rc metrology consulting [email protected]. what does it measure? know the uncertainty of your...
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What What does it does it
measure?measure?Know the Know the ununcertainty of your certainty of your CMM using a $10 calculator…CMM using a $10 calculator…
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Outside the BoxOutside the Box““So we fix our eyes So we fix our eyes not on what is seen, not on what is seen, but on what is unseen. but on what is unseen. For what is seen is For what is seen is temporary, but what temporary, but what is unseen is eternal…”is unseen is eternal…”
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Outside the BoxOutside the Box
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Outside the BoxOutside the Box 1 + 3 = 2² 1 + 3 + 5 = 3² 1 + 3 + 5 + 7 = 4² 1 + 3 + 5 + 7 + 9 = 5² 1 + 3 + 5 + 7 + 9 + 11 = 6² 1 + 3 + 5 + 7 + 9 + 11 + 13 = 7² 1 + 3 + 5 + 7 + 9 + 11 + 13 + 15 = 8² 1 + 3 + 5 + 7 + 9 + 11 + 13 + 15 + 17 = 9² 1 + 3 + 5 + 7 + 9 + 11 + 13 + 15 + 17 + 19 = 10²
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CMM game planCMM game planOrder it up…Order it up…We will establish a strategic, We will establish a strategic,
easy to implement, statistical easy to implement, statistical system to learn the certainty system to learn the certainty of any given CMM applicationof any given CMM application
Plan, Do, Check, Action…Plan, Do, Check, Action…
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Our Goal Our Goal To improve the measurement To improve the measurement
capability of our CMM by capability of our CMM by increasing the certainty of the increasing the certainty of the measurements we are measurements we are making.making.
This improvement may seem This improvement may seem to be very small.to be very small.
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Small Improvements Small Improvements The difference between a The difference between a
career in the Minor Leagues career in the Minor Leagues and the Baseball Hall of Fame and the Baseball Hall of Fame is only 1 more hit per week.is only 1 more hit per week.
A Baseball season is played A Baseball season is played April – September = 26 weeksApril – September = 26 weeks
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The Minor Leagues The Minor Leagues In a normal season a player In a normal season a player
will encounter 500 at-bats.will encounter 500 at-bats.125 hits in 500 at-bats…125 hits in 500 at-bats…125 / 500 = .250 batting 125 / 500 = .250 batting
average.average.Toledo MudhensToledo Mudhens
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Imagine if ??? Imagine if ??? If a player could get just 1 If a player could get just 1
more hit per week…more hit per week…151 hits in 500 at-bats…151 hits in 500 at-bats…151 / 500 = .302 batting 151 / 500 = .302 batting
average.average.The Hall of FameThe Hall of Fame
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Uncertainty???Uncertainty??? ISO-9000, QS-9000:1994, state: ISO-9000, QS-9000:1994, state:
“Inspection measurement and test “Inspection measurement and test equipment shall be used in a equipment shall be used in a manner which ensures that the manner which ensures that the measurement uncertainty is known measurement uncertainty is known and consistent with the required and consistent with the required measurement capabilitymeasurement capability.”.”
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Uncertainty???Uncertainty??? TS-16949: Recommends internal TS-16949: Recommends internal
inspection labs comply with ISO/IECinspection labs comply with ISO/IEC 17025…17025… “When estimating the “When estimating the uncertainty of a measurement, uncertainty of a measurement, all all uncertainty components which are uncertainty components which are of importance in the given situation of importance in the given situation shall be taken into accountshall be taken into account using using appropriate statistical methods of appropriate statistical methods of analysis.”analysis.”
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Uncertainty???Uncertainty???Doesn’t it?Doesn’t it?Can’t we?Can’t we?Right???Right???Isn’t it?Isn’t it?Don’t they?Don’t they?
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Uncertainty is:Uncertainty is:The upper estimated limit of The upper estimated limit of
how wrong a given reading how wrong a given reading (or value) can be.(or value) can be.
Kerry 53% Bush 47% (±4%)Kerry 53% Bush 47% (±4%)Kerry 57% Bush 43%Kerry 57% Bush 43%Bush 51% Kerry 49%Bush 51% Kerry 49%
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The The TrueTrue Value is: Value is:Always unknown and Always unknown and
unknowable unknowable (MSA 3(MSA 3rdrd edition) edition)
Average value taken from an Average value taken from an infinite number of readings.infinite number of readings.
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The Plug Gage The Plug Gage ParadoxParadox
Tell me what it measures: Tell me what it measures: Outside Diameter.Outside Diameter.
Caliper (.001”)Caliper (.001”) Micrometer (.0001”)Micrometer (.0001”) Bench micrometer (.00005”)Bench micrometer (.00005”) How many readings (1,3,9,12)How many readings (1,3,9,12)
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The Plug Gage The Plug Gage ParadoxParadox
Where do we measure? (on Where do we measure? (on the end or in the center)the end or in the center)
What if it’s not round (and it What if it’s not round (and it won’t be)won’t be)
Diameter ????????Diameter ????????
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The Plug Gage The Plug Gage ParadoxParadox
Because the measurement Because the measurement definition was not clearly definition was not clearly defined we will never be defined we will never be certain of our measured certain of our measured result.result.
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Measurement Measurement DefinitionDefinition
Micrometer .0001”Micrometer .0001”3 readings each end and 3 readings each end and
middle (Total n=9)middle (Total n=9)Report 9 reading average, Report 9 reading average,
minimum reading, and minimum reading, and maximum readingmaximum reading
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Standard DeviationStandard DeviationSigmaSigmaSpread of measurement dataSpread of measurement data
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Standard DeviationStandard Deviation
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Sample Data Sample Data CollectionCollection
Must be RANDOMMust be RANDOMAttempt to represent the Attempt to represent the
entire populationentire populationThe sample will always be a The sample will always be a
sample and display less sample and display less variation than the populationvariation than the population
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Sample and Sample and PopulationPopulationClock cars in a designated Clock cars in a designated
45mph speed limit zone45mph speed limit zone6 hours / 1 week = Ave, min, 6 hours / 1 week = Ave, min,
and maxand max24 hrs / 4 weeks = Ave, min, 24 hrs / 4 weeks = Ave, min,
and maxand max120 hrs / 26 weeks = Wow!120 hrs / 26 weeks = Wow!
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Probe calibration Probe calibration controversycontroversy
Define the measurementDefine the measurementProbe 9 points on 1” master Probe 9 points on 1” master
sphere: 8 points around sphere: 8 points around equator and 1 point on north equator and 1 point on north polepole
3 measurements / 25 days3 measurements / 25 days
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1” Sphere results1” Sphere results75 reading ave = .999878”75 reading ave = .999878”1 Sigma = .000088”1 Sigma = .000088”68% .999790” – .999966”68% .999790” – .999966”95% .999702 – 1.000054”95% .999702 – 1.000054”99.97% .999614 – 1.000142”99.97% .999614 – 1.000142”
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The HistogramThe Histogram
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0.99950 0.99960 0.99970 0.99980 0.99990 1.00000 1.00010 1.00020
Measurement
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Use the HistogramUse the Histogram
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0.99950 0.99960 0.99970 0.99980 0.99990 1.00000 1.00010 1.00020
Measurement
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Play the OddsPlay the Odds
0
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0.99950 0.99960 0.99970 0.99980 0.99990 1.00000 1.00010 1.00020
Measurement
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CMM game planCMM game planBefore we start measuring Before we start measuring
our parts we can measure our parts we can measure the 1” master sphere 3 times the 1” master sphere 3 times and compare our results to and compare our results to our Histogram.our Histogram.
Do we want to Do we want to order it up?order it up?
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Concentricity of a Perfect Concentricity of a Perfect PartPart
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Define the MeasurementDefine the Measurement5 point XY Baseplane5 point XY Baseplane12 point Cylinder as Z axis12 point Cylinder as Z axis9 point Circle (bottom) as XY 9 point Circle (bottom) as XY
origin and Datumorigin and Datum9 point Circle (top) as feature9 point Circle (top) as feature3 measurements / 25 days3 measurements / 25 days
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The HistogramThe Histogram
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Ring gage concentricityRing gage concentricity75 reading ave = .00015”75 reading ave = .00015”1 Sigma = .00009” 1 Sigma = .00009” 47.5% of the time (or + 2 47.5% of the time (or + 2
sigma) it measured worse sigma) it measured worse than .00015” (or as high than .00015” (or as high as .00024”)as .00024”)
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Another Look !Another Look !
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Uncertainty???Uncertainty???Can’t we just??? Can’t we just??? and then just say…and then just say…
Dropped partsDropped partsCan’t we just Can’t we just ignore gravity????ignore gravity????
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The Myth of “True” The Myth of “True” PositionPosition
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The Myth of “True” The Myth of “True” PositionPosition
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The Myth of “True” The Myth of “True” PositionPosition
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Define the MeasurementDefine the Measurement
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Define the MeasurementDefine the Measurement7 point XY Baseplane7 point XY Baseplane5 point X axis line5 point X axis line5 Point Y axis line5 Point Y axis lineXY origin at intersectionXY origin at intersection9 point circle (Z -.100”)9 point circle (Z -.100”)3 measurements / 25 days3 measurements / 25 days
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Where is the center???Where is the center??? Average .00092”Average .00092” 1 sigma of .00030”1 sigma of .00030” 68% of the time our value 68% of the time our value
obtained was between .0006” obtained was between .0006” and .0012” (.0006”)and .0012” (.0006”)
95% of the time our value 95% of the time our value obtained was between .0003” obtained was between .0003” and .0015“ (.0012”)and .0015“ (.0012”)
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.00092”
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95%95%
.0003”
.0015”
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References and References and AcknowledgementsAcknowledgements
MSA 3rd Edition MSA 3rd Edition by AIAGby AIAG
Mitutoyo of AmericaMitutoyo of America Cliff’s Quick Review - Algebra, Statistics, Cliff’s Quick Review - Algebra, Statistics,
and Geometryand Geometry ASME Y14.5-1994 ASME Y14.5-1994 Geometric Dimensioning Geometric Dimensioning
and Tolerancingand Tolerancing
H.E.S. Honda Engineering SpecificationsH.E.S. Honda Engineering Specifications DCC CMM Programming - Part Alignment DCC CMM Programming - Part Alignment
and Vector Points and Vector Points by Scott Beaversby Scott Beavers
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References and References and AcknowledgementsAcknowledgements
Technical Shop Math Technical Shop Math by John G. Andersonby John G. Anderson
Tooling and Production MagazineTooling and Production Magazine Modern Machine Shop MagazineModern Machine Shop Magazine Cybermetrics: GAGEtrak softwareCybermetrics: GAGEtrak software NWCI Calibration and InspectionNWCI Calibration and Inspection Nelson Precision - Nelson Precision - A Mitutoyo CompanyA Mitutoyo Company
Qualtech Tool and EngineeringQualtech Tool and Engineering Hower Tool - Ossian, IndianaHower Tool - Ossian, Indiana
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References and References and AcknowledgementsAcknowledgements
NWE/Foxconn - Santa Clara, CANWE/Foxconn - Santa Clara, CA Mitutoyo of AmericaMitutoyo of America SFC (Retired) Thomas J. Ravenell, SFC (Retired) Thomas J. Ravenell,
Ft. Bragg, NCFt. Bragg, NC
Dave Schwab - Dave Schwab - Nelson PrecisionNelson Precision
Terry Davis - Terry Davis - MitutoyoMitutoyo
Mike Dukehart - Mike Dukehart - MitutoyoMitutoyo
Jerry Guffy - Jerry Guffy - MitutoyoMitutoyo
James Vannoy - James Vannoy - CMM Technology, Inc.CMM Technology, Inc.
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References and References and AcknowledgementsAcknowledgements
Scott BeaversScott Beavers - CMM Resources - CMM Resources
Travis East - Travis East - Geometry 2.8 FreewareGeometry 2.8 Freeware
Dr. Bill McNeeseDr. Bill McNeese Dr. Henrik S. NielsenDr. Henrik S. Nielsen Gordan SkattumGordan Skattum My Wife, RamonaMy Wife, Ramona