Traceable in-process dimensional measurement

Short Name: TIM, Project Number: IND62
Factory 15

On machine in-process dimension measurement


Europe is the world’s largest producer and exporter of precision engineering production tools, such as cutting and milling machines. Millions of jobs in automotive and aeronautical manufacturing rely on these machines to reliably fabricate the complex components which underpin sophisticated products. The early identification of faulty components has the potential to increase productivity by 20%.

 

Many of the production machines incorporate measurement systems to confirm that components meet specification before they leave the machine. These measurement systems need periodic recalibration, where carefully controlled environments are used to eliminate the significant errors associated with shop floor temperature variations. Installed methods for confirming system performance on the machine itself would make measurements of complex shaped components more reliable and increase the early identification of parts nearing specification limits.

 

The EMRP project Traceable in-process dimensional measurement developed new reference materials and procedures for accurate, in-process calibration of installed measurement devices.

 

The project developed:

 

  • Temperature stable reference materials with well characterised and complex geometries to simulate the intricate shapes of precision components to provide in situ measurement system calibrations.
  • A portable climate simulation chamber, which can house a medium-size dimensional measuring machine, enabling evaluations of how changing temperature affects performance and measurement accuracy.
  • Validated procedures for determining machine tool positioning uncertainties using the new reference standards, as well as developing methods for making temperature-dependent error corrections to minimise measurement uncertainties.
  • Five best practice guides, which form the basis of a training course for industrial users on how to make measurements and determine factors that contribute to measurements uncertainty.

 

Spotting components that are nearing the edges of tolerance during the manufacturing process, and taking corrective action, relies on the ability to make continually accurate measurements. This in turn requires that instrument calibrations remain true and reliable, and that corrections matching environmental operating conditions are available for use. This project has given industry the tools and techniques needed to perform in situ calibrations of dimensional measurements, and verify that complex parts produced by machine tools meet specification. Companies in Finland and Slovenia have already benefited from project developments, giving improved accuracy for their manufacturing process measurements. Project procedures and investigations have also fed into new documentary ISO standards on geometric production tolerances, helping to improve dimensional measurements practices across Europe.

 

Robust on-machine measurement techniques will lead to more reliable and accurate measurements, enhancing machine productivity and reducing energy consumption by 30 %. Higher quality products and lower manufacturing costs will both help increase the competitiveness of European industry.

 

Coordinator: Klaus Wendt, PTB (Germany) 
For more information, please contact the EURAMET Management Support Unit:
Phone: +44 20 8943 6666
E-mail: msu@npl.co.uk

Project website
Publications
Calibrated CAD model of freeform standard
2016

21st IMEKO World Congress 2015 Measurement in Research and Industry

Assessing fringe projector volumetric error sources
2016

Proceedings of the 16th international conference of the european society for precision engineering and nanotechnology

Calibration of freeform standard
2015

Proceedings of the15th International Conference of the European Society for Precision Engineering and Nanotechnology

Calibration of grid plates bearing a high density of targets
2015

Proceedings of the 15th international conference of the european society for precision engineering and nanotechnology

Blowing hot and cold: temperature sensitivities of 3D optical scanners
2015

Proceedings of the 15th international conference of the european society for precision engineering and nanotechnology

DESIGN OF A MEASUREMENT STANDARD FOR MONITORING METROLOGICAL PERFORMANCE OF MACHINE TOOLS
2015

Proceedings of International Conference on Innovative Technologies IN-TECH2015

New Material Standards For Traceability Of Roundness Measurements Of Large Scale Rotors
2014

Proceedings of the 58th Ilmenau Scientific Colloquium

TRACEABLE IN-PROCESS DIMENSIONAL MEASUREMENT – European Metrology Research Programme, project No. IND62
2014

Proceedings 9th International DAAAM Baltic Conference - Industrial Engineering

TRACEABILITY FOR ROUNDNESS MEASUREMENTS OF ROLLS - European Metrology Research Programme, project No. IND62
2014

Proceedings 9th International DAAAM Baltic Conference - Industrial Engineering

Temperature-invariant material standard for monitoring performance of machine tools
2014

Journal of Trends in the Development of Machinery and Associated Technology

Other Participants
Daimler AG (Germany)
EMO - Orodjarna d.o.o. (Slovenia)
Fundacion Tekniker (Spain)
Gorenje Orodjarna, d.o.o., Velenje, Partizanska 12 (Slovenia)
Magnicon GmbH (Germany)
RollResearch International Oy (Finland)
Universidad de Zaragoza (Spain)
VEPLAS Velenjska Plastika d.d. (Slovenia)