QUALITY MANUFACTURING TODAY
www.qmtmag.com September/October 2015
From Photons to Figures
Image Filtering as Essential Steps for Accurate Quantitative Analysis.
Brightfield image of corroded copper
Heightmap
Filters help to enhance relevant features for qualitative and quantitative analysis
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CONTENTS
Sep/Oct 2015 News and Comment
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Events 5 From Photons to Figures
Essential image processing steps for accurate quantitative analysis
Optical measurement for A350 XWB Non-contact sensors for structural and fatigue testing
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Measurement - Just how wrong can it be? 14 Trevor Toman sets the scene for the Make Measurement Matter event
Front cover: Olympus Website: www.olympus-ims.com/en/microscope Email: microscopy@olympus-europa.com Telephone: +49 40 23773 0
3D CT scanning for aerospace composites 18
Editor Andy Sandford Email: editorial@qmtmag.com
Inside the head of T rex
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Best practice approach to preparing to take a measurement
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Matching measurement to machines
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Express delivery for massive oil parts
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Serving increased capacity
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How does your 3D optical scanner perform on the shop floor?
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Calibration efficiency
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Refining NDT with 3D scanning
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Director/Publisher Dawn Wisbey Email: dawn.wisbey@qmtmag.com Tel: +44 (0)20 8289 7011 Mob: +44 (0)7974 640371 Design and Production Manager Rob Tremain Email: studio@qmtmag.com IT Director Pat Coyne Email: pat.coyne@qmtmag.com Website: www.qmtmag.com Media enqiries media@qmtmag.com QMT Magazine is a multi-media business magazine for the quality, measurement, inspection and test industries, supported with a fully searchable interactive website www.qmtmag.com. QMT Mobile: website is available in mobile-optimised form. Log on with your phone and you will be directed automatically to the mobile pages. QMT App: download Quality Manufactory Today app for iPad and Android tablets
@QMTMAG Quality Manufacturing Today is published by Cranbrook Media Ltd. Registered company No. 06048241 Registered office: N.J. Ruse Associates, Eagle House, Cranleigh Close, Sanderstead, South Croydon, CR2 9LH Printers: Circle Services Ltd Š Cranbrook Media Ltd
CT widens its application area to in include the inspection of composite aerospace components
Researchers are using X-ray CT to examine the skull of a mighty dinosaur
The third in our series of articles from the NPL
A subcontractor had to upgrade his metrology to measure the parts he was making on new machines
Large UK manufacturer brings in a super-sized CMM
Subcontractor Ardor Engineering adds a new CMM
NPL is set to open a verification facility to support 3D scanning in production
A UKAS service provider keeps on top of its documentation
A petroleum industry company finds 3D scanning more flexible than conventional NDT
Products 40
QMT Sep/Oct 2015 www.qmtmag.com
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NEWS
EDITOR’S COMMENT A satisfying dish There’s plenty of food for thought in this issue of QMT. How about this for a starter? Coventry University’s Trevor Toman says “Business needs to get away from the notion that all measurement is correct, because there is a probability that our measurements are incorrect.” Find out what he has to say after that on page 14. There is further mental nutrition in our cover story from Markus Fabich of Olympus, who looks at how to make sure you are seeing what you want in quantitative digital light microscopy. We are also looking at some pretty diverse technology applications too – ranging from using noncontact sensors to test composite structures for the fuselage of the Airbus A350 XWB, to looking inside the skull of a Tyrannosaurus rex using the world’s biggest X-ray computed tomography scanner. And while you are digesting that, then why not finish off with a selection from our new product pages. There are some interesting and innovative ideas there, including a ‘pay-as-you-go’ probing system and a complete automated shop floor inspection system So I hope you enjoy reading this issue – bon appetit! Andy Sandford Editor QMT
MATERIALS TESTING Bloodhound stars at MTI The world land-speed record attempt car, Bloodhound SSC, will be one of the star performers at the Materials Testing Exhibition in Telford from 8 to 10 September.
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Materials Testing 2015 will feature around 60 exhibitors – many of whom will be demonstrating products and equipment for the first time – along with a programme of seminars including talks ranging from NDT for 3D printing and using phased array ultrasound, to corrosion analysis in pipelines. There will also be a demonstration area, where manufacturers can bring along samples for testing and discuss their particular inspection problems. There will also be a special free Bloodhound Networking Event on the evening of 8 September. The event is open to conference delegates and exhibitors and those who pre-register. This will be a unique chance for people from the NDT sector to see and hear about the Bloodhound project, get up to date with the latest developments within the industry and to meet fellow industry colleagues. Please note that space for this event is limited and pre-registration is subject to availability via the link on the British Institute of NDT website. www.bindt.org
INVESTMENT Manufacturing investment at Bowers Bowers has made further investments in production machinery at its main bore gauge manufacturing plant in Bradford, UK.
2015 has seen an investment of £180,000 in the replacement of existing machines within its wire EMD and grinding departments. These include the latest Sodick SL4000Q machine with linear drives, submerged cutting technology and auto wire threading. Its installation has increased both capacity and productivity in the wire EDM area and allowed Bowers to produce in house work that was previously carried out by outside suppliers. The company says that the investment that has arguably had the most visible impact has been the upgrading of the grinding department with three new machines from Andmar Machine Tools. These three machines replaced five old machines and have already improved product quality and cycle times. The company explains that, “Both these investments are an indication
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of the group’s commitment to developing our manufacturing facility and ensuring we continue to produce the best bore gauges in the world”. www.bowersgroup.co.uk
CALIBRATION 45 years UKAS accredited AMETEK Land Instruments, based in Sheffield, is celebrating the 45th anniversary of its UKAS accredited infrared temperature calibration laboratory.
It was the first UKAS laboratory to be accredited, back in 1970, for the issue of calibration certificates for thermal measurements and also the first to be accredited for the issue of certificates that met the requirements of ISO 17025 (calibration of equipment). Over the past four and a half decades, the laboratory has provided temperature calibration services for industries ranging from automotive to glass, steel, aerospace, defence and food. The lab carries out the traceable calibration of radiation thermometers over the range –10°C up to 2500°C and has the certified lowest calibration uncertainty outside the National Physics Laboratory for temperatures above 500°C. The laboratory also provides a calibration and re-calibration reminder service for temperature sensors and sources including non-contact infrared pyrometers, thermal imagers and blackbodies. www.landinst.com
SHOWROOM Yorkshire metrology centre Cutwel has opened a fully equipped Metrology Centre at its offices in West Yorkshire. Situated just off Junction 26 of the M62, the new showroom is now open for anyone to visit on an appointment basis, visitors to the centre will be greeted by a member of Cutwel’s technical team who will accompany them during their visit. Within the showroom is a wide range of instruments from all of Cutw-
QMT Sep/Oct 2015
NEWS el’s measuring tool suppliers including Insize, Mahr, Johs Boss, M.Conti and Blum Novotest. Visitors can try out small tool instruments such as calipers, micrometers and touch probes and see live demonstrations of larger measuring systems. Cutwel has also located its Hawk 3D Proto, 3D Printing Division at the same location. Customers are more than welcome to combine visits to both showrooms at the same time. www.cutwel.net
EDUCATION euspen Challenge winners
neering and nanotechnology. National heats were held across Europe earlier in 2015 identifying the best national students, who came together to compete in international teams for the coveted title of euspen International Challenge Winners in Stockholm. www.euspen.eu
USED MACHINES Second time round Hexagon Metrology UK has completed the latest phase of its ongoing investment programme with the opening of a second user co-ordinate measurement machine showroom.
A team of students from the UK, Sweden and Spain won the 2015 euspen Challenge by designing and building a fully-functioning optical measuring machine from scratch in just over a day.
EVENTS 21 – 24 September CIM 2015 International Metrology Conference Paris, France www.metrologie2015.com 30 September – 1 October TCT Show + Personalize NEC Birmingham, UK www.tctshow.com
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15 October Make Measurement Matter Kettering, UK www.makemeasurementmatter.co.uk
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4 – 5 November Advanced Engineering NEC, Birmingham, UK www.advancedengineeringuk.com
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9 – 11 November EPMC Manchester, UK
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Winners Alberto Figueroa, Hüsnü Aslan and Christian Young
The machine had to be capable of carrying out a precision 2D measurement, accurate to within 13 microns. During the event (which was held at and supported by the KTH Royal Institute of Technology and Hexagon Metrology Nordic AB in Stockholm), students were required to address a technical challenge, and to conclude with a presentation of their solution. An international jury of leading industrialists and academics selected one team for their overall best solution, and awards were also given to teams recommended for their most innovative solution and best presentation. University of Huddersfield PhD student Christian Young joined students Alberto Figueroa de Godos from Bilbao Faculty of Engineering in Spain, Aslan Hüsnü from Aarhus University in Denmark to take the award for the Overall Best Solution to the Challenge. In a race against the clock, the teammates constructed a fully-functioning machine and then gave a detailed presentation to the panel of judges. The international competition is designed to identify students throughout Europe with potential to be future leaders in the field of precision engi-
The new facility at the measurement solutions provider’s head office in Telford offers a selection of used Hexagon Group machines, suitable for either tactile probing or scanning, which have undergone an extensive and thorough reconditioning process. As the original equipment manufacturer, Hexagon Metrology also repairs or replaces all of the key elements of the machines as necessary. It equips them with the latest software and firmware, including the RC1 retrofit controller, which often boosts accuracy performance and exceeds the original specification. Hexagon Metrology provides the same service and support services as new machine purchases, meaning warranty, service and calibration packages, and part programming can be provided locally. www.hexagonmetrology.co.uk.
TRAINING NDT apprenticeships The UK Government has approved a new apprenticeship standard for nondestructive testing (NDT). Employers who want to offer these apprenticeships should indicate their intention by contacting BINDT – the British Institute of Non-Destructive Testing on apprentices@bindt.org . Roger Lyon, Phase 3 Trailblazer Apprenticeships Project Manager for BINDT, said: “This has been an immense effort by the Employers’ Development Group and our success
18 – 20 November HxGN LIVE Hong Kong
www.epmc.events
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www.hxgnlive.com
• QMT is a media partner has been achieved against a background of significant rejection of other Trailblazer apprenticeship standards. Approval of the standard was the major hurdle, but now we have achieved this we can press on with the assessment plan, costing model and other appropriate documentation. “As part of BINDT’s strategic plan, NDT Apprenticeships will help to address the ageing profile of NDT technicians, it will encourage employers to take on new staff at reduced training costs and it will enable school leavers to embark on a worthwhile career in NDT.” www.bindt.org/apprenticeships
COMPANY NEWS ZEISS buys into Steinbichler ZEISS Industrial Metrology has bought a majority stake in Steinbichler Optotechnik GmbH that will boost its position in optical 3D digitisation. Steinbichler Optotechnik GmbH supplies optical 3D digitisation systems and surface inspection solutions for car body and sheet metal parts. www.steinbichler.com
QMT Sep/Oct 2015 www.qmtmag.com
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COVER STORY
From Photons to Figures
*Markus Fabich is Product and Application Specialist for Materials Science Microscopy at Olympus SE & CO. KG (Hamburg, Germany)
Figure 1: Background shading correction. Inconsistent shading can be corrected using a dark image, creating a flat line profile and resulting in a final image with even shading.
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Essential steps for accurate quantitative analysis
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etween image capture and analysis lies the essential, but sometimes overlooked, step of image processing. Markus Fabich* of Olympus discusses the importance of filter methods in ensuring consistent and comparable images for quantitative digital light microscopy. As technologies have evolved, digital image processing has become an integrated part of the microscopy workflow, often built into acquisition and analysis software. In light microscopy applications demanding clear and accurate quantification of images, the selection of optimal contrast and quantification methods is essential. Between these lies the equally essential step of image processing – the application of filter methods to raw image data. Filter methods enable the production of a final image containing fewer unwanted artefacts, which is both understandable to the human eye and suitable for quantitative analysis. A variety of filter methods have been developed to reduce noise and enhance detail, the importance of which can sometimes be overlooked. For example, in the inspection of high grade components, where minor defects could lead to component failure, filter methods can ensure that specimens are examined consistently, accurately and efficiently, preventing defective components from continuing down the production line. In the case of research publications, non-destructive
filter methods can go a long way towards ensuring image manipulation is traceable and within guidelines. Their inclusion within microscopy systems is vital to both industrial and academic microscopy workflows. Filter methods may be classified into three categories: point, local and global operations:
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QMT Sep/Oct 2015
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COVER STORY
Figure 2: Random high frequency noise detection. Random noise can be distinguished from genuine objects in images by detecting pixels that do not have any association with their surrounding pixels. The Gaussian filter detects and reduces random noise but does not affect the point spread functions of real objects.
Point operations - final pixel intensity is only dependent on the original intensity of that pixel. These tend to be applied across an entire image and for all images in a session, accounting for camera system and illumination bias. Local operations - final pixel intensity is influenced by surrounding pixel intensities. They are used to apply smoothening and sharpening effects to individual images. Global operations - final pixel intensity is dependent on all pixels in an image. Intensities are stretched or clipped to within a desired range for brightness or contrast adjustments. The optimum method or combination of methods largely depends on the goal of imaging. For high level, detailed analysis, it is therefore imperative that the operator is able to select from a choice of filter methods for the most effective downstream image.
posterization. In order to correctly display these higher bit depth images for accurate observation and analysis, they need to be temporarily remapped to the 8 bit depth of a monitor. To avoid clipping, where the intensity levels above 255 are displayed as pure white, alternative mapping ratios are applied, such as 16:1 for 12 bit images. Here each consecutive set of 16 intensities is displayed as a single level, allowing the raw image to be displayed without visible clipping. Microscope operators can also take advantage of mapping by using intensity scaling to manipulate an image, deliberately condensing the range of intensities to increase contrast or shifting all intensities to increase or decrease brightness in the raw image. This type of point operation is applied across the whole image in a linear fashion or on a curve.
Bit depth in image acquisition
Background and shading corrections are more permanent changes than intensity scaling, applied to correct for background generated internally within the imaging equipment, or inconsistent lighting. Background correction is a point operation that allows the camera dark image (image data captured without intentional illumination) to be subtracted. An operator can manually apply this using the image histogram, selecting a threshold greyscale value that allows separation of the background and actual signal peaks. Similarly, variations in shading due to inconsistent illumination can be corrected automatically using a blank image to create a flat line profile of illumination (Figure 1).
Colour cannot be directly determined by camera sensors, and so RGB digital images are instead composed of greyscale intensity values in each channel – red, green and blue – stored as bits. Increasing the number of bits increases the number of intensity levels that can be stored. At least 100 intensity levels are required to ensure a smooth gradient, and to avoid the different levels becoming visible (known as posterization). An 8 bit image, with 256 levels of intensity, is more than sufficient for this. However, the application of filters can lead to the loss of raw image data, and so microscope cameras are designed to capture 12 bit or 16 bit depth images to avoid visible
Background and shading correction
Noise reduction
Noise reduction methods are local operations, where a pixel is influenced by its neighbours. From grids of values (convolution kernels) a mathematical operation is applied to a central target pixel based on these intensities. Noise reduction filters smoothen the transition in intensity from pixel to pixel and mean and median filters, for example, apply the mean or median value from the pixels contained in the convolution kernel. The resulting effect is a reduction in noise, but also a reduction in sharpness of edges by smoothening of contrast. For identifying and removing random high frequency noise internal to the camera system, the Gaussian filter can be a powerful tool. It relies on the smallest detectable particle on a sample to cover at least three adjacent pixels, creating a point spread function. Random noise appears as single high contrast pixels (Figure 2), and therefore can be differentiated from real signals that are diffraction limited. This makes the Gaussian filter superior to the Mean or Median filters in eliminating noise while retaining point spread functions, especially when imaging highly detailed samples that require careful
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QMT Sep/Oct 2015
COVER STORY
Original image
The convolution kernels are designed such that adjacent pixels of equal intensity are not affected, and therefore selective to edges. Random high-frequency noise, however, can affect the outcome and it is therefore generally recommended that noise removal is performed beforehand. Sobel and Laplace are two complex, but powerful edge detection filters that can significantly alter the image (Figure 3). Although use of these filters generates images that do not reflect what is being observed through the eyepieces or on the monitor, they do accurately represent edges, as required for quantitative analysis.
Integrating filter methods into microscopy workflow
Sobel filter
Filter methods have become an essential part of quantitative digital microscopy. In response to this trend, filter methods are integrated directly into the latest digital light microscopes, such as the Olympus DSX series for non-destructive industrial inspection and the LEXT OLS4100 metrology microscope. This is also the case for specialised materials science software, where the Olympus Stream software family provides a full set of image processing methods at the user’s fingertips. This guides the operator through acquisition, processing and analysis, reducing hands-on time and making best use of the high-quality optics. Following acquisition, options enable background and noise reduction, as well as edge enhancing to produce images for quantitative analysis. Previews are provided to quickly test the comprehensive range of filter methods before alterations are applied non-destructively, ensuring the original raw image data is retained. Including these functions in microscopy systems has allowed quick and easy integration of filter methods into the workflow of operators with all levels of experience.
Summary Laplace filter
quantitative analysis, such as high grade electronics.
On the edge - accurate quantitative analysis
Smoothening allows an operator to analyse an image with less bias from random noise. This process, however, also affects high contrast edges, which become less distinct. Edge detection filters are multi-stage local operations based on convolution kernels enhancing the edges of objects. Enhanced contrast ensures quantitative measurements remain as accurate as possible. Following the application of the smoothening filter, the signal is converted from low-pass to high-pass and merged with the original. As a result, dark edges become darker and the light edges become lighter, increasing contrast for pixels not already at the lower or upper intensity limit.
For industrial inspection microscopy, the application of the most appropriate filter method can vastly improve the ease and accuracy of downstream quantitative analysis. These methods may include point, local or global operations, which can be used to reduce random noise and enhance detail both locally and globally across an image. The availability of modern image processing software has greatly facilitated the accessibility of filter methods, and their integration into microscopy systems has allowed microscope operators to quickly and easily choose and apply the correct filter method from a comprehensive selection. All without risking permanent alteration of the original raw image data. Integrated systems ensure consistency across a range of images from multiple imaging sessions, and their comprehensive software has come to play an essential role in modern light microscopy. www.olympus-europa.com
QMT Sep/Oct 2015 www.qmtmag.com
Figure 3: Edge detection with the Sobel and Laplace filters. Both Sobel and Laplace edge detection filters use two convolution kernels. Sobel converts homogenous regions to zero intensity, allowing the use of remapping to enhance edges. Laplace converts homologous regions to a medium grey level and creates high contrast edges.
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AEROSPACE
Optical measurement for A350 XWB
Fig 1: The winglet is 8m long, 2m high and 3m wide. Around 110 tons of steel was used on the test stand.
Airbus supplier FACC and its subsidiary CoLT integrate non-contact sensors from GOM in fatigue and structure testing
T
o reduce weight and fuel consumption, the aerospace industry increasingly relies on lightweight materials and new material combinations. That’s why the entire fuselage of the new Airbus A350 XWB consists of carbon fibre composite (CFC) materials. In total, 53% of the long-haul aircraft is made from CFC, with the remainder including titanium and new aluminum alloys. As a result, the A350 consumes about one quarter less fuel than conventionally constructed aircrafts However, these lightweight materials and new material combinations must meet the same high standards of performance, safety and durability as traditional materials. Accordingly, the materials and the components manufactured from them are tested intensively. To this end, the aerospace industry increasingly relies on optical metrology. The non-contact systems provide data for part geometries as well as for 3D displacements and deformations. Static and dynamic deformations are determined based on individual points or full-field measurements. The measurement data optimise simulation and design processes and thus increase aircraft safety. Before certification, the A350 had to pass intensive tests. Airbus supplier FACC examined fibre composite materials and components of the A350 at its Composites Lab & Test Center (CoLT), a subsidiary on the company’s premises in St. Martin (Austria). Tests for the certification of the winglets
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and wingtips were especially extensive. The entire element, with a length of more than 6m, was analysed statically and dynamically in a special testing facility for long-term and peak loading. The tests also included damage tolerance testing. These analyses were necessary because the component mainly consists of fibre composite materials with metal connections.
Non-contact deformation measurement The load, fatigue and damage tolerance tests provided information about the structural behavior of the component. As well as using standard measurement techniques, for the first time, the FACC subsidiary fully integrated non-contact sensors from GOM in the test setup. Unlike conventional methods such as strain gauges the two PONTOS systems recorded 3D displacements and deformations of the winglet. In total, the test object was 8m long, 2m high and 3m wide – around 110 tons of steel were used on the test stand (14m long, 8m high and 10m wide). (Fig. 1) Loads were achieved with 15 servo-hydraulic push and pull cylinders, with the force transmitted by five yokes. The two noncontact sensors measured dynamic deformations at around 220 points, with each point being analysed three-dimensionally in the x, y and z direction. In addition, more than 2,000 synchronized channels measured static strain, deformation, force, pressure and temperature. (Fig. 2) On the actual A350, the winglet and wingtip – the
QMT Sep/Oct 2015
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AEROSPACE
Fig 2: The PONTOS sensors measure the dynamic deformations at around 220 points, each of which can be analyzed three-dimensionally.
inside elements of the assembly – are fixed on the main wing box. In order to realistically reflect these connection points and the behavior of the main wing box during the test, a dummy wing box was used. It was specifically designed for the test and is identical to a real wing box in terms of material properties and connection of the winglet.
Complete 6DoF Analyses
Fig. 3: The evaluation of the point-based data enabled full 6DoF analyses. This way, test engineers could see exactly how the winglet moves in space and at which points it is particularly deformed.
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During structure testing, the component was loaded statically across several stages to simulate the loads occurring during flight. In this way, the test engineers examined three scenarios: maximum torsion and maximum load upward and downward. During fatigue testing, the engineers ran through real flight profiles to analyse the behavior of the component within one life cycle. During static and fatigue testing, load factors were applied to account for variations in the material properties and possible weight increases in the component. For the damage tolerance tests, the winglet was damaged in advance at certain points. This way, the test engineers simulated manufacturing errors, as well as damage caused by hail impact and bird strikes in order to precisely analyse the effects on material and component behaviour under load. Unlike conventional measurement devices such as strain gauges and transducers, optical systems such as PONTOS determined 3D displacements and deformations while additionally measuring real speed and acceleration. The evaluation of the point-
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based data enabled full 6DoF analyses. This way, test engineers could see exactly how the winglet moves in space and at which points it is particularly deformed. (Fig. 3) The PONTOS system can be easily integrated into the test setup, with inspection points identified by measurement markers. Using an optically tracked touch probe, nominal positions can be determined and adapters can be measured.
Back projection of strain gauge positions With the new PONTOS Live software module, the test run could also be measured online, enabling users to see directly in the software what happens during testing. Additionally, the measuring data could be communicated to other programs via a digital interface and could directly be processed by them. It was also possible to record and process
QMT Sep/Oct 2015
AEROSPACE
Fig. 4: For an accelerated test setup, the ATOS 3D scanner performed a back projection of the strain gauge positions.
analog signals from external measuring devices. Optical measuring systems also accelerated test setup. For instance, 200 strain gauge positions, which were defined in advance by Airbus and CoLT test engineers, were marked and applied to the component within one working day. (Fig. 4) GOM‘s distributor and service provider in Austria, Westcam, first measured the winglet and its components with a TRITOP portable photogrammetry system which captures the 3D coordinates of objects. After the measuring data was aligned to CAD, an ATOS 3D scanner performed a back projection of the strain gauge positions. During this process, the sensor projected the positions directly onto the winglet based on the measurements. The positions are visualised as 3D elements in the CAD software. Staff from CoLT simply marked the correct points, which led to considerable time savings. Up to then it was very work-intensive to determine the positions with measuring tapes, starting from the edges or bore holes. For demanding geometries, such as at the inner side of a leading edge,
CoLT Composites Lab and Test Center FACC Operations is one of the world’s leading companies in the design, development and production of fibre reinforced composite components and systems for the aviation industry. Its range of products reaches from structural components for the fuselage and wings, to engine components, to complete passenger cabins for commercial aircraft, business jets and helicopters. FACC is a supplier to all large aircraft manufacturers, including Airbus, Boeing, Bombardier, Embraer, Sukhoi, and COMAC, as well as to engine manufacturers and their suppliers. The Composites Lab & Test Center on FACC’s premises in St. Martin (Austria) started operation in 2013. It gives FACC one of the most modern facilities for analyzing, testing and certifying fibre composite materials and components.
positioning using conventional methods was very complicated and the GOM systems made it possible in a fraction of the time. Optical metrology also allowed the positions of the applied strain gauges to be checked. They could be measured again with TRITOP photogrammetry or the handheld GOM Touch Probe and compared with the CAD data.
Simulation verification based on 3D data Lightweight materials are an essential part of the aerospace industry. Correspondingly, OEMs and suppliers test the new materials intensively to guarantee their performance, safety and durability. Optical measuring systems can be easily integrated in different test stands; at the same time, they determine static and dynamic deformations via pointbased and
full-field inspections. The results are available immediately after the measurement and can be displayed in easy to understand charts, videos and images. One important area in which 3D measurement data is used is simulation verification. Modern flight vehicles are extremely complex, so everything is simulated during the development process. To compare the simulations with reality, comprehensive 3D measurement data is necessary instead of just a few individual signals. The results enable users to review and improve simulation parameters, as well as to optimise current and future design processes. Therefore they can reduce the number of costly test runs and consequently speed up product development. At the same time, the 3D measurement results allow conclusions to be drawn on safety risks, part durability, as well as creep and aging processes. This increases not only the safety, but also the lifetime of products. www.gom.com
QMT Sep/Oct 2015 www.qmtmag.com
Fig 5: The GOM PONTOS non-contact measurements system
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OPINION
Measurement - Just how wrong can it be? A QMT media partner event
Ahead of the GTMA’s Make Measurement Matter 2015 event, Chairman for the event and Head of Metrology for Coventry University, Trevor Toman, speaks to QMT
H Head of Metrology for Coventry University, Trevor Toman
e explains that “Business needs to get away from the notion that all measurement is correct, because there is a probability that our measurements are incorrect. Therefore, we should understand the probability density function of our data and then quantify the probability and bias.” This information on how our measurement process is behaving is critical to the understanding of the process under study. Generally speaking the real purpose of metrology is fairness in society and trust in our transactions; if you buy a litre of fuel at the forecourt how close to a litre are you actually getting? How accurately do you think it can be measured? On a full tank for the car, any variation might not add up to much. However, when you consider a shipping tanker filled with fuel the variation can accumulate to a significant cost or profit. Measurement really does matter.
Over 45 inspection, metrology and measurement services companies will be at MMM 2015
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Within a manufacturing company the role of metrology, first and foremost, has to be seen as a business tool and not as an unwelcome cost. As Trevor Toman states: “Used correctly, metrology actually adds value and reduces costs, that will ultimately improve the relationship with customers. In order to achieve this we need metrologists that can really understand our measurement systems and management that understands the implications of good quality metrology. “While measurement systems put a stamp of quality on a product, a process or even a service, metrology puts the stamp of quality on the measurements made by those systems. Metrology gives us the confidence to make the right business judgements and decisions. It enables us to understand and quantify the behaviours of processes.” As the complexity of manufacturing increases so does the need to achieve production that is right first time, because repairs are not process-controlled and cost significantly more than an investment in good in-process metrology. Repair processes and costs are also rarely factored into the business structure. A good metrologist understands this and can reduce the need for repair and rework very significantly. Coventry University is using an approach to developing competencies for metrologists with coloured belts that emulate the lean manufacturing designations. “My approach with the green and black belts I mentor,” Trevor Toman explains, “is to challenge the assumption that my data is good. My role as a metrologist is to assume that the measurement data is always wrong. What
QMT Sep/Oct 2015
Busted! This company’s QA program AND reputation Like Humpty Dumpty, it is hard to put the pieces back together once a real world product quality disaster strikes. The ultimate cost of a recall will be far, far greater than any savings from cutting corners or not investing in a quality assurance program in the first place. With our broad spectrum of physical testing machines, software, and technical support, Tinius Olsen can help you assure quality from material to end product. To international standards and your toughest specifications. Reputations (yours and ours) depend on it.
The first name in materials testing. www.TiniusOlsen.com
OPINION
Make Measurement Matter will showcase the latest metrology technology
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I need to understand is how wrong. Once I know that, I can determine a value for it and make evidence-based decisions knowing the level of confidence I can place on my measurement systems. This is ‘measurement uncertainty’ and it is very important to every business. A measurement is simply not valid without an understanding of its uncertainty. “I also have to compare the measurement uncertainty that I can achieve with the tolerance required for the part, product or process. If my measurement uncertainty exceeds the required tolerance, I am using the wrong approach to my measurement, and possibly the wrong equipment. A good metrologist will also understand why the stated tolerance has the value assigned to it – and should be able to challenge it. “Medical disciplines tend to have a different culture from manufacturing industry; they start from the understanding that treatments are imperfect and then work towards understanding how imperfect – how uncertain. Once they achieve that they can decide whether a treatment is good enough or not. If not, the studies needed to achieve the understanding will have provided opportunities to improve the treatment and the measurements needed to assess it.” Metrology applies a level of honesty by quantifying the confidence in any measurements made, a concept that people in calibration laboratories fully understand. Now, many major businesses are applying the best practices that exist under the controlled environment in the laboratory onto the shopfloor. Why? Because they need to meet the tighter tolerances required to make things to a better standard. It does not have to be more expensive, if you have a good system and it is capable then quantifying the capability of the measurement systems allows the level of control to be increased – this is laboratory mentality.
“Understand it as a metrologist would; a good metrologist will always apply the right measurement system for the job in hand. There is no point using a co-ordinate measuring machine when Vernier calipers will adequately perform the task. We need to promote understanding measurement from first principals rather than just throw everything on a CMM,” Trevor Toman says. Good metrology that is applied with understanding embeds reality and confidence in measurement results that allows management to make decisions with the greatest degree of confidence. It will also tell you how well you are performing, acting as a key tool to help a business to outperform global competition. Trevor Toman says: “Any new product launch on the shopfloor will have detailed processes that are created by an engineering team that understands how the product will be made, but often there is not enough thought put into the measurement. If as much care was applied to metrology we could avoid both the cost of rejecting good parts, and the cost of supplying substandard parts to the customer.” He concludes: “Better to understand what you can achieve than base decisions on shifting measurement results. Variation is both the enemy of production and the biggest enemy of any measurement system. If we can reduce the variation in the measurement system then we can truly understand the real variation that exists in our production process.” Good measurement systems equate to fairness, honesty and the understanding and control of production processes and Make Measurement Matter 2015, held on 15th October at the Kettering Conference centre, will provide the ideal opportunity for visitors to find out about how metrology can influence and improve their businesses. www.gtma.co.uk
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QMT Sep/Oct 2015
NEW ACCRETECH SURFACE, FORM AND ROUNDNESS SOLUTIONS FROM BOWERS GROUP RONDCOM TOUCH WITH TABLET COMPACT ROUNDNESS MEASURING INSTRUMENT
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15/06/2015 12:53
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CT SCANNING
3D CT scanning for aerospace composites Reconstructed 3D CT volumes showing slice capabilities
Today’s faster and better CT scanning technology is widening its area of application in NDT – including the inspection of composite aerospace components
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North Star Imaging’s X5000 Computed Tomography system – equipped with their 4G CT Workstation utilizing 4 NVIDIA GPU’s running in parallel for fast CT
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ndustrial CT technology is improving very quickly. While a few single CT slices could take hours to generate years ago, it is now possible to reconstruct complete 3D models with billions of Voxels (three dimensional Pixels), in just seconds. This opens the door for numerous new applications like 3D inline automatic defect recognition, 3D reverse engineering, rapid prototyping, 3D metrology, and so on, so it has now become a very competitive technology for 3D scanning. The principal benefit of using 3D CT for scanning or digitisation is that a complete model with both external and internal surfaces of an object is obtained without destroying it. Moreover, CT works with any surface, shape, colour or material (up to a certain density and/or thickness penetrable with X-rays). Generally, a modern start-to-finish CT scan can be as fast as a two seconds or take longer than an hour, depending on the resolution requirements and size and/or density of the object. Overall, the resolution is excellent both internally and externally, which in turn can fulfill virtually any designer’s needs.
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Computed Tomography in Use Computed Tomography has proven to be an outstanding tool for many industries, especially aerospace. The demand for CT continues to be tremendous; largely due its versatility and capabilities to do what other technologies cannot. CT scans nondestructively provide excellent resolution internally and externally, which then allows for measurement on surfaces both inside and outside an object. Also, due to the penetration of X-rays, CT scans are unaffected by certain object characteristics such as dark, reflective or transparent surfaces and/or shaded zones on the item that can cause difficulty with other 3D scanning methods. Furthermore, 3D CT reconstruction models can be directly compared to CAD models and/or other CT models in order to display differences or commonalities in measurements, densities, voids, etc. The images at the top of the page show a 3D CT reconstruction of a wrinkled composite plate. The CT model can be manipulated in real time 3D and it is also possible to slice through in any direction for internal inspection. The reconstruction process consists of complex algorithms that transform the stack of 2D X-ray images to a 3D Voxel volume model. This process uses a GPU (Graphics Processing Unit) based software which utilizes the new NVIDIA graphic card capabilities. NVIDIA’s graphic card employs hundreds of computation cores. This massive number of cores accelerates the process and increases the speed of 3D CT reconstruction by a factor of up to 50x. Developed with a CUDA interface and the latest technology in graphic cards, this proprietary North Star Imaging software now makes it possible to perform very fast CT reconstruction, which in turn boosts the number of achievable scans. Due to the high speed capabilities, inline CT scanning for 100% quality inspection or 3D metrology control is now attainable. The image left shows an example of a modern CT system layout. It consists of a radiation shielded enclosure, which houses the X-ray tube, detector and rotational stage. Adjacent to the enclosure is
QMT Sep/Oct 2015
CT SCANNING
Sliced 3D CT volume of a wrinkled composite plate showing measurement functionality
a computer workstation, consisting of a 2D X-ray console for the set up and acquisition steps, and a 3D CT supercomputer workstation for volume reconstruction and visualisation. Many options are possible through the use of a 3D CT reconstruction volume model. For basic 2D measurements, the Slice Window pictured above is generated from the cutting plane in the 3D volume. From there a length, diameter, angle, etc‌ can be applied on the single image. The main benefit, of course, is that any feature, part or even defect inside a structure or an assembly can now be measured without destroying it. The 3D CT reconstruction, which is made of several million or billion Voxels, can also be transformed to a surface model. The resolution of the 3D model depends on the number of Voxels generated from CT reconstruction. A threshold value of radiodensity is chosen by the operator and set using edge detection image processing algorithms. From this, a 3-dimensional model can be constructed and displayed on screen. Multiple models can be constructed from various different radiodensity thresholds, therefore allowing different colours to represent each component of an assembly. Typically, models are composed of thousands of polygons up to 50 million polygons. The pictures below show a surface reconstruction (polygon mesh) of structural honeycomb and an aerospace assembly. All the internal structural features are reconstructed as well since the CT reconstruction provides volumetric information.
With the generated polygon mesh surface model, many different applications become available to the user. The output format (points cloud, STL, WRL ‌) is compatible with most CAD software for reverse engineering applications, rapid prototyping machines for modeling, finite element analysis software for simulations, etc. In most cases, the polygon mesh generated by the CT system can be used in the above applications without modification and typically, the resolution is higher than needed. However, in order to modify or take measurements of the CT surface model with a CAD software, the CT model needs to be processed to make it editable. New generation modelling software (e.g. Geomagic, Rapidform, Polyworks) propose semi-automatic tools to transform the polygon mesh to Nurbs Surfaces and parametric CAD models. User intervention is still necessary for manual operation in transforming the scanning surface to real solid CAD.
Comparing 3D CT image to CAD model Dimensional analysis is one key application available for model comparison. Since CT and especially microCT provides very accurate dimensions on surfaces, the technology is often used for metrology studies. Measurements can be done either directly on the surface using any CAD or Metrology software, or it can automatically compare the CT model with the CAD model, or even the CT model with another CT model. All in all, 3D CT is now accessible for most industries as a viable tool; user-friendly interfaces, increased scan speeds, and decreasing prices have all attributed to the rapid growth of this technology in the marketplace. Having very accurate internal dimensions without destroying the item, along with the ability to compare to a reference model is entirely unique to CT. There are no shaded zones, it works with all kinds of shapes and surfaces, there is no post-processing work needed and the resolution is excellent. Above all, the greatest benefit is the ability to nondestructively obtain the internal structure of the object, and CT is the only technology capable of achieving such performance. www.4nsi.com
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3D CT surface reconstructions of structural honeycomb and an aerospace assembly
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CT SCANNING
Inside the head of T rex
German researchers are using X-ray CT to examine the skull of a mighty dinosaur
From left, Prof. Randolf Hanke, Dr. Michael Böhnel and Nils Reims developers of XXL-CT, Dr. Anne Schulp, paleontologist and dinosaur expert from the Naturalis Biodiversity Centre in the Netherlands
Above and right, The images are computer tomography scans of a major Tyrannosaurus rex skull taken at the Fraunhofer Development Centre for X-Ray Technology EZRT using the world’s biggest CT scanner. © Naturalis Biodiversity Center/Fraunhofer IIS
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In 2013, researchers from the Naturalis Biodiversity Center in Leiden, Netherlands made a remarkable discovery in Montana in the United States: one of the best preserved Tyrannosaurus rex skeletons ever found. Experts date the remains of the female dinosaur to 66.4 million years. The skull alone of the magnificent specimen weighs an incredible 500 kilograms. Every single bone of this find offers new knowledge about the world’s most famous dinosaur and its habitat. Edwin van Huis, head of the Naturalis Biodiversity Centre, said: “This discovery will have an enormous impact on dinosaur research for decades to come,” To get a glimpse of the internal structures of the remains without damaging the fragile skeleton, the Dutch researchers are relying on the know-how of the Fraunhofer ISS Institute for Integrated Circuits. Using XXL CT, the world’s biggest X-ray computed tomography scanner, the Fraunhofer Development Centre for X-Ray Technology in Fürth, Germany is capable of generating high-resolution data, in this case from images of the T Rex. “We’re extremely pleased that the Naturalis Biodiversity Centre has placed their trust in us. With its unique CT technology, Fraunhofer’s Development Centre for X-Ray Technology can make a significant contribution to help shape dinosaur research,” says Prof. Randolf Hanke, head of the centre. The CT images offer researchers a world of opportunities. The precise, cross-sectional x-rays of the skull benefit the conservation and preservation of the remains. Surprises, such as hidden fractures, can be reliably detected in advance and then taken into consideration during the preparation. Furthermore, using the x-ray data and a 3D printing process, a true-to-original copy of the skeleton can be produced. Dr Anne Schulp, paleontologist and dinosaur researcher at the Naturalis Biodiversity Centre, said:”Concealed areas are especially interesting for us. With this method we are in a position to
reconstruct the structure of the skeleton, especially since the skull is in such excellent condition in this case. I’m extremely excited about the mold of the inside of the skull. We can show what the brain looked like without having to open up the irrecoverable skull.” The Fraunhofer Development Centre for X-Ray Technology develops non-destructive inspection methods that allow the examination of objects with respect to flaws or quality defects without impairing their functionality. The specialist departments offer individual solutions from optical 3D measuring systems to industrial X-ray cameras as well as turnkey X-ray systems for industrial production levels. Moreover they offer structure and process analyses for research applications. The experts accompany the customer from the first idea through feasibility studies up to the marketable product.
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The Naturalis Biodiversity Center is an internationally-recognised research facility that aims to describe, understand and conduct research in the field of biodiversity for the good of man and the future of the planet. Its activities include developing a collection of biological and geological diversity and making it available to more and more people, as well as carrying out scientific research that contributes to worldwide efforts aimed at restoring biodiversity and understanding interaction between the species. www.iis.fraunhofer.de
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TRAINING
Keith Bevan is Delivery Manager for Training at the National Physical Laboratory
Best practice approach to preparing to take a measurement The third in a series of articles designed to help QMT readers in their everyday measurement needs from Keith Bevan, the Delivery Manager for Training at the National Physical Laboratory (NPL) Our last article (published in June’s QMT) looked at the measurement considerations that will allow you to make better measurements in the workplace, outlining the advice NPL gives to measurement professionals at the preliminary stages of the measurement process. In this article we examine the next step of the process, when professionals are preparing to take a measurement. In your preliminary assessments you will have determined what needs measuring, the next stage of planning is to ensure you have selected the right measurement instrument for the task and have considered the environmental requirements in your planning. We look at both of these issues in this article, as well as advising on what to do with the measurement results.
Choosing your measurement instrument
The choice of tool you need will depend on whether you are working to a procedure or if planning a measurement for the first time. With a procedure you will know which instrument
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to use, as it will be clearly stated within the procedure. However, not everybody will have that luxury, so let’s continue as if you do not have access to a procedure. The first step is to refine the choices available to you. The drawing tolerance allows you to put a limit on the uncertainty of measurement of the equipment you can use. This, in turn will limit the number of potential tools you can use. From those tools available do not make the mistake of believing the most accurate is the best option. Doing so could increase costs, waste time and take a valuable resource away from being used where it is genuinely needed. For example, do you use a generalpurpose measuring instrument such as a CMM or would a more specific instrument like a height gauge - whose purchase price can be up to 10 times less than a CMM - perform the task equally well? Understanding the capabilities of any equipment will inform you what is appropriate for a given measurement. However, this knowledge very much depends on
QMT Sep/Oct 2015
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TRAINING The results showed that temperature considerations were often overlooked, with up to 85% of delegates failing to inquire about temperature during the test. There are several considerations on temperature to remember when planning a measurement; from ensuring the workpiece is at ambient temperature to having suitable thermal stablisation procedures. Also, as defined in ISO 1, all dimensional measurements should be reported at a standard reference temperature of 20 °C. More detailed advice on temperature compensation can be found in NPL’s Good Practice Guide #80.
What to do with the measurement results
you understanding the manufacturer’s specification and the calibration certificate for the instrument. Armed with this information, international standards such as ISO 14253 and the drawing tolerances you should be able to make an informed decision. However, manufacturers’ specifications can be hard to interpret as different manufacturers may have different test methods and articulate their test results in different ways. They will quote terms such as accuracy, resolution and error. This can be confusing, and mixing up terms like these and others such as tolerance, uncertainty and precision can mislead your measurement preparation as a result. To help you make an informed decision NPL has developed a series of good practice guides that aim to improve measurement understanding and technical abilities. NPL Good Practice Guide #80, Fundamental Good Practice in Dimensional Metrology, has a section dedicated to such terms, and can be downloaded free of charge on the NPL website.
Environmental considerations
Once the right tool has been selected, measurement professionals need to consider environmental effects in their planning. Adequate lighting in the area where the measurement will be made is needed, as are controlled levels of dust, moisture and vibration. Perhaps the largest environmental issue to consider when planning a measurement task is temperature, as this can influence measurement results (both the part being measured and the measurement tool itself). Data from the Coordinate Metrology Society (CMS) Measurement study reports show that temperature is one of numerous considerations often overlooked. The CMS invited delegates at its annual conferences from 2010-2014 to participate in a series of measurement tasks, using either a laser tracker or an Articulated Arm CMM. These tasks were observed and monitored to provide data and knowledge for on-going metrology education.
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Measurement planning should also consider how the results are recorded, tracked and stored. As part of this plan you should ensure there is a clear way for the data gathered to be related to the job. For example, is there a task reference number that should be used for consistency? If you are using software to collect or store the data you need to check you are using the right version – both of the CMM software and of the part programme. It is simple to go online and update most software. If you are using a CMM to take the measurement a programme will be written to move the machine, contact the relevant surfaces, compute Gaussian associated features and then make calculations based on those features. A mistake in any of those steps can lead to errors in the final output. There is a certain amount of good practice that needs to be followed to ensure the correctness of any program created and this can be accessed in Good Practice Guide #41 CMM Measurement Strategies. Once the data is collected you also need to know how to process and analyse it. For example, is there a script you need to follow? Also, bear in mind what the final output of the measurement result will be, and how the measurement will be reported as part of this, such as visually or through a written report. Finally, when you share the results make sure you know and account for any data security issues, such as commercially confidential information.
Any problems?
Remember that help is always available should you encounter a problem at any stage of the measurement process. This help can be from someone senior within your company, from the original manufacturer of the equipment, especially if using a CMM or through a recognised external body such as NPL. As well as Good Practice Guides, NPL provides a range of training programmes, available through the classroom and via e-learning, that can give measurement professionals the confidence they need to make better measurements in the workplace. www.npl.co.uk
QMT Sep/Oct 2015
Inspection, Digitising & Measurement Seminar organised in conjunction with
CMMs
Matching measurement to machines
The turbine component being machined on the Spinner 5-axis vertical machining centre.
New manufacturing technology meant that Nisan Engineering had to take another look at its metrology capabilities
The aluminium turbine component being inspected on the Nikon Metrology Altera 8.7.6 CNC CMM in a cycle time of 10 minutes at Nisan Engineering, Leicester.
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D
inesh Prajapati, a director of Leicesterbased subcontract machinists, Nisan Engineer, takes the view that there is no point machining a component if you cannot check that it is within tolerance. His problem though was that parts were becoming increasingly difficult to inspect after the company which traditionally used 3-axis CNC machining centres, installed a 4-axis horizontal-spindle model in 2013 and a 5-axis vertical machining centre in August last year. Much more complicated components were being produced on these machines and some of the features were impossible to inspect on the company’s manual CNN which dates back to the 1990s. If the features were critical and could not be inspected by hand using other conventional metrology equipment, work had to be turned away, as in most instances there would not have been time to send the parts out for checking. Nisan addressed this with the Purchase of a Nikon Altera 8.7.6 CNC CMM which can inspect the most complex parts it produces. What’s more, parts are now measured in a fraction of the time that was previously needed on the manual machine. While the new CMM was being installed, Nikon Metrology retrofitted identical control software, called CMM-Manager, to Nisan’s manual Mitutoyo BH504 CMM. It considerably increased the speed with which components can be inspected, giving it
a new lease of life. Mr Prajapati gave a couple examples of the significant benefits obtained using the new CMM and the upgraded machine. The first refers to a part produced on the 5-axis machining centre that could not previously be inspected at all, and the second concerns a 4-axis machined component that is now inspected more comprehensively and faster on both the CMMs.
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5-axis productivity The 5-axis job is an aluminium housing measuring 172 mm in diameter by 52 mm high that forms part of a turbine used for renewable energy generation. After CNC turning of the bore and outside diameter it is milled and cross-drilled at various angles on a machining centre. One hole is at 30 degrees, another at 45 degrees and a third at 52 degrees. All are of 0.8 mm diameter and intersect at a point. These holes could not practically be measured on the manual CMM, even with the new software, whereas it is an easy process on the Altera using a very fine touch probe in the Renishaw PH10T motorised indexing head. The entire part is checked in two automatic cycles taking a total of 10 minutes, including automatic probe exchange, during which time the operator is free to do other tasks. Tightest tolerance is 10 microns total on the OD and bore.
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European Portable Metrology Conference & Exhibition 2015 PROCESS IMPROVEMENT THROUGH 3D MEASUREMENT TECHNOLOGY
The annual European Portable Metrology Conference (EPMC) starts this year in the UK in Manchester and is scheduled to appear in Germany next year. This conference will continue to build on 10-year’s success of its predecessor, the Large Volume Metrology Conference (LVMC). LVMC was initiated by Airbus UK in 2004 as an applications-oriented event focused exclusively on the development and use of portable 3D measurement technologies in manufacturing industries. Our technical committee from the UK and Germany provides a value-added programme generated by experts representing end users, systems manufacturers, universities and standards labs. The conference is a unique event offering both newcomers and experienced end users: • Insights into current portable 3D metrology systems and their application • Meetings with expert users • Networking with like-minded professionals from their own & other technology areas Exhibitors have the ideal opportunity to present their products to this interested audience which is exclusively focused on portable 3D metrology. Join our conference this year!
CMMs
The benefits of the retrofit software can be seen in the measurement of a family of EN8 steel gas flow meter cylinders produced on a twin-pallet, 4-axis horizontal machining centre. These are machined in 10 sizes from solid billets measuring from 74.5 to 145 mm in diameter and 270 to 557 mm long. A bore of between 34 and 65 mm diameter is machined during the first operation, followed by drilling, tapping and milling around the periphery during op 2. Bores have to be accurate to 37 microns total and other dimensions to between ± 0.1 and ± 0.2 mm, while the faces of the component are tied up to the bore to within 50 microns concentricity and parallelism.
Inspection on the manual CMM used to take 40 minutes. It was followed by conventional handgauging of a threaded hole and manual inspection of certain other inter-related positional features that could not be included in the CMM procedure, which added a further 10 minutes. With the Altera CMM inspection takes just 9 minutes and includes extra measurements to give a more comprehensive result. The cycle has to be programmed the first time, but on all subsequent occasions it is available for immediate reuse. On the older machine the new Nikon Metrology software enables the measurement of all features, according to Mr Prajapati. It cuts the original inspection time by around 20% and eliminates manual intervention, so over a quarter of an hour is saved. With the previous software, it was necessary to type in code and repeatedly change the projection, whereas CMM-Manager is intuitive and completes these tasks automatically, saving even more time. Moreover, the identical program from the Altera can be loaded into the CMM-Manager software on the Mitutoyo CMM so that the operator can follow the same cycle to complete the inspection. Onscreen component images and fixturing instructions speed set-up, while live reporting shows actual sizes measured versus the nominal. Mr Prajapati said: “Nikon Metrology completed our Mitutoyo CMM software retrofit first, and provided initial training, which allowed me to familiarise myself with its capabilities before starting to use the CNC machine. “I was measuring components on the Mitutoyo within half a day of the software training. Apart from the speed of operation, the other significant benefit is the comprehensive reporting that is possible. “It shows immediately if a feature is within tolerance or not, while results are collected and presented in graphical or tabular form and can be stored on a hard drive and emailed to the customer. Previously, reporting was restricted to simple
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QMT Sep/Oct 2015
Image of the turbine component on the control screen of the Altera 8.7.6 CMM.
Opposite: Top, The same cylinder being inspected on the Mitutoyo CMM with Nikon software. Bottom, Image of the gas flow meter cylinder on the control screen of the Altera 8.7.6 CMM.
Mr Prajapati said, “Repeatedly repositioning the head by hand on the manual CMM takes half an hour each time. Doing this three times to inspect the holes plus several more times to access other features would take five or six hours, far too long to be a viable method of inspecting the turbine component. Additionally, it would risk introducing inaccuracies. “The 5-axis machine would be waiting for over half a shift for the first-off inspection to be completed, wasting an expensive machining resource. “Then for example if a drill breaks during production and needs to be replaced, rechecking those machined features would hold up production, further raising the cost per part of manufacture.”
CNC versus manual inspection
One of the EN8 gas flow meter cylinders, measuring 130 mm in diameter by 550 mm long, being inspected on the Nikon Metrology Altera 8.7.6 CNC CMM in a 9-minute cycle.
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printouts and involved up to half an hour’s typing if it was a complex component.”
Inspection procedures The first-off part is always sent to the metrology department. Then, depending on the size of the run, component complexity and drawing tolerances, every 10th component is typically checked on one of the CMMs. A random sample from the end of the batch is also fully inspected. This core metrology regime is assisted by periodic on-machine measurements of key features by operators using conventional measuring methods. Extensive use is also made of on-machine probing to check datums and detect tooling errors. For example, the turbine component has three features probed on the machining centre and the flow meter cylinders have 10 features examined. Programs are created via different routes. If a CAD model exists, as it did for the aluminium turbine part, the data is entered into CMM-Manager and the inspection routine is produced directly from it. If only a drawing is available, as in the case of the flow meter cylinders, a graphic of the part is built up and a measuring cycle created by manually moving the probe to the relevant inspection points on the CMM.
Subcontract inspection service When Nisan formulated its plan to modernise the metrology department at Leicester, it decided to invest in the construction of a temperaturecontrolled inspection room in addition to the Nikon Metrology CMM and extra software at a total cost of £70,000. By Autumn 2015, when all programs have been created for existing repeat jobs and the department is fully operational, Mr Prajapati predicts that only half of the resource will be needed for internal inspection, based on the current single day shift. He therefore intends to offer metrology services to other manufacturers. www.nikonmetrology.com
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CMMs
Express delivery for massive oil parts A supersized CMM is helping a Gateshead, UK, manufacturer measure large oil and gas components
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Contract manufacturer Express Engineering has installed a massive co-ordinate measuring machine (CMM) to undertake the rapid and accurate inspection of large oil and gas components. To enable oversize components to stand upright when being measured, the CMM was modified by an extended Z axis and a 1.2m diameter hole bored through its granite measuring table The machine, a Mitutoyo Crysta-Apex C with a 2000mm by 4005mm by 2005mm measuring volume, is the largest machine ever sold by Mitutoyo UK. Established in 1973, Express Engineering has grown from its origins as a precision engineering and tool-making company become a contract manufacturing group with a global reach. It supplies the oil and gas market with a wide range of highly integrated precision machined components, kits of parts and fully assembled pressure tested products, including wellheads, Christmas tree valves, manifolds, completions, tooling, flowlines and connections. Given their critical nature and the environments they operate in, the quality of the products is paramount. So, in addition to regular in-process, on-machine checks, comprehensive final inspection routines performed by a range of inspection aids, including Mitutoyo CMMs that are located strategically throughout the Gateshead facility. This recently installed Mitutoyo CMM is an adapted version of a large capacity Mitutoyo Crysta-Apex C, model 204020. To enable oversize components to stand upright when being measured, the CMM was modified by an extended Z axis and a 1.2m diameter hole bored through its granite measuring table. Riser plates were fitted to elevate the granite table and a lower component support was located beneath the hole. These
modifications enable extra-large components such as 2-metre high, 4-tonne wellheads to be lowered by crane through the table and accurately measured at a single setting. Express Engineering quality manager Bill Mole said: “Previous to purchasing our new Mitutoyo CMM, to inspect our increasing range of larger components with demanding dimensional tolerances, such as wellheads that stand 2 meters high, we would make a partial inspection on one of our larger CMMs, then reposition the component to complete the inspection routine. “Although our previous inspection techniques were accurate, the volume of wellheads, and other large oil& gas industry components we now manufacture, meant that we needed to find a quicker, more efficient solution. “Now, in addition to further improving our already excellent large-component accuracy capability, our new CMM has enabled us to slash our inspection times on components such as wellheads. For instance, a comprehensive final inspection routine on a complex wellhead that previously took over 12 hours, now takes just 4 hours. “Not only does our new CMM help us to adhere to the most challenging of component lead times, it is a perfect example of Express Engineering’s continuing commitment to ensuring the highest standards of manufactured quality.” Particularly important for Express Engineering, due to the in-depth report requirements and traceability demands of the global oil and gas industry, is Mitutoyo’s userdefined report generation software. Supplied as standard with all Mitutoyo CMMs, the flexible function allows reports to be created in a range of formats including PDF, HTML and JPEG. www.mitutoyo.co.uk
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QMT Sep/Oct 2015
CMMs
Serving increased capacity A UK subcontractor has invested in a new CMM to keep up with expanded capacity Ardor Engineering Ltd specialises in the production of high-quality, precision machined components in materials that include superalloys and other exotics for customers in sectors that include nuclear, oil & gas and defence. A recent move to new premises doubled the company’s floor-space, allowing it to add new CNC machine tools and increase output. To help the company’s busy quality department keep-pace with raised production the company decided to invest in a new CMM that could perform rapid, automated measuring routines to handle the volume of work passing through the quality department. Managing Director Michael Kilbride said: “The nature of our demanding customers and the challenging work we undertake necessitates the administration of a rigorous quality policy. This is implemented through
the operation of an all-inclusive quality management system that encompasses all of Ardor’s activities from admin functions, through manufacturing, to final inspection and component delivery. “Having considered several alternative CMMs, an impressive demonstration of Aberlink’s Axiom Too convinced me that the machine had all of the attributes we needed. In addition to having the accuracy specification we were looking for, the Axiom Too was also able to perform the quickest, automated CNC measuring routines of all the CMMs we looked at. The machine’s generous component support meant that we would be able to measure a single large part, or load multiple smaller components. “The machine’s impressive speed has removed the possibility of inspection bottle-necks and its ability to generate comprehensive inspection reports is much appreciated by our customers.” The Axiom Too is the best-selling CMM from Aberlink Innovative Metrology and is available in manual and CNC variants and in a range of capacities. www.aberlink.co.uk
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VERIFICATION
How does your 3D optical scanner perform on the shop floor? On 30 September 2015 NPL will be launching a performance verification facility to support the increasing use of 3D optical scanners in industrial environments. Here Dr Martin Dury describes what the facility has to offer and why you need to use it.
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Optical scanners provide point-cloud data collection, portability and speed and will play a significant role in the future of quality control for production line metrology. Being readily available and using fast-developing technology the capabilities of 3D optical scanners are not yet fully understood and scanners are known to have difficulties measuring certain surfaces and geometries. Sales demonstrations often employ artefacts optimised to give results that show the best capability of the instrument; the artefacts may be finished with particularly co-operative surfaces such as ’battleship grey‘ paint and comprise unchallenging shapes. For an end-user measuring production engineering objects in a real-world environment, the spurious and unreliable dimensional data that an inappropriate scanner can produce may be both time consuming to correct and may damage user confidence in the technology. As optical scanners become more commonplace, end-users will need help with identifying suitable instruments for their needs, while scanner manufacturers will need independent verification to support and demonstrate their instrument capability claims. To encourage industry’s growing use of
3D scanning technology the National Physical Laboratory (NPL), the UK’s National Measurement Institute, is establishing a 3D optical scanner performance verification facility which is due to be launched in September 2015. Fringe projectors, articulating arm CMMs incorporating laser scanners and other types of portable 3D optical scanners are quickly taking the place of Cartesian-based tactile probing CMMs because of their advanced metrology benefits. Having been developed in the 1950s, Cartesian CMMs are well understood, trusted and methods of verifying their performance are well established. In contrast, optical scanners, whose development has accelerated with increasing access to low cost, powerful computers and cheaper optics, are relatively new and are still being developed. While optical scanners are unlikely to give Cartesian CMM-level accuracy, they offer the potential for great positives, such as massively increased measurement speeds, equipment portability and relative ease when measuring freeform surfaces. However, their limitations are still being understood and international performance verification standards, like ISO 10360 for CMMs, that describe suitable tests and procedures for
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QMT Sep/Oct 2015
VERIFICATION their acceptance and use are yet to be developed. Currently available guides such as VDI/VDE 2634, the German guideline for optical 3D measuring systems, address neither freeform surfaces, surface finish nor instrument measurement performance while operating in unfavourable environments. In 2009, NPL established the National FreeForm Centre to support the growing industrial take up in the use of non-contact 3D coordinate measuring systems. Scientists at the Centre have since developed artefacts with known dimensions such as the NPL dimensional freeform standard (Figure 1), which are now available and supplied complete with traceable measurement data together with associated measurement uncertainties. A purpose-built dimensional verification laboratory is now being developed to assess many different aspects of 3D optical scanner performance combined with their environmental sensitivities. The aim of this new facility is to provide global industry with greater measurement confidence when using 3D scanners in various environmental conditions. The portability and fast operation of optical systems make them particularly attractive to use away from the metrology laboratory and in environments where lighting and temperature conditions can quickly vary, such as on the production line, or outside at excavation sites and crime scenes. Temperature is of critical importance when performing accurate dimensional measurements, not only affecting the object being measured, but also known to influence the performance of optical scanners. Being devices that use projected light to make dimensional measurements, it should be of no surprise to discover that ambient light can also affect these instruments. Understanding the limitations of a piece of equipment and how its environment can affect the measurements is vital when trying to performing accurate metrology in non-ideal surroundings. The purpose built laboratory (Figure 2) has adjustable lighting and temperature to allow 3D optical scanner performance testing over a range of typical use conditions. Some 3D optical scanners have difficulty in accurately measuring objects of particular colours, materials or surface finishes and subsequently give results that contain anomalous data or regions where very little data are measured; while additional measurements may help to resolve these issues, they can be time consuming and costly. Knowing the limitations of a potential scanner before committing resources would certainly benefit
the end-user and also help scanner manufacturers to manage their customers’ expectations. Multifaceted test artefacts have been built at the National FreeForm Centre to quantify the ability of optical scanners to measure different surfaces and test pieces are being developed for businesses that would benefit the most from 3D optical scanner uptake, such as the aerospace, automotive, manufacturing, medical and heritage industries. In addition to temperature, lighting and surface finish, articulating arm CMMs incorporating laser scanners may also be affected by scan speed and produce higher quality data and more dimensionally accurate scans when moved slowly, which costs time. The National FreeForm Centre has therefore developed a system (Figure 3) to find the optimum balance between scan velocity and measurement quality as well as examining the effects of scan height and joint encoder angle on the measurements. The 3D optical scanner verification facility combines a unique mix of staff with world quality expertise in dimensional metrology from decades of accumulated knowledge, a purpose-built laboratory, test artefacts and procedures designed to challenge 3D optical scanners to their limit. It has been developed for optical scanner users who already have or are thinking of buying a system and want to independently verify that it will work in the environment where they intend to use it and in the way that they want to use it, and that it will measure the objects that they want to measure to the accuracy that they require. The facility is also aimed towards optical scanner manufacturers who want to have an advantage over their competitors by getting their instrument capability claims independently verified at the National Physical Laboratory. The verification facility will be launched on 30th September 2015. For further information contact Dr Martin Dury (martin.dury@npl.co.uk) www.npl.co.uk/freeform
QMT Sep/Oct 2015 www.qmtmag.com
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CALIBRATION
Calibration efficiency IndySoft Software makes sure a UKAS accredited calibration service provider keeps up with demand UKAS accredited Roxspur Measurement & Control Ltd (RM&C) provides both on-site and in-house calibration to either UKAS or national standards. The company provides full certification of a range of disciplines including temperature pressure, flow and electrical parameters. In addition to staff at the company’s Sheffield based calibration laboratory, RM&C employs a team of engineers accredited for the on-site calibration of equipment including autoclaves, furnaces, thermocouples and RTD probes, scales and balances, ovens and chambers, indicators and controllers, pressure and electrical measuring equipment. Because of rising demand for the company’s calibration services, the company felt that its calibration management software was too slow and unable to deliver the functions needed for maximum operational efficiency. To help speed-up operations and increase efficiency the company started looking for suitable software designed for use in commercial calibration laboratories. Mark Donnelly, RM&C Calibration Services Manager explained, “Although each of the software systems that we saw performed well, Commercial Lab Management calibration software from IndySoft was the only one that gave us all of the features that we needed. In addition, the IndySoft calibration software was easy to use, simple and logical, and when required, configurable to our own specific requirements. “Having purchased our first user licences, as our use of IndySoft software has been so
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successful we have since expanded and added further licences. Our use of IndySoft’s Calibration Software for Commercial Labs has helped to streamline our laboratory’s administration function, speed-up our calibration procedures across all of the disciplines that we cover and also simplified the tracking of customer’s instruments. “As well as our customers enjoying the benefit of having vital instruments returned to them quicker than ever before, the use of our IndySoft software has meant that we have significantly reduced the time spent in generating and issuing calibration certificates. “In addition to using IndySoft calibration software in our lab, our engineers that perform calibrations at customer’s facilities use IndySoft on their Motion Tablet computers. This has made our external calibration function much more efficient, reduced the potential for errors and saved many hours of administration work. “We have customised our IndySoft software home page to allow quick views of equipment and process status and also developed flow charts to map process and to better visualise work flow. We are now able to store unlimited numbers of records related to companies, equipment and histories. It also helps that we have a simplified interface enabling us to obtain the information we need in just a couple of clicks. “Having made the decision to run with IndySoft’s Calibration Commercial Lab Edition, we anticipated a complicated transition period from using our previous system. There were inevitably initial teething problems but we were surprised at how quickly we saw the benefits from the new system. After we
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CALIBRATION
explained our needs, IndySoft’s staff made a series of useful suggestions related to general ‘house-keeping’ and system shortcuts, then configured the software to suit our requirements. “Although, prior to purchase we were convinced that the use of IndySoft Commercial Lab Management calibration software would provide us with a major step forward, the software has proven even more advantageous than we anticipated. Not only has the speed and efficiency gained by the use of the software helped throughout our business, our customers are now receiving a faster and enhanced service from us.” IndySoft calibration software provides businesses of any size the ability to manage both their internal quality needs and external customer demands, all the while monitoring the day-to-day financial aspects of their operation. With support for leading enterprise platforms, Commercial Lab Management can be deployed on growing and largescale corporate systems. Companies can configure their own event-driven system with checkpoints; rule sets and documentation
at every point along the equipment path, ensuring assets are handled according to existing quality procedures. IndySoft Europe Managing Director, Jake Bishop added, “As well as selling IndySoft Commercial Lab Management software to smaller commercial calibration laboratories that have previously used manual systems, increasingly we are being contacted by larger UKAS laboratories that are looking to replace out-dated, inefficient management software. “As potential users are becoming aware of the multiple advantages that can be gained by the use of modern, easy to use calibration related software that is fully supported and maintained, we are receiving increasing requests for demonstrations. Although IndySoft Commercial Lab Management software was designed to provide the advanced functions required by commercial calibration facilities and is ISO 17025 compliant, over several years the inclusion of additional functions requested by users means that the software has evolved into what we regard as the ideal system.” www.indysoft.co.uk
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NDT
Refining NDT with 3D scanning Right, In situ 3D scanning of a pipeline, below left, The Creaform HandySCAN 700 scanner, below right, Column skirt after being fireproofed and sanded in preparation for corrosion inspection
Methodology 1. Once the surface is prepared (sanded and with its insulation removed) by on-site contractors, positioning targets are applied to it. Positioning targets allow the scanner to triangulate its position against the control surface during the 3D data acquisition process. Estimated time: 1 hour. 2. Reference arrow positioning allows the positioning of the indications in relation to X and Y references identified beforehand. 3. Positioning target acquisition and 3D surface scanning (approx. 20 m2 with a resolution of 1.5 mm). Estimated time: 45 minutes. 4. Data recording and site cleaning and restoration after inspection. Estimated time: 30 minutes. 5. Data processing and preparation of the inspection report. Estimated time: 12 hours. The above application and methodology are based on the control of a 20 m2 surface carried out by DEKRA Industrial during a single intervention. This will enable the company to reduce data processing times in the future.
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A French specialist in NDT for the petroleum industry has found that 3D scanning is a more flexible alternative to conventional NDT DEKRA Industrial is one of the leaders in the prevention of industrial and occupational hazards in France and Europe. Its expertise in identifying and assessing hazards is instrumental in risk prevention for a variety of companies. Material inspection, which mostly takes place in the French region of Lyon, encompasses a wide range of conventional and non-conventional NDT services and tools. These include conventional and phased array ultrasonic testing, time-offlight diffraction (TOFD), eddy current, robotics, electromagnetic acoustic transducer (EMAT), conventional and digital X-ray inspection, 3D laser measurements, alternating current field measurement (ACFM), thermography, Lixi Profiling, guided waves, AcousticEye and surface inspection.
Corrosion control on a column skirt Since Autumn 2014, DEKRA Industrial has been using Creaform’s HandySCAN 3D scanner and VXelements data acquisition software in conjunction with the Pipecheck, software platform to assess corrosion and mechanical damage in pipelines, refinery columns, and storage tanks. “We made the decision to invest in Creaform’s 3D scanner and software as the solutions would allow us to perform all applications and
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tasks usually required in typical NDT environments with the flexibility that we needed. It is the best tool to effectively control pipelines, skirts or columns— even when access is difficult and no power supply is within reach,” explained Nicolas Cricoveanu, Head of Advanced NDT at DEKRA Industrial. One of DEKRA Industrial’s recent NDT applications was to control the external corrosion of a column skirt in a refinery. The skirt had a diameter of 3 m and the surface to inspect started at a height of 0.6 meters and ended at 2 m, with a nominal thickness of 10 mm. The skirt interior was covered with a concrete layer that prevented access to the opposite surface. The surface itself was complex and included many support plates, cavities, manholes, insulation supports (about 50 on the control area), guards and mounting bolts. The objective was to inspect 100%
QMT Sep/Oct 2015
NDT Top left and inset: Mapping of the column skirt after scanning. The scans highlight the corrosion (red areas) at the bottom of the skirt. Below left: Detailed views of the manhole (middle) and of a lower area of the column skirt (bottom). The grey zones on the map indicate the insulation supports and presence of a welded joint. Creaform’s Pipecheck software also helps to accurately estimate each indicator or group of indicators revealed on the color map by providing the profiles of material losses and their associated depths.
About DEKRA
of the accessible surface. As the state of deterioration of the external surface was too advanced to use a conventional ultrasonic control or a manual pit gauge, the HandySCAN 3D and Pipecheck software allowed operators to scan the surface in 3D to assess the extend of damage around the skirt’s circumference. Later, the results were presented in an official inspection report generated in Pipecheck. Before making the switch to Creaform’s inspection system, DEKRA Industrial used a manual pit gauge and ultrasonic controls to inspect surfaces when their opposite surfaces were accessible and in good condition. However, in this case, the state of the surface would not have allowed for manual inspection according to the tests carried out before DEKRA Industrial’s intervention. The method used with Creaform’s solution provided relevant results – and at the same time reduced inspection times. Had DEKRA Industrial used manual pit gauges, it would have required a minimum of 3 to 4 hours without providing guaranteed results. Nicolas Cricoveanu says: “The external damage assessment provided reliable high-quality results. We can now perform controls more quickly and accurately than with manual tools. As such, both the service provider and the client benefit from productivity gains since it greatly reduces downtimes due to control operations.” www.creaform3d.com
DEKRA is the European leader in inspection and certification for the building, industry, environment and transport sectors. Its head offices are located in Stuttgart, Germany. DEKRA Industrial oversees DEKRA Group’s inspection, measuring, and certification operations in the health, safety and environment (HSE) and construction industry. DEKRA Industrial was founded in 1883 and, thanks to its rapid growth, is now the second largest business unit of the company, with a turnover of 674.2 million Euros in 2013. The company works with over 6700 collaborators. The company’s operations in France accounted for sales of 220 million Euros in 2013, thanks to the hard work of 3100 employees. Supported by a network of over 90 offices DEKRA Industrial has more than 100,000 clients in France alone. www.dekra-industrial.fr
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PRODUCTS
Pay-as-you-go probing Renishaw will unveil its new affordable, pay-as-you go machine probe system at the EMO machine tool exhibition in Milan. The company says that the Primo twin-probe system represents a breakthrough business model that will bring high-end precision manufacturing within reach of every company.
A combination of minimal upfront costs, a free, comprehensive training package, and immediate parts replacement in a unique ‘pay-as-yougo’ model, means the Renishaw Primo system represents a significant step forward in the way that machine tool probes can be introduced. The Primo system offers users all of the advantages of automated setting at a very affordable price. The twin-probe system comprises the Primo Radio Part Setter, Primo Radio 3D Tool Setter and Primo Interface. The Primo Radio Part Setter accurately locates a work-piece prior to machining and the Primo Radio 3D Tool Setter measures the length and diameter of cutting tools. Users buy a six-month credit token which enables unlimited use of the Primo machine tool probe system during that period. Once the credit expires, users can simply purchase an additional credit token to extend system usage by another six months. Registration of a valid credit token activates Primo Total Protect,
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which provides cover against accidental probe damage. To make the probes as simple as possible to use, Renishaw’s GoProbe software and supporting training kit is a comprehensive self-study package with a range of training tools and modules. www.renishaw.com/primo
Hardness tester launch at Bowers seminar Bowers will be launching the latest generation Innovatest Falcon hardness tester at its Material Testing Seminar on 16 September. The event, which takes place at the company’s demonstration suite in Camberley, Surrey, aims to give customers an insight into the principles of hardness testing, along with an overview of the solutions available from Bowers and a handson workshop in the afternoon. Attendees are invited to bring their own material or components to be tested on the day by experts from Bowers and Innovatest. One of the highlights of the day will be the first chance to see the new Falcon 500 advanced Vickers hardness testing system from Innovatest. The FALCON 500 series, Micro Vickers, Vickers and Micro Brinell hardness testing machines are a new generation of instruments, improving conventional hardness testing methods and focused on eliminating user influence on the test results.
Its force actuator system utilises an electronically controlled closed loop system and advanced force sensor technology, to achieve absolute accuracy, reliability and repeatability, on each of the forces used for a test. Besides this advanced
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electromechanical force application system, the FALCON offers superior quality mechanical and optical components, used to complete the instrument. The Falcon 500 is ideally suited for performing CHD, Nht, Rhtare testing and weld joint hardness testing as detailed in various international standards such as EN ISO 9015. The FALCON 500 series has the option of overview and full view autofocus zoom cameras with additional surface illumination which gives an overview or full view of the sample or samples to be tested. Its IMPRESSIONS ‘click and go’ functionality allows random test point selection on the screen, while the high speed motorized X-Y stage perfectly positions the selected test point under the indenter and measuring objective. Attendees to the Seminar will also have the chance to explore the full product range that Bowers has to offer. Solutions on show include a comprehensive display of bore gauging and precision hand tools from Bowers and Moore & Wright, with non-contact measurement from Baty International. Swiss-manufactured measuring instruments from Sylvac and Trimos with inclination systems from Wyler are available to experience firsthand. Discover Surface, Form and Roundness solutions from Accretech, along with inspection solutions for the Oil & Gas sector from Gagemaker. The event is free to attend, but places are limited so early registration is advised. www.bowersgroup.co.uk/seminar/en
Automatic sensor exchange Hexagon Metrology has launched the SENMATiQ universal sensor interface for Leitz ultra high-accuracy coordinate measuring machines. Premiered at Control 2015 earlier this year, the system enables the fullyautomatic exchange of sensors within part programs. Designed to make programming easier while maximising machine uptime and productivity, the SENMATiQ interface is integrated directly into the quill of the CMM and uses a mechanical loading system to engage the sensor without operator intervention. A built-in probe identification system recognises the sensor immediately and checks its status, so there is no need to
QMT Sep/Oct 2015
PRODUCTS recalibrate between exchanges. The data gathered by each sensor is contained within the same software session, enabling users to gather a comprehensive overview of the workpiece using the best sensor available for every aspect and feature.
SENMATiQ is based around on a universal sensor switch and intelligent sensor module, enabling it to accept all common sensor types including analogue scanning sensors, optical and vision sensors. The interface system also means additional sensors can be easily integrated, offering an agile and future-proof solution to overcome complex measurement challenges on a single CMM. The SENMATiQ sensor toolset includes the HP-S-X5 3D scanning probe, capable of carrying stylus extensions of up to 500 mm. Also available is the motorised indexing probe head HH-AS-2.5 with HP-S-X1 scanning sensor and the PRECITEC LR optical sensor for non-contact measurements on matte, reflective, glass or transparent materials. www.hexagonmetrology.com
Cut CMM programming time PAS CMM is an automated software tool for coordinate measuring machines that is said to be able to cut programming times by up to 90%. The software is compatible with all major CAD formats, whilst incorporating simple to use advanced multi-axis CMM programming features. In addition to the existing SolidWorks option this latest release of PAS CMM now includes native CAD data options for CATIA, ProENGINEER & Siemens NX. PAS CMM UK says that the tool complements existing CMM infrastructure and does not replace anything. It simply creates a DMI file that loads straight into the relevant environment for the coordinate measuring machine – including
PC-DMIS, OpenDMIS, MCOSMOS, CAMIO/Studio and Modus. “You wouldn’t consider machining a 3D part without using a good CAM system, so why think any differently when it comes to programming your CMM?” states Carlton Chamarette, MD PAS CMM UK Limited. He says that CMM programming has traditionally been problematic and time consuming, resulting in qualified operators being costly and difficult to retain. With PAS CMM it is claimed that first time users are programming complex 3D parts in their first day with the vast majority of customers having only two days’ training. The advanced programming features of PAS CMM allow users to significantly reduce: capacity issues, programming bottlenecks, stopped parts waiting for CMM inspection and missed delivery dates. It is suitable for all kinds of component including prismatic parts, complex blades, automotive, aerospace, defence and motor sport applications.
There are already over 200 users in the UK, including Beechwood Engineering, Bromford Industries, Castle Precision, Caterpillar, ISCAR, JAIVEL, Lockheed Martin, Magellan Aerospace and Raytheon. PAS CMM UK is offering a free 30 day trial so that companies can see for themselves the results it can achieve. www.pascmmuk.com
Shop floor CMM system CMM Master from Verisurf Software is a complete automated shop floor inspection system that combines the capabilities of Verisurf software with the Equator comparative gauge. It says the result is a fast, easy,
accurate, affordable and portable programmable CMM system.
Verisurf says that the CMM Master can greatly increase throughput and reduce scrap rates, at a fraction of the cost of traditional CMM systems. It is a light weight and compact solution that runs on single phase power with no need for costly compressed air supply. It is completely portable and can easily be configured for use on the shop floor or in the QA lab. It allows automated or manual joystick inspection and can be programmed offline from CAD or inline in ‘teach’ mode with the joystick. The software can simulate measurement routines including probe scanning to help prevent potential CMM crashes before they occur The system automatically generates AS9102 First Article Inspection Report and inspection data that can be exported to other popular presentation formats including, Microsoft Word, PowerPoint and Adobe 3D PDF Viewer. In keeping with Verisurf’s commitment of providing open solutions, the same software also enables quality engineers to program and run automated inspection routines on fixed gantry CMMs and other portable devices across the manufacturing enterprise. It says the goal is to increase efficiency while reducing customer training, data management and support costs. Verisurf Software is a complete coordinate measurement CAD system with 3D surface modelling; traditional 2D drafting and 3D model associative GD&T. The software can open any CAD model and can use STL files to create CMM inspection plans to automate the inspection of 3D printed prototypes and additive manufactured parts. www.verisurf.com
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PRODUCTS
Length gauge for delicate materials Non-contact inspection by laser scanning or other optical systems ensures that delicate components are not damaged while they are being measured; and soft or compressible materials are not deformed. The disadvantage is that non-tactile measuring cannot match the precision of touch probes and photoelectric scanning of linear encoder graduations.
To address the problem of how to measure sensitive components accurately, Heidenhain has introduced a new length gauge that ensures the tactile probe it carries imparts negligible force to the surface being inspected. It is a result of an extremely low measuring force curve between 0.01N and 0.07N over the 12 mm measuring range. If a pin were to replace the standard probe contact, the pressure would not be sufficient to burst a balloon. The METRO 1281 MW length gauge can, for example, safely inspect small plastic gears, glass objects, semiconductor wafers or polished medical components without scratching the surface. Transparent or reflective materials that can present difficulties when scanning optically can likewise be measured simply and exactly. High precision ball bearing guides are a core component of the METRO 1281 MW. The combination of these guides and high-precision photoelectric scanning achieves repeatability of less than 0.03 µm over the full measuring range. The length gauge system accuracy lies within ±0.2 µm. In addition to having a low measuring force, the unit features a Zerodur precision graduation with a 2 µm signal period. Zerodur has
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a thermal coefficient of expansion of almost 0 ppm/K in the 0°C to 50°C range, so ambient temperature effectively has no influence on expansion of the scale during normal operating conditions. www.heidenhaingb.com
Green light for difficult materials A new green light laser scanner for portable and fixed CMMs will give enhanced performance on highly reflective materials. The ScanR from represents the sixth generation of CMM-laser scanners from Perceptron, and is said to dramatically extend the range of engineering materials that can be laser-scanned, offering a significant customer advantage over red and blue laser scanners when scanning highly reflective and carbon fibre parts. Highly reflective materials such as machined aluminum and carbon fibre composites have always been a challenge for laser scanners, requiring part spraying with a powder coat, which severely inhibits its practical use on repetitive production parts.
The new generation of ScanR CMM Laser Scanner is said to solve many longstanding application problems associated with laser scanning. Performance improvements include an enhance dynamic range, with wider coverage of colour and reflectivity, the ability to scan more materials and improved accuracy thanks to a thinner laser line with a
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higher signal to noise ratio. ScanR integrates with Perceptron’s TouchDMIS metrology software, offering a simple one-touch scanning interface and allowing initial user setup using tactile-probe with subsequent sharing of the generated part coordinate system. Feature extraction from the generated point cloud allows automatic inspection of part features against nominal feature definitions selected from CAD. Production parts can be programmed to be inspected automatically with scanning zone and parameters adjusted per feature for data acquisition and cycle time optimisation. Perceptron’s CEO Jeff Armstrong said: “The launch of the new ScanR Universal CMM Laser Scanner extends our leadership position and fully exploits the business synergies of the COORD3 CMM and Next Metrology Software acquisitions executed earlier this year.” www.perceptron.com
Homogeneous scanning Top-Hat elements are often used as diffractive optical elements (DOEs) in order to produce a homogenous line using a dot laser. This method however leads to a decrease in the intensity distribution at the edge, across the width of the line. In contrast, the M-shaper DOE from Laser Components is said to be perfectly suited for a high homogeneity in all directions. It modifies a laser beam in such a way that the intensity at the edge is higher than at the centre of the element. The cross section of the intensity distribution resembles the capital letter M, giving this product its name. Using the M-shaper to scan across a line will produce the beam quality of a Top-Hat element in both the length and the width, resulting in optimal scanning performance. These results could not be achieved using either refractive or reflective elements. Laser Componetns has a range of standard, semi standard and custom designs. www.lasercomponents.co.uk
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Training on all Faro software, Delcam, Aberlink, Geomagic, onsite inspection services using arms and laser trackers www.manchester-metrology.co.uk Manchester Metrology Ltd Unit 12,Greenside Trading Centre, Greenside Lane, Droylsden, Manchester. M43 7AJ Tel:-01616378744 Fax:-01614250944