurance; 25% resource sa-

measurements for inspection. High measurement

vings; a more efficient deployment of personnel and

speed in conjunction with high vertical resolution

shorter lead times at a better output ratio.

enables machine to machine communication while

The main CLM application clearly lies in mold and

measurements of form, position, and surface finish

tool making. The area based, dense and high reso-

ensure quality and adherence to various tolerances.

lution metrology by Alicona allows better control of

If the measured value does not meet the target

the production process than a simple tactile point

value, the CLM machine automatically modifies and

measurement for example.

verifies the process and machine parameters for Through the presentation of a unique combination

further manufacturing. This fast interaction between

of high resolution optical 3D measurement techno-

machine and measurement sensor is, amongst

logy and automated machine programing Alicona

other things, enabled by the high measurement

Manufacturing brings the manufacturing generation

speed and high vertical resolution across small and

to the next level. Based upon “Smart Manufactu-

large measurement volumes. Mark Raleigh, US

ring”, Alicona Manufacturing is setting the trend of

EDM specialist and CEO of EDM Department Inc.

integrated manufacturing by offering a novel pro-

agrees that enabling self-controlled production

duction system where components are measured

through this pioneering technology will present

directly inside the machine. The internal measure-

worldwide users with a multitude of benefits. A few

ment evaluates possible deviations from the target geometry and reports them directly to the machine which eliminates the need to remove parts for measurement. Based upon the internal evaluation, the machine automatically modifies the process parameters for further manufacturing. As a result of this closed loop “processing-measuring-modifyingprocessing”, users experience up to four times the accuracy in comparison to traditional measurement methods. Mark Raleigh, Co-CEO of Alicona Manufacturing, is enthusiastic about this revolutionary processing method as he explains, “The integrated measurement sensor verifies what the machine is currently doing. As a result, the production accuracy is increased while adverse effects of the environment are reduced.”

Closed-Loop Manufacturing: High precision EDM machine with integrated optical 3D measurement sensor enables self-optimized performance during production

32

alicona I Closed-Loop Manufacturing

Alicona Manufacturing is a joint venture formed through the collaboration of Alicona, global supplier of optical 3D surface measurement solutions, and EDM Department Inc., specialist in micro and precision manufacturing, located in Bartlett, IL. The venture combines the technological expertise of Alicona Imaging GmbH and the production know-how of EDM Department to further the development and creation of advanced high resolution optical measurement solutions for manufacturing. With Closed-Loop Manufacturing the joint venture between Dr. Stefan Scherer (CEO Alicona) and Mark Raleigh (CEO EDM Department) offers a state-ofthe-art, self-optimizing machining method for the production of precision components in the µm and sub-µm range. The intent of this cooperation is to formulate and develop solutions that will meet the ever rising demands of the manufacturing industry by increasing productivity and efficiency while enabling greater profitability.

Alicona Manufacturing meets customers’ needs by offering a full line of closed-loop machining applications including: products, services and consulting expertise.

www.aliconamanufacturing.com

Mark Raleigh CEO EDM Department Inc

₺Up to a fourfold increase in machining accuracy,

The innovative machining center with integrated 3D measurement sensor enables self-optimized performance in production

Automated high resolution 3D measurement of a slide used for demolding of injection molding components guarantees adherence to all tolerances within µm range

elimination of clamping errors, automated quality assurance, 25% resource savings, a more efficient deployment of personnel and shorter lead times at a better output ratio. ₺

Closed-Loop Manufacturing I alicona

33

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.

THE PRACTICE “Before IF-ToolPrecision, there worldwide was no comparable system available – neither in function nor in precision.”

Michael Ackermann Quality management Bass GmbH & Co.KG

34

alicona I IF-ToolPrecision

IF-EDGEMASTERHOB EDGE MEASUREMENT AT TOOTH FLANK, TOOTH ROOT AND TOOTH TIP

The IF-EdgeMasterHOB is one of Alicona’s optical 3D tool measurement systems and a market specific adaption of the optical cutting edge measurement device IF-EdgeMaster. A large working distance of 33 mm allows effortless measurement of cutting edges even in areas that are hard to access. Users measure hob cutters at every stage of manufacture, regardless of surface finish or coating.

USERS MEASURE:

THE PRACTICE

» Edge roundness at tooth flank, tooth root and tooth tip

“Being able to measure the edge radius of both, tooth tip and tooth flank over this

» Radius, wedge angle, true edge geometry ("waterfall"

broad range is, as far as I know, not possible with any other system.“

and/or "trumpet" type) through ellipse fitting method

» Positive and negative bevel

Tobias Schulz Head of quality assurance in gearing

» Chipping and roughness

» Wear and difference to CAD models or reference geometries

LMT Werkzeugtechnologie

GENERAL SPECIFICATION Travel range

66 mm (26 mm motorized)

Rotation table

+/- 90°

Illumination

LED ring light with 24 segments

Weight

30 kg

Dimensions

299 mm x 254 mm x 502 mm (W x D x H)

Sample size

Diameter 25 mm - 300 mm

OBJECTIVES Sampling distance

µm

10x SX

20x

1.1

0.55 25

Min. repeatability (vertical)

nm

40

Max. scan height (approx.)

mm

22

12

Best vertical resolution

nm

100

100

Working distance

mm

33.5

13.0

Measurement field X x Y

mm

1.76 x 1.32

0.88 x 0.66

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

20x

µm

6

4

°

20

20

Uncertainty of angle

°

0.5

0.5

Max. Bevel length

µm

500

250

IF-EdgeMasterHOB I alicona

35

IF-EDGEMASTER HOW TO MEASURE CUTTING EDGES OPTICALLY AND REPEATABLE ALSO IN PRODUCTION

THE SYSTEM Automatic cutting edge measurement IF-EdgeMaster is an optical 3D measurement device for automatic cutting edge measurement. Edges are measured regardless of type, size, material or surface finish of the tool. Users measure radii > 2 µm 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 Stable results include traceable roughness measurements 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. An intelligent illumination technology enables optimized illumination of surfaces with short exposure times, leading to fast measurements.

THE APPLICATION From the green part to the polished component 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 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

36

alicona I IF-EdgeMaster

GENERAL SPECIFICATION Travel range X/Y

25 mm x 25 mm

Travel range Z

130 mm (26 mm motorized)

Illumination

LED ring light with 24 segments

Weight

12 kg

Dimensions

195 mm x 316 mm x 418 mm (W x D x H)

OBJECTIVES Sampling distance Min. repeatability (vertical) Max. scan height (approx.)

Best vertical resolution Working distance Measurement field X x Y

µm nm nm mm mm mm

10x 1 40 16 100 17.5 2x2

20x 0.5 20 12 50 13 1x1

50x 0.2 10 9 20 10.1 0.4 x 0.4

10x 5 20 300 150 800

20x 3 20 150 75 400

50x 2 20 80 50 160

2x SX 5 1240 25 3500 34 10 x 10

5x SX 2 180 25 510 34 4x4

10x SX 1 45 25 130 33.5 2x2

20x SX 0.5 25 19 70 20 1x1

50x SX 0.2 15 12 45 13 0.4 x 0.4

5x SX 10 20 2000

10x SX 5 20 450 250 800

20x SX 3 20 250 100 400

50x SX 2 20 150 80 160

RANGE OF RESOLUTION AND APPLICATIONS Min. measurable radius Min. measurable wedge angle Min. measurable roughness (Ra) Min. measurable roughness (Sa) Max. bevel length Max. measurable slope angle

ACCURACY Edge angle Edge radius

SOFTWARE Measurement modules Automation Import/Export Languages

µm ° nm nm µm °

β = 70…110° R = 5 µm – 20 µm R > 20 µm

2x SX 20 20 4000 up to 87

U = 0.15°, σ = 0.02° U = 1.5 µm, σ = 0.15 µm U = 2 µm, σ = 0.3 µm

Standard: Automatic edge measurement (edge radius/form/contour; form deviations) Optional: Chipping; roughness, edge break measurement, flash measurement Integrated 3D Script Editor, Labview Framework und Remoting 3D data sets (e.g. AL3D, STL, G3D, IGES, STP); common image formats (e.g. BMP, JPG, PNG); simple export of results (CSV, 2D, 3D, QDAS export) German, English, French, Japanese, Chinese

MEASUREMENT OBJECT Surface texture Max. height Max. weight Sample preparation

Surface topography Ra above 9 nm with Lc 2 µm, dependent on surface structure 155 mm 4 kg none IF-EdgeMaster I alicona

37

TOOL MEASUREMENT Worldwide leading tool manufacturers use Alicona for quality assurance of cutting edges and geometries within their production. The broad range of Alicona technologies is comprised of fully automatic measurement solutions for production and comprehensive analysis modules, including visualization for a laboratory. All measurements, regardless of the application site, are characterized by high resolution, traceability and repeatability. By means of elliptical measurement, Alicona users get precise and actual results of their tool kit edge’s shape. In addition, options such as measurement of roughness, edge break and ridges offer a wide range of opportunities for numerical evaluation of edge quality.

38

alicona I Tool measurement

MEASUREMENT OF RADIUS AND FORM With the use of radius-fit, radius, clearance angle (α), wedge angle (β), rake/chipping angle (ɣ), edge symmetry (K) as well as negative and positive bevel lengths are measured. Measurements include projected bevel length, true bevel length and bevel angles.

MEASUREMENT OF „TRUE“ CONTOUR THROUGH ELLIPTIC FIT Inserts with both waterfall and trumpet shapes are measured. A fit of elliptic shapes into the edge region describes the shape by two radial parameters. The edge can also be compared to user-defined basket arch files of arbitrary shape.

Tool measurement I alicona

39

FORM DEVIATION WITH DIFFERENCE MEASUREMENT 3D measurements are automatically compared to an imported 3D data set or reference geometry. Measurable parameters are e.g. min./max./mean deviation to reference surface. Also, form deviations are clearly visible by advanced color visualization.

FLASH MEASUREMENT Users measure width and height of an insert´s burr (or flash) which can occur during molding. The numerical verification of the burr enables the early identification of potential wear of molding tools during the manufacturing of inserts.

40

alicona I Tool measurement

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

CHIPPING MEASUREMENT

effortless change of specimen

High resolution enables the measurement of ISO 4287 conform parameters (Ra, Rq, Rz, Rp, Rv...) along the edge, making e.g. edge defects measurable and visible.

» 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. 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

TOOL ROUGHNESS MEASUREMENT

components or other surfaces with

In addition to chipping along the edge, users are also able to measure tool roughness both profile and areal based.

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 5 nm 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

CHAMFER MEASUREMENT

production near environment Measurable paramters of an edge break are e.g. chamfer width, various angles, width of edge break, normal distances and other ISO 1375 conform parameters.

Tool measurement I alicona

41

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 Zdirection. 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.

42

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

"One of the greatest advantages, besides the high vertical resolution, is the fact that with Focus-Variation we are able to perform traceable measurements of geometry and roughness of different edge forms."

be used for a functional description of a cutting

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

edge. Recent developments in metrology help us to

The main subject of our current studies is dealing

as we use the system for the measurement of a tool

move forward with relevant activities. This is why,

with possible effects that the cutting edge form

and a workpiece.

among other factors, the impact of a form of the

might produce on the processing result in addi-

cutting edge and its roughness is examined as to

tion to the edge radius. Therefore every common

For a research association, visualization plays an

their influence on the results of processing. Here

edge form, ranging from simple edge roundness

important role as well. It delivers an additional eva-

the Focus-Variation turns to be increasingly esta-

to a more complex, elliptic form has to be com-

luation possibility for a better analysis of a tool. The

blishing itself as an appropriate technology. The

pletely measured. At GFE we perform these mea-

visualization in true color information with Infinite-

area based, high resolution measurements that can

surements primarily by means of InfiniteFocus

Focus also allows us to detect coated areas quickly

optical measuring system. Due to a lateral reso-

and without much effort.

be achieved by Focus-Variation open new possibilities for research, and, consequently, new insights

lution in the submicrometer range and a vertical

into cutting edge characterization which was not

resolution in nanometer range, the device is ideal

possible in such a form until now. One of the most

for defining necessary roughness parameters.

significant benefits for us is the fact that we are

With the 3D measurement device by Alicona we

now able to perform traceable measurements of

also measure additional parameters such as the

both geometry and roughness of various edge

roughness on the clearance and chip surface.

types.

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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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 2 nm 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.

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PRACTICAL EXPERIENCE CUSTOMERS ABOUT ALICONA

46

alicona I References and user case stories

Our customers describe the way they use Alicona for quality assurance purposes. The applications found daily in various fields create additional benefits that you too can experience from using Focus-Variation.

With our 3D optical measurement system we present our user-oriented and sustainable solutions. The application examples mentioned

here illustrate the need to meet the requirements of our customers not only from a technological viewpoint, but also satisfy the demands concerning handling, flexibility and servicing. Each of our 3D measurement systems is based on the principle of direct marketability that originates from constant dialogue with Alicona users.

Do you want to take part in development of Alicona measurement solutions? Let us know your requirements: CreativeLab on our online Service Portal- AliconaFamily is waiting for you!

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Source: Makino

48

alicona I References and user case stories

MICROMACHINING SUPERIOR SURFACE FINISH MEASUREMENT Validation and promotion of ultra-precision machine platforms Before the use of Alicona, Makino was unable to confidently validate and promote the capabilities of its ultra-precision machine platforms. Today, measurements with Focus-Variation have become an integral part of machining process optimization and surface characterization. “Alicona is a much more flexible technology than any other measurement system we have ever used or evaluated”, Makino says.

What

What

Higher surface finish at lower costs

Surface roughness and flatness

Makino is a world leader in EDM technology,

Makino measures surface roughness and form of

ABOUT

What

IS MEASURED

THE CUSTOMER STATES

providing faster processing times and superior

machined components. Requirements change

surface finishes for even the most complex and

from part to part. Typically, components include

involved part geometries. Surface characterization by

steep flanks and a high aspect ratio. Measure-

Alicona enables Makino to sufficiently understand

ments are fast and provide real time feedback,

and improve their technologies, and, even more

which enables the adjustment of machining para-

important, confidently validate and promote the

meters within minutes, significantly compressing

capabilities of ultra-precision machine platforms.

overall process development lead times. In addition

Today, Makino performs traceable measurements

to surface roughness and form, measurements

and operates with a measurement technique that

include edge measurement, comparison to CAD

allows measurement of roughness and form on

data, volume analysis and difference measure-

highly irregular surfaces of micro scale parts.

ments.

John W. Bradford Micromachining R&D Manager Makino

“Alicona enables us to quickly develop a machining process and make specific process iterations with adjustments as small as 1um in depth and size. This ability impresses potential customers and often results in the customer purchasing our machine. This cycle has repeated itself countless times in the two years that we have owned the Alicona system.”

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Source: Alicona

50

alicona I References and user case stories

TOOLMAKING PROCESS RELIABILITY IN CUTTING EDGE PREPARATION 3D measurement of the “real” edge contour OTEC offers innovative drag finishing machines for high precision surface finish. “Perfect surfaces”, as the supplier states, are achieved quickly and cost-effectively. Customers benefit from optimal machining results with precise edge rounding. For cutting edge measurement, OTEC obtains high resolution surface measurement with Alicona. 3D measurement of chipping, edge radius and traceable roughness measurement provide the supplier with competitive advantages. In sample processing, excellent service is provided.

What

What

Deburring, grinding, smoothing and polishing

Complex and highly contoured surfaces

By using OTEC machines, cutting edges can be

Complex geometries of deburred, ground,

ABOUT

IS MEASURED

rounded down to 1µm. In order to verify geometries

smoothed and polished components are

in this detail and accuracy, a 3D measurement

measured. InfiniteFocus is used to verify

system that provides a high resolution is required.

defined tolerances in terms of cutting edge

This is why OTEC has decided to go for Alicona.

preparation. In addition to the measurement

Instead of utilizing only common radius-fit, the

of edge radius and various edge angles,

high resolution of InfiniteFocus enables trace-

OTEC also achieves the measurement of

What

THE CUSTOMER STATES

able and repeatable measurement of the “real”

chipping along the cutting edge. For test

edge contour including its elliptical form.

purposes, InfiniteFocus is also used to

Soran Jota Managing Director

measure stamped components, turned

Otec Präzisionsfinish GmbH, Germany

parts and milled work pieces. In process engineering, OTEC applies high resolution

“In order to produce a defined edge shape in

3D measurement for process monitoring.

the µm-range, a highly precise 3D measurement technique is required. The high measurement quality offered by Focus-Variation was the decisive factor for us to continue cutting edge measurement with using Alicona systems.

Today, we achieve a higher resolution and higher accuracy. Also, we are now able to measure more tool geometries and types than before.

In addition, we appreciate Alicona as a very user-oriented supplier. The intuitive handling of the systems clearly shows an in depth understanding of the users requirements. In our opinion, there is currently no better way to do it.”

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Source: Cassidian

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alicona I References and user case stories

AEROSPACE AND AERONAUTICS ERROR ANALYSIS Reduction of material and labor costs Initially Cassidian intended to purchase a measurement device for failure analysis. It did not take the areospace and defence enterprise long to realize the great potential InfiniteFocus has to offer in different areas and today this potential is fully exploited. Typical applications other than failure analysis are incoming goods inspection and the verification of high surface quality for customers.

What ABOUT

What

IS MEASURED

Incoming goods inspection, failure analysis and avoiding customer complaints

Titan, high strength steels and fibre composites

High resolution measurement of geometry and

complex forms are measured. The measu-

surface finish is performed to verify the manu-

rement of these various components include

facturer's information and identify defects prior

radii, threads, diverse angles and roughness.

to further processing. The surface quality of

Since Cassidian uses InfiniteFocus, surface

components is determined with a numerical

characteristics are measured, that in the

measurement in order to avoid unsuitable and

past, were either difficult to access or

expensive materials in production. A thorough

could not be accessed at all. These include

report that includes practically oriented visuali-

root of a thread and thread flanks of gear

zation and measurement results that are easy

drives. Surface damage of various sizes

to read, verifies compliance with the agreed

and dimensions are measured, even on

specifications and the stipulated surface finish.

round components.

What

THE CUSTOMER STATES

Varying components, many of which have

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

Since this was introduced customer complaints

"Due to its high flexibility, InfiniteFocus had paid

at final inspection of aircraft are reduced to a

for itself within the first year.

minimum.

Initially the system had been purchased for failure analysis and for measuring the depth of surface damage. However, it became apparent very soon that the measurement device can be universally used. Today we operate across departments which makes both, quality assurance and development more comprehensive and at the same time easier and more efficient."

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Source: Alpha Bio Tec

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alicona I References and user case stories

DENTAL IMPLANTS FORM AND ROUGHNESS FOR SAFE SEALING

3D measurement of implant and abutment Alpha Bio targets the ongoing improvement of measurements during development, production and final inspection of both dental implants and accessories. InfiniteFocusSL is used in all stages of the manufacturing process and enables “accurate, reliable and repeatable measurements”, says Alpha Bio. Both form and surface finish measurements even across large measurement fields are performed in only one system.

What

What

Innovation in development, production and final inspection

Internal conical connection and surface finish

ABOUT

IS MEASURED

Quality engineering at Alpha Bio focuses on mea-

InfiniteFocusSL is used to measure form and

surement systems that are more precise, more

roughness. Among other geometries, form mea-

accurate and more reliable in terms of repeatability

surement includes the verification of a cone´s

and reproducibility. With InfiniteFocusSL, the leading

open conical angle, its roundness as well as different

manufacturer of advanced implantology and

radii and other geometry requirements. In addi-

prosthetics solutions is now able to perform

tion to form, also surface finish measurements

both roughness and form measurements with

are achieved. Both, internal and external roughness

only one system. In particular, form measurement

even at the thread flank is measured. When measu-

has opened up new measures in quality assurance,

ring the external roughness of an implant, areal

as it allows the measurement of the internal conical

measurements (Sa, Sq, Sz…) lead to more signi-

connection of implants. In combination with

ficant results to verify the surface state.

roughness measurement, this ensures the safe sealing of implant and abutment.

What

THE CUSTOMER STATES

Josef Meisler Quality Engineering Alpha Bio Tec

“My first impression about Alicona was the high expertise and professionalism of its people. I immediately felt that I can rely on a strong partnership and continuous support as well as on the accurate and repeatable measurements achieved by the system.

With InfiniteFocusSL I now measure parameters that I have never been able to inspect before. The Alicona 3D measurement system significantly upgrades Alpha Bio´s quality engineering metrology lab.“

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Source: Roush Yates

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alicona I References and user case stories

AUTOMOTIVE HIGH PERFORMANCE RACING ENGINE

Failure analysis and in-depth surface finish inspection With NASCAR Sprint Cup, Roush Yates is well known for its powerful and reliable racing engines. Here, failure analysis is the key to understand the durability of engine components. To increase performance, Roush Yates was looking for a system with high depth of field to do more extensive surface finish inspection. Today, the work with InfiniteFocus has led to improved processes and maintained quality control.

What

What

ABOUT

IS MEASURED

Durability of engine components

Fracture analysis

Failure analysis is a critical task in Roush Yates´

Typically, crankshafts, camshafts, pistons,

continuing development. It is the key to under-

connecting rods, valves, valves springs, and

stand the durability of engine components as

rocker arms are measured. Most of the com-

they are being developed and implemented in

ponents are reflective with a high contrast

production. InfiniteFocus is mainly used to mea-

ratio and steep, uneven surfaces. The high

sure the geography of fracture sights which

vertical resolution of InfiniteFocus enables

“normally would not be possible with other sy-

the measurement of also micro cracks over

stems”, as the racing engine builder says. The

large measurement areas. In addition, color

system enables measurement, documentation

information allows seeing differences in

and understanding of both dimensions and sur-

surface characteristics, which in turn helps

face of critical components.

to understand foreign materials and debris.

What

THE CUSTOMER STATES

Brett Manwill Reliability / Design Engineer Roush Yates Engines

“We are now able to analyze surfaces very fast and make quick decisions about components without the long lead times of off-site analysis. Alicona surface roughness measurements allow us to determine if a component´s surface is inconsistent or is outside of the quality controls´ desired range over a large surface area. Prior to purchasing InfiniteFocus we did not have any system that had the depth of field to inspect an entire fracture surface.”

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Source: Alicona

58

alicona I References and user case stories

PRECISION PART NON-DESTRUCTIVE ROUGHNESS MEASUREMENT 3D measurement of inner geometries As a leading manufacturer of tight-tolerance and critical-use products, INTAI puts a strong emphasis on high quality metrology equipment. Alicona is used to perform non-destructive surface roughness measurements in the medical, aerospace and automobile industries. Among other surface parameters which are usually difficult to access, INTAI is now able to also measure the inner geometry of precision parts and has strengthened its position as a superior manufacturing service provider.

What

What

Precision parts in the automotive, medical and aerospace industry

Inner roughness of precision parts

INTAI Technology Operation stands for continuous

Alicona is used within the medical, aerospace

improvement and operational excellence in all

and automobile business unit for the mea-

ABOUT

IS MEASURED

business units. To help maintain this standard,

surement of micro components. Often, these

Alicona is used for non-destructive surface

parts have complex forms including steep flanks

roughness measurement in blind holes. The for-

and varying reflection properties. Mainly, INTAI

merly utilized method was destructive and no

performs both profile and areal based

longer sufficient as INTAI required SPC (statistical

roughness. Utilizing Alicona, INTAI also measu-

process control) data and used parts were too

res a component’s inner radius angles and

expensive to continue with a destructive measure-

positions not accessible with alternative measu-

ment technology. Among other surface parameters

rement methods.

which are usually difficult to access, INTAI is now

What THE CUSTOMER STATES

Chris Chua Manager INTAI Technology Corporation

able to measure the inner geometry of precision

“We purchased the Alicona system because of

parts.

its accuracy and the non-destructive measurements. The optical technology saves money and speeds up our development processes.

We decided to go for Alicona as our parts are too expensive to be measured in a destructive manner. Also, Alicona allows us to easily identify possible problems in the development phase. In general, the flexible use of the measurement system is extremely beneficial to us as we use Alicona for all sorts of measurements in all business units.”

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Source: Jarvis Cutting Tools

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alicona I References and user case stories

CUTTING TOOLS EDGE RADII AND SURFACE FINISH Full form measurement of taps Jarvis Cutting Tools was looking at a number of 3D measurement systems to measure edge radii and surface finish. The high variety of measurable tool types together with the efficiency of quality assurance was the decisive factor to go for InfiniteFocus. The manufacturer of customized tools with very specific geometry requests performs full form measurement in only one system.

What

What

ABOUT

IS MEASURED

Manufacturing of customized tools with specific geometries

Edge radii and surface finish

Jarvis Cutting Tools stands for the manufacturing

InfiniteFocus is used in combination with

of application specific HSS (high speed steel)

the rotation unit “Real 3D”. Users at Jarvis

and carbide taps. Understanding how only little

Cutting Tools perform full form measurement

nuances of surface finish affect the performance

of taps with steep flanks and different coa-

of a tool at the customer opens up new possibi-

tings. In particular, thread and flute of taps

lities to achieve customized requests for diffe-

are traceably and repeatably measured.

rent geometries, gauging requirements and tool

Measurable parameters include e.g. va-

life. The tool manufacturer is now able to per-

rious diameters, radii, roughness, diverse

form fast and easy quality assurance of a num-

angles and pitch reliefs. Instead of measu-

ber of different tool types and sizes. Analysis and

ring each edge individually the full tap with

testing loops are verified within the same day.

all relevant edges is captured in only one

Also, the development of new standardized ways

measurement.

to measure various processes, e.g. grinding, increases productivity and quality.

What

THE CUSTOMER STATES

Costikyan Jarvis Chief of Operations Jarvis Cutting Tools

“Before the use of InfiniteFocus, we were quite ignorant about surface finish. We defined it into rough and smooth, not being aware of how many nuances there can be which affect the performance of the tool at the customer. So when we started working with Alicona, a total new world opened up. We now understand the link between the measurements and the quality of our products.”

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alicona I References and user case stories

Source: Shanghai Cheng Qin Tools

CUTTING TOOLS DEVELOPMENT AND APPLICATION OF CNC TOOLS

Improved cutting tool design The use of InfiniteFocus enables the service provider Shanghai Cheng Qin Tools to significantly extend its services in tool design and measurement capability. The ability to perform and visualize full form measurement of complex geometries strengthens the supplier´s standing as an experienced expert in the field of high precision cutting tools.

What

What

ABOUT

IS MEASURED

Tool design, tool measuring and tool material analysis

Full form measurement of cutting tools

The main application is the edge measurement

The tool´s automatic 360° rotation with

of drills, reamers, screw taps, micro end mills

the Real3D rotation unit allows complete

and various kind of inserts, e.g. cemented carbide

form measurement from all perspectives.

insert, CBN and PCD. Comprehensive measurement

In particular, Shanghai Cheng Qin Tools fo-

functionalities combined with high measurement

cuses on the edge symmetry (K, a, b),

speed and high repeatability allow the 3D mea-

edge radius, chipping angle, clearance

surement of a wide range of various tools. For

angle, wedge angle and rake angle. Also,

Shanghai Cheng Qin Tools this enables significant

measurements of form deviation or refe-

advantages in tool design and efficient trouble

rence geometry are performed. Detailed

shooting.

3D visualization with registered color in-

What

THE CUSTOMER STATES

Lu Hong Bo Manager Shanghai Cheng Qin Tools Co., Ltd.

formation illustrates high accuracy and high quality of the cutting tool´s surface state.

“Before we used Alicona, we were not able to perform measurements in this detail. We now are able to conveniently measure a wide range of different tools with high vertical resolution, enabling us to analyze surface details we could not verify before. Also, with InfiniteFocus we achieved the best results in terms of speed, traceability and repeatability during our evaluation of optical measurement systems. What we also like about Alicona is the excellent service, know-how and friendliness of the staff.”

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Source: John Jay College

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alicona I References and user case stories

FORENSICS ASSOCIATION OF TOOLS WITH SPECIFIC TOOLMARKS

3D measurement of firearms and toolmarks The research centers and institutes housed at John Jay College of Criminal Justice produce intelligence that is used by corporations, academic researchers, policy makers and the media. With the use of Alicona, specific tools are associated with specific toolmarks. The 3D measurements with registered color information support court exhibits by creating easily displayed qualitative landmark identification.

What

What

Surface topographies of toolmark impressions

Bullets, cartridge cases and impressions made by hand tools

John Jay College of Criminal Justice is the

Forensic surface metrology applications include the 3D measurement of surfaces made by virtually any tool, including screwdrivers, chisels, pliers, crowbars, hammers and firearms. Typically the toolmarks are deformed and have steep flanks.

Commonly, the convenience of the Real3DRotationUnit is utilized in performing full form and roughness measurements of bullets. In addition, the automatic rotation unit allows easy surface area measurement of damaged bullets. Also, surface data sets along with roughness, waviness, correlation and texture parameters of firing pin impressions, breach face impressions, pin drag, primer shear and ejector marks (all potentially found on cartridge cases) are readily obtained. Registered 3D color information can be used to support court exhibits as it enhances clarity and allows for visual displays of qualitative landmark surface identification.

ABOUT

preeminent national and international leader in education for justice. With the use of Alicona, surface topographies of toolmark impressions made by firearms and common hand tools are verified.

This 3D data is then processed with state-ofthe-art statistical pattern recognition algorithms in order to associate specific tools with specific toolmarks. The connection that is made between toolmark impressions with a respective hand tool can be used in court settings to help court officers and juries approach a more objective verdict.

IS MEASURED

What

THE CUSTOMER STATES

Stephanie Pollut (left) with Nicholas D.K. Petraco (right), Associate Professor John Jay College of Criminal Justice

“When I came across Alicona, I was attracted by the ability to easily perform full form and roughness measurements of our toolmarks.

The Real3DRotationUnit enables very convenient measurement of cylindrically symmetric surfaces. Alicona delivers remarkable measurements with steep slopes and is very efficient at producing toolmark surface data for the unique identification of specific tools.�

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MEASURING FROM EVERY ANGLE INFINITEFOCUS REAL3D

Full and completely automatic measurement of form and roughness with Real3D Users measure surfaces from numerous perspectives. With our fully auto-

Tilt axis (4. axis)

Motorized from -15° to +95°

matic rotary drive AdvancedReal3DRotationUnit, rotationally symmetric

Rotation axis (5. axis)

360° (motorized, endlessly rotatable)

components can be measured in 3D from different angles to get a complete

Rotation axis accuracy Tilt axis accuracy

+/-9.9’’ +/-20’’µ

dataset. Motorized and high-precision tilt and rotation axes ensure fully

Weight

13.6 kg

automated, repeatable and traceable measurement of form and

Sensor position

240 mm

roughness on the whole measured object. Alicona users can also visualize and

Max. weight of the sample

measure surface features such as diverse flank angles, thread pitch and undercuts. Compatibility of rotation units with clamping systems 3R and Erowa allows for precise and rapid interaction between processing and measurement. In addition, a number of various adapters enable the 360° rotation and measurement of components without rotational symmetry.

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alicona I InfiniteFocus Real3D

Clamping systems

4 kg 3R, Erowa, three-jaw chuck

ALICONA ACCESSORIES GRIPS

1

2

3

4

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, IF-Profiler

3 ROTATION-GRIP Clamping device for horizontal mounting of components such as drills or milling cutters. Tools are rotated into the desired position to also easily measure cutting edges.

Usable for: InfiniteFocus, InfiniteFocusSL, IF-EdgeMaster

2 ADVANCED INSERT-GRIP Grip for the measurement of small objects in variable oblique positions. This grip can be adjusted to most specimens and also locked in the desired position. Measurement comfort and repeatability are increased.

Usable for: IF-EdgeMaster, InfiniteFocus, InfiniteFocusSL

4 TOOL-GRIP Grip for user-friendly and repeatable clamping of shaft tools. Tools with diameters of up to 30 mm and lengths of up to 250 mm are measurable.

Usable for: IF-EdgeMaster, InfiniteFocusSL, InfiniteFocus

5 REAL3D ROTATION UNIT Clamping device with a motorized rotation axis for full form and roughness measurement.

The indivdual measurements from different perspectives are automatically merged into a complete 3D dataset.

Usable for: InfiniteFocus, InfiniteFocusSL, IF-EdgeMaster

5

Tilt axis (4. axis)

Manually from -20 to +90° (locking every 5°)

Rotation axis (5. axis)

Motorized 360° (endlessly rotatable)

Tilt axis accuracy Max. weight of the sample

+/- 20” 1.5 kg

Clamping systems

three-jaw chuck

Clamping diamter

0.5 mm to 16 mm (open aperture 12 mm)

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ALICONA ACCESSORIES GRIPS

1

ALICONA ACCESSORIES GRIPS

2

3

5

6

1 CLAMPING-SET A set of different clamping bars for mounting and securing specimens in a certain position: A flexible solution for flat, steep and round components.

Usable for: IF-EdgeMaster, InfiniteFocus, InfiniteFocusSL

7

2 45째 MIRROR Optical 45째 mirror to also measure the inner geometry of components.

Usable for: InfiniteFocus

8

3 NANO GRIP Sample holder to fix components with a smooth contact surface in XY. Usable for: InfiniteFocus, InfiniteFocusSL, IF-EdgeMaster, IF-Profiler

4 RING LIGHT Cable-free LED ring light with seperately controllable segments based on concentrator optics. Users benefit from optimally illuminated surfaces with high contrast and short exposure time.

Usable for: InfiniteFocuss

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

6 SPACER-PLATE 4

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: 17.5 mm and 35 mm.

7 VACUUM-PLATE Used to vacuum clamp the specimen when measuring. Especially useful for thin-walled or sensitive material, e.g. sheets, paper or rubber.

8 ROTATION-TABLE Hardware for aligning components along X or Y axis of the system.

Ideal for the measurement of horizontal or vertical grooves.

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alicona I Accessories

ALICONA ACCESSORIES GRIPS

9

10

11

12

9 VERIFICATION TOOL

10 CALIBRATION TOOL

Standard, traceable to the PTB, with miscellaneous form artifacts such as steep slopes, angles and cylinder sizes. Used for verifying the accuracy of form measurements.

Usable for: All Alicona 3D measurement systems

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

Usable for: All Alicona 3D measurement systems

11 ROUGHNESS STANDARD Roughness standard for optical and tactile measurements traceable to the PTB. With this tool, the accuracy of optical roughness measurements is verified. All ISO optical measurement techniques are validated.

Usable for: All Alicona 3D measurement systems

13

12 EDGE CALIBRATION TOOL Standard, traceable to national metrology institutes, for the verification of edge measurements. It shows radii from 1 µm to 20 µm.

Usable for: All Alicona 3D measurement systems

13 IF-TRAVELLER Case for the flexible transport of Alicona’s InfiniteFocusSL, IF-EdgeMaster and IF-Profiler.

It is designed to easily pack and unpack the systems for 3D measurements independent from a defined location.

Usable for: InfiniteFocusSL, IF-EdgeMaster, IF-Profiler

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SELECTED CUSTOMERS

Atomic

Alpha Bio Tec

Bass

Bosch

Cassidian

Ceratizit

Dentsply Implants

Diehl Metall

EDM

ETH

Fraunhofer IPA

Fraunhofer Vision

FZG

GF Machining Solutions

GFE

Heidelberg

Intai

IFAS

Inspire

Jarvis

John Jay

Kiefel Technologies

LMT Fette

Makino

NFI

Nobel Biocare

NPL

OTEC

PTB

PTS

Profin

Rohde & Schwarz

Roush Yates

SIMTEK

Sutton Tools

Sandvik

Sarix

TU Hamburg Harburg

Thyssen Krupp

Vargus

Vollmer

VW

University of Wisconsin

KomatsuSeiki

Shanghai Cheng Qin Tools

Selected customers who have contributed to the magazine series FOCUSvariation.

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alicona I Selected customers

THANK YOU! A magazine containing more than 70 pages can’t be created alone!

That’s why I want to thank everyone who helped us with their expertise, editing, creativity, initiative and emotional support they brought in while working on the situations that can be entitled as “How-canthis-ever-be-completed-in-time”. All this allowed the 5th edition of FOCUSvariation, a magazine about Alicona measurement technologies, to go to press in a timely manner. Also, many thanks to all those who participated in the process with their practical assistance.

I am particularly pleased that the face for this 5th edition, which also

introduces the 5th generation of InfiniteFocus, is a “true” Alicona face.

Karin successfully participated in the strenuous photo shoot (which you would hardly believe unless you saw it yourself) and managed to express the message we wanted to communicate: We are ready and waiting for you!

More information about our experience working on the cover can be found in the blog of our online Service Portal, AliconaFamily!

Astrid Krenn, Head of Marketing & Communication

alicona

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Alicona Headquaters Alicona Imaging GmbH Dr.-Auner-Straße 21a 8074 Raaba Austria phone +43 316 403010 700 fax +43 316 403010 711 info@alicona.com Alicona Germany Alicona GmbH Buchenötz 2 83471 Schönau Germany phone +49 8652 6553901 fax +49 8652 6553902 info@alicona.de

Alicona Asia Alicona Korea Pacific Co. Ltd. #301. Hwaseong Bldg.

10-1 Maebong-gil Seongdong-gu Seoul Republic of Korea phone +82 9159 6854 sales.asia@alicona.com

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 phone +49 151 1214 3339 sales.de@alicona.com

Germany New Laender phone +49 160 93393277 sales.de@alicona.de

Germany North phone +49 175 2932223 sales.de@alicona.com

Germany South/East phone +49 151 23530254 sales.de@alicona.com

IF-20102011-5

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 2B Rue de Brabant 25000 Besancon France phone +33 786 9679 00 sales.fr@alicona.com

Alicona US Alicona Corporation 1261 Humbracht Circle Suite G, Bartlett IL 60103 USA phone +1 630 372 9900 fax +1 630 372 9965 sales.us@alicona.com