The Productivity Partners� Four companies and over 200 people supporting Upper

Midwest manufacturing:

Productivity IncProductivity Inc� Machine tools & tooling

Applied CIM TechnologiesApplied CIM Technologies� CADCAM Software & Tool management software

Productivity QualityProductivity Quality� Measurement equipment sales, support & calibration

Advanced Inspection ServicesAdvanced Inspection Services� Contract dimensional inspection services

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Productivity Quality

� Established in 1991 by Productivity Inc to provide a separate focus on dimensional measurement equipment� 45 Employees

� 3 Areas of product specialization1) Gaging and precision hand tools2) QA Capital equipment3) Machine tool probe systems

Advanced Inspection Services

� Established by Productivity Quality in 2000 to support:� Complete dimensional inspection

� Capability studies

� On-Site Inspection with portable CMM�s� CMM programming services

� Part digitizing, Reverse Engineering, CAD

ISO 17025 Accredited

Advanced Inspection Servicesis accredited by A2LA to the ISO/IEC 17025 standard for dimensional testing.

Why AIS?

� Reasons why companies outsource inspection to AIS:� To handle work-flow

� Need for an A2LA accredited lab

� Do not have the equipment for the job

� Do not have internal expertise for the job

How We Inspect� Different Parts Require Different Inspection

Equipment and Techniques:� Material?� Rigid or soft? (i.e. steel or silicon)

� Tolerance?� +/- .010� or +/- .0002�

� Geometry of part?� 2D flat part or complex 3D part� Size

� Print Requirements?� Standard dimensioning or advanced GD&T

Inspection Methods

� Four common methods of inspection:� Hand Tools� Caliper, Micrometer, etc.

� Surface Plate Set-up� Dial or Digital indicators

� Contact CMM� Touch Probe

� Vision CMM� Non-Contact Optical or Laser

Inspection Methods� Hand Tools (Caliper, Micrometer)

� Advantages� Quickly check certain characteristics

� Basic Inspector knowledge

� Disadvantages� Manual

� �1D� linear measurements only

� *External surfaces only

� Accuracy� Micrometers approx. +/- .0002�� Calipers approx. +/- .001�

Inspection Methods� Surface Plate Set-up (Dial and Digital Indicators)

� Advantages� Able to attain high level of accuracy

� �Old school� approved

� Disadvantages� Manual

� Very time-consuming

� Proper set-up and technique is critical

� *External surfaces only

� Accuracy� Dial indicators with resolution of .00005�

Inspection Methods� Contact CMM (Touch Probe)

� Advantages� Programmable, fully automatable

� 3D measuring capabilities

� Inspect to CAD (depending on CMM software)

� Disadvantages� Flexible Parts

� *Only external or probe accessible surfaces

� Accuracy� Bridge type CMM�s Approx. +/- .0003� (volumetric)

� Portable CMM�s Approx. +/-.001� to +/-.010�

Inspection Methods� Vision CMM (Optical and laser)

� Advantages� Programmable, fully automatable

� Inspect to CAD (2D)

� Disadvantages� Not fully 3D

� *Only external or �line of sight� accessible surfaces

� Accuracy� Approx. +/- .0003� (volumetric)

The Next Level� To Achieve Even Higher Levels of Accuracy

� Tighter Temperature Control � 68 +/- .5 Degrees Fahrenheit

� Due to Coefficient of Thermal Expansion

� Ultra-High Accuracy Equipment� Leitz PMM-C (Contact CMM)

� Approx. accuracy of +/- .6µm (equivalent .000024�)

� Mitutoyo Round Test� Approx. accuracy of +/- .2µm (equivalent .000008�)

� Mahr 828 Horizontal Measuring Machine � Approx. accuracy of +/- . 5µm (equivalent .000020�)

Inspection is Changing� Inspection Requirement are changing due to-

� Evolution of Manufacturing� Manufacturing more complex parts� Manufacturing tighter tolerance parts

� Inspection Standards Evolving� To address more complex parts � To increase accuracy of dimensional analysis

� Reducing rejection of �good� (functional) parts� Reducing acceptance of �bad� (non-functional) parts.

� Advancement of GD&T� (Geometric Dimensioning and Tolerancing)� Especially Profile of Line\Surface

Traditional Print

GD&T Print

Inspecting To CAD� Increasing Use of Profile Requires Ability to

Inspect to CAD

� Methods of Inspecting To CAD� CMM�s

� Software capable of inspecting to CAD

� Post-Process Inspection Software� Measure point set of part (CMM, Laser, etc)� Analyze point set in CAD inspection software

» Geomagic Qualify (Raindrop)» SmartFit 3D (Kotem)» MeasureFit 2D (Kotem)

Inspecting To CAD� Profile of surface requires complete analysis of

all specified surfaces� Increasing use of lasers and other methods of

acquiring large data sets quickly� Laser Scanners

� Fast point acquisition� Many different variations� *Line of sight acquisition

� White Light Scanners� Fast Acquisition� Able to achieve higher accuracy� Many different variations� *Line of sight acquisition

A Common Challenge

� What about internal features?� All methods discussed are unable to measure �unreachable� areas of a part (i.e. internal cores)

� Common Solution� Section the part to reach internal geometry

� Problems with sectioning part� Part is destroyed

� Part changes when sectioned� Features may dimensionally change when cut

� Could be minor or significant

A New Solution

� CT Reconstruction� Complete Part Acquisition� External and internal features

� Data is similar to laser or white light data� 3D

� Very dense point cloud or STL (polygonal) model� Able to be imported into CAD inspection software