Coordinate Measuring Machine (CMM)
A Coordinate Measuring Machine (CMM) is a device used to measure the exact shape, size,
and position of a part in 3D space. It helps compare the actual dimensions of a part with the
required (ideal) dimensions.
It works by using a probe that touches the part and moves along three directions (X, Y, Z) to
measure and collect data.
Main Parts of a CMM:
1. Probe head and probe – This touches the part and detects its surface.
2. Mechanical structure – Allows the probe to move in 3 directions (X, Y, Z).
3. Displacement sensors – Measure the position of the probe.
4. Drive and control system – Moves the probe automatically.
5. Computer system – Records measurements and compares them with required values
using special software.
Working:
● The part to be measured is fixed on a table.
● The probe moves and touches different points on the surface of the part.
● Every time the probe touches the surface, its X, Y, and Z coordinates are recorded.
● These values are used to calculate size, shape, and geometric features like:
○ Flatness
○ Roundness
○ Cylindricity
○ Straightness
● The data is analyzed using the software to check whether the part meets the design
requirements.
Block Diagram:
Types of CMM:
1. Bridge Type
○ Most common type.
○ High accuracy.
○ Good for small to medium parts.
2. Cantilever Type
○ Open access on three sides.
○ Easier to load/unload parts.
○ Used for smaller components.
3. Gantry Type
○ Suitable for very large parts.
○ Common in aerospace and automotive industries.
4. Horizontal Arm Type
○ Used for measuring large flat parts like car bodies.
○ Less rigid than other types but has wider reach.
5. Portable CMM
○ Handheld and flexible.
○ Used for measuring parts that can’t be moved to a regular CMM.
Applications of CMM:
● Manufacturing industries – To check dimensions of machine parts.
● Automotive industry – For checking car parts like engines or body panels.
● Aerospace – For ensuring precision in aircraft components.
● Tool and die making – To inspect molds and dies.
● Quality control – To ensure products meet design standards.
Types of Coordinate Measuring Machines (CMM)
1. Cantilever Type
● The vertical probe moves along the Z-axis.
● It is supported by a cantilever arm that moves in the Y-axis.
● The arm can also move laterally in the X-axis.
● Advantage: Fixed table provides good accessibility to the workpiece.
● Disadvantage: Bending of the cantilever may reduce accuracy.
● Suitable for: Long, thin parts with smaller measurement ranges in other axes.
2. Moving Bridge Type
● Most widely used CMM type.
● The table is stationary; the bridge moves.
● Advantage: Reduces bending effects, offers better measurement accuracy.
● Disadvantage: Risk of yawing (or “walking”), which can reduce accuracy.
3. Fixed Bridge Type
● The bridge is rigidly attached to the machine bed and does not move.
● Advantage: Eliminates yawing, offers high rigidity and measurement accuracy.
4. Column Type
● Sometimes called a universal measuring machine.
● Has high rigidity and is very accurate.
● Used mostly in: Gauge rooms, not general inspection.
● Advantage: Exceptional precision.
5. Horizontal Arm Type
● Also called a layout machine.
● Has a moving horizontal arm, and the probe moves along the Y-axis.
● Advantage: Large, open workspace ideal for large parts.
● Used in: Automotive industry for measuring car bodies, panels, etc.
6. Gantry Type
● Uses four vertical columns to support overhead X and Y axes.
● The workpiece support is independent of X and Y axes.
● Advantage: Allows walking alongside large workpieces for easy measurement.
● Ideal for: Very large parts (e.g., in aerospace or shipbuilding).
CMM Controls
1. Manual Drive CMM
● The operator physically moves the probe along the machine axes.
● Measurements are shown on a digital readout.
● Data is recorded manually or printed.
● All calculations must be done by the operator.
● No automation or computer assistance.
2. Manual Drive with Computer-Assisted Data Processing
● The operator still moves the probe manually.
● The computer performs some calculations, such as:
○ Unit conversions
○ Geometry calculations (e.g., angles between planes)
● Eases the measurement process, but movement is not motorized.
3. Motor Drive with Computer-Assisted Data Processing
● Electric motors move the probe under the operator’s control (e.g., joystick).
● The computer handles:
○ Probe positioning
○ Geometric computations for feature assessment
● Provides higher efficiency than manual-only systems.
4. Direct Computer Control (DCC)
● Fully automated and motorized, like a CNC machine.
● Movements are controlled by a dedicated computer using a programmed sequence.
● The computer also handles all data processing and calculations.
● Requires part programming for automated inspection.
DCC CMM Programming Methods
1. Manual Leadthrough Programming
● The operator physically guides the probe through the desired inspection path.
● Points and surfaces are recorded into the machine's control memory.
● The program is later executed automatically by the CMM controller.
2. Offline Programming
● Similar to CNC programming.
● The program is written off-line using the part drawing.
● Then downloaded to the CMM controller for automatic execution.
● No need for manual probe guidance during programming.
TYPES OF PROBES
Two Main Categories:
1. Contact Probes
● Touch-Trigger Probe:
○ Detects probe deflection through a change in electrical resistance.
○ Sends a signal (often LED + sound) to indicate contact.
○ Records contact point in coordinate space.
○ Consists of: probe head, probe, and stylus.
● Analog Scanning Probe:
○ Remains in continuous contact with the part’s surface.
○ Ideal for measuring contours, curves, and complex surfaces.
○ Offers higher speed and better accuracy than touch-trigger probes.
2. Non-Contact Probes
● Used when the object is delicate (e.g., wax, clay, PCB) and may deform under contact
force.
● Laser Scanning Probe:
○ Projects a laser beam onto the surface.
○ Uses triangulation to determine location.
○ Offers high speed and precision.
● Video Probe:
○ Captures a digital image.
○ Measurements are based on pixel count from the image.
○ Can generate multiple data points in one video frame.
PROBE SYSTEM COMPONENTS
● Probe Head – Contains mechanism and electronics for movement & signal processing.
● Probe – Senses the surface (can be contact or non-contact).
● Stylus – Touches the object; comes in various shapes for different measurement tasks.
CALIBRATION OF CMM
● Purpose: Ensure accuracy along all axes (X, Y, Z).
● Tools:
○ Laser beam, Retroreflector, Beam Splitter
● Axes are calibrated to detect and correct:
○ Alignment errors
○ Squareness between axes
○ Probe movement errors
APPLICATIONS OF CMM
1. Automotive, machine tool, electronics, aerospace industries.
2. Inspection of tools, gauges, test equipment.
3. 100% inspection in aircraft and space vehicles.
4. Dimensional accuracy checks.
5. Assessment of:
○ Shape
○ Position
○ MMC (Maximum Material Condition)
6. Sorting components within tolerance.
7. Reducing downtime and cost in NC machine inspection.
ADVANTAGES OF CMM
● Faster inspection rate.
● High accuracy.
● Reduced human error.
● Lower operator skill requirement.
● Less fixture and maintenance cost.
● Faster setup, calculation, and recording.
● Eliminates need for multiple gauges.
● Reduces scrap and incorrect rejection.
● Decreases off-line analysis time.
DISADVANTAGES OF CMM
● Misalignment between table and probe.
● Probe runout (mechanical offset).
● Z-axis movement may not be perfectly perpendicular.
● X and Y axes may not be perfectly square.
● Possible digital system errors.
CAUSES OF ERRORS IN CMM
Mechanical & System Errors:
● Imperfect alignment of the table and probes.
● Probe runout and perpendicularity errors in the Z-axis.
● Guideway issues: straightness and perpendicularity affect accuracy.
● Probe-related factors:
○ Length of the probe (longer probes cause more deflection).
○ Calibration, repeatability, zero-point setting, and reversal errors.
● Digitization errors from the electronic system.
Environmental Errors:
● Temperature variation (of the CMM, specimen, and lab) affects measurement
uncertainty.
● Workpiece weight may deform the guideways if beyond maximum load.
● Translation errors: caused by scale division and straightness inaccuracies
perpendicular to axis.
● Perpendicularity error: occurs when the X, Y, and Z axes are not perfectly orthogonal.
Error Control Measures:
● Use master plates to calibrate before use.
● Keep probe length minimal to reduce deflection.