Experimental approach for the uncertainty assessment of 3D complex geometry dimensional measurements using computed tomography at the mm and sub-mm scales

The dimensional verification of miniaturized components with 3D complex geometries is particularly challenging. Computed Tomography (CT) can represent a suitable alternative solution to micro metrology tools based on optical and tactile techniques. However, the establishment of CT systems’ traceability when measuring 3D complex geometries is still an open issue. In this work, an alternative method for the measurement uncertainty assessment of 3D complex geometries by using CT is presented. The method is based on the micro-CT system Maximum Permissible Error (MPE) estimation, determined experimentally by using several calibrated reference artefacts. The main advantage of the presented method is that a previous calibration of the component by a more accurate Coordinate Measuring System (CMS) is not needed. In fact, such CMS would still hold all the typical limitations of optical and tactile techniques, particularly when measuring miniaturized components with complex 3D geometries and their inability to measure inner parts. To validate the presented method, the most accepted standard currently available for CT sensors, the Verein Deutscher Ingenieure/Verband Deutscher Elektrotechniker (VDI/VDE) guideline 2630-2.1 is applied. Considering the high number of influence factors in CT and their impact on the measuring result, two different techniques for surface extraction are also considered to obtain a realistic determination of the influence of data processing on uncertainty. The uncertainty assessment of a workpiece used for micro mechanical material testing is firstly used to confirm the method, due to its feasible calibration by an optical CMS. Secondly, the measurement of a miniaturized dental file with 3D complex geometry is carried out. The estimated uncertainties are eventually compared with the component’s calibration and the micro manufacturing tolerances to demonstrate the suitability of the presented CT calibration procedure. The 2U/T ratios resulting from the validation workpiece are, respectively, 0.27 (VDI) and 0.35 (MPE), by assuring tolerances in the range of +- 20–30 micro-m. For the dental file, the EN < 1 value analysis is favorable in the majority of the cases (70.4%) and 2U/T is equal to 0.31 for sub-mm measurands (L < 1 mm and tolerance intervals of +- 40–80 micro-m)

Comparison of surface extraction techniques performance in computed tomography for 3D complex micro-geometry dimensional measurements

The number of industrial applications of computed tomography (CT) for dimensional metrology in 100–103 mm range has been continuously increasing, especially in the last years. Due to its specific characteristics, CT has the potential to be employed as a viable solution for measuring 3D complex micro-geometries as well (i.e., in the sub-mm dimensional range). However, there are different factors that may influence the CT process performance, being one of them the surface extraction technique used. In this paper, two different extraction techniques are applied to measure a complex miniaturized dental file by CT in order to analyze its contribution to the final measurement uncertainty in complex geometries at the mm to sub-mm scales. The first method is based on a similarity analysis: the threshold determination; while the second one is based on a gradient or discontinuity analysis: the 3D Canny algorithm. This algorithm has proven to provide accurate results in parts with simple geometries, but its suitability for 3D complex geometries has not been proven so far. To verify the measurement results and compare both techniques, reference measurements are performed on an optical coordinate measuring machine (OCMM). The systematic errors and uncertainty results obtained show that the 3D Canny adapted method slightly lower systematic deviations and a more robust edge definition than the local threshold method for 3D complex micro-geometry dimensional measurements