Economic benefits of metrology in manufacturing

In streamlined manufacturing systems, the added value of inspection activities is often questioned, and metrology in particular is sometimes considered only as an avoidable expense. Documented quantification of economic benefits of metrology is generally not available. This work presents concrete examples from industrial production, in which the added value of metrology in manufacturing is discussed and quantified. Case studies include: general manufacturing, forging, machining, and related metrology. The focus of the paper is on the improved effectiveness of metrology when used at product and process design stages, as well as on the improved accuracy and efficiency of manufacturing through better measuring equipment and process chains with integrated metrology for process control

Verification of a CT scanner using a miniature step gauge

The work deals with performance verification of a CT scanner using a 42mm miniature replica step gauge developed for optical scanner verification. Errors quantification and optimization of CT system set-up in terms of resolution and measurement accuracy are fundamental for use of CT scanning in dimensional metrology. Influence of workpiece orientation, magnification, source-object-detector distances and surface extraction method on metrological performances of a CT scanner was evaluated. Results show that the position of the workpiece in the CT cabinet is fundamental to get reliable measurements, while the highest magnification (best resolution) does not assure the best accuracy

Fatigue properties of Ti6Al4V cellular specimens fabricated via SLM: CAD vs real geometry

Abstract Fully dense titanium alloy implants have long been used for the replacement and stabilization of damaged bone tissue. Nevertheless, they can cause stress shielding which brings to a loss of bone mass. Additive manufacturing (AM) allows obtaining highly porous cellular structures with a wide range of cell morphologies to tune the mechanical properties to match that of the patient's bone. In this work, the fully reversed fatigue strength of cellular specimens produced by Selective Laser Melting (SLM) of Ti-6Al-4V alloy was measured. Their structures are determined by cubic cells packed in six different ways and their elastic modulus is roughly 3GPa to match that of trabecular bone. Part of the specimens was left as sintered and part treated by Hot Isostatic Pressing (HIP). The fatigue resistance of such AM parts can be affected by surface morphology, geometrical accuracy as well as internal defects. Micro X-ray computed tomography (CT) was used in this work to compare the geometry of the produced specimens with the CAD model and to carry out residual stress measurements using the Plasma FIB-SEM-DIC micro-hole drilling method

Measurement of micro moulded parts by Computed Tomography and comparison to optical and tactile techniques

This paper focuses on dimensional verification of two micro-injection moulded components, selected from actual industrial productions, using CT metrological tools. In addition to CT scanning, also a tactile Coordinate Measuring Machine (CMM) with sub-micrometre uncertainty and an Optical Coordinate Measuring Machine (OCMM) allowing fast measurements suitable for in-line quality control were employed as validation instruments. The experimental work carried out and the analysis of the results provide valuable conclusions about the advantages and drawbacks of using CT metrology in comparison with CMM and OCMM when these techniques are employed for quality control of micro moulded parts

generalization of profile texture parameters for additively manufactured surfaces

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A Testpart for Interdisciplinary Analyses in Micro Production Engineering

AbstractIn 2011, a round robin test was initiated within the group of CIRP Research Affiliates. The aim was to establish a platform for linking interdisciplinary research in order to share the expertise and experiences of participants all over the world. This paper introduces a testpart which has been designed to allow an analysis of different manufacturing technologies, simulation methods, machinery and metrology as well as process and production planning aspects. Current investigations are presented focusing on the machining and additive processes to produce the geometry, simulation approaches, machine analysis, and a comparison of measuring technologies. Challenges and limitations regarding the manufacturing and evaluation of the testpart features by the applied methods are discussed.Video abstrac

X-ray computed tomography for additive manufacturing: a review

In this review, the use of x-ray computed tomography (XCT) is examined, identifying the requirement for volumetric dimensional measurements in industrial verification of additively manufactured (AM) parts. The XCT technology and AM processes are summarised, and their historical use is documented. The use of XCT and AM as tools for medical reverse engineering is discussed, and the transition of XCT from a tool used solely for imaging to a vital metrological instrument is documented. The current states of the combined technologies are then examined in detail, separated into porosity measurements and general dimensional measurements. In the conclusions of this review, the limitation of resolution on improvement of porosity measurements and the lack of research regarding the measurement of surface texture are identified as the primary barriers to ongoing adoption of XCT in AM. The limitations of both AM and XCT regarding slow speeds and high costs, when compared to other manufacturing and measurement techniques, are also noted as general barriers to continued adoption of XCT and AM

Characterisation of the topography of metal additive surface features with different measurement technologies

The challenges of measuring the surface topography of metallic surfaces produced by additive manufacturing are investigated. The differences between measurements made using various optical and non-optical technologies, including confocal and focus-variation microscopy, coherence scanning interferometry and x-ray computed tomography, are examined. As opposed to concentrating on differences which may arise through computing surface texture parameters from measured topography datasets, a comparative analysis is performed focussing on investigation of the quality of the topographic reconstruction of a series of surface features. The investigation is carried out by considering the typical surface features of a metal powder-bed fusion process: weld tracks, weld ripples, attached particles and surface recesses. Results show that no single measurement technology provides a completely reliable rendition of the topographic features that characterise the metal powder-bed fusion process. However, through analysis of measurement discrepancies, light can be shed on where instruments are more susceptible to error, and why differences between measurements occur. The results presented in this work increase the understanding of the behaviour and performance of areal topography measurement, and thus promote the development of improved surface characterisation pipelines

Application of compact laser-driven accelerator X-ray sources for industrial imaging

X-rays generated by betatron oscillations of electrons in a laser-driven plasma accelerator were characterised and applied to imaging industrial samples. With a 125TW laser, a low divergence beam with 5.2±1.7 × 107photonsmrad−2 per pulse was produced with a synchrotron spectrum with a critical energy of 14.6±1.3keV. Radiographs were obtained of a metrology test sample, battery electrodes, and a damage site in a composite material. These results demonstrate the suitability of the source for non-destructive evaluation applications. The potential for industrial implementation of plasma accelerators is discussed