CMM
UNIT IV 9
LASER AND ADVANCES IN METROLOGY
Precision instruments based on laser-Principles-
laser interferometer-application in measurements
and machine tool metrology- Coordinate
measuring machine (CMM): need, construction,
types, applications- computer aided inspection
COORDINATE MEASURING MACHINE (CMM)
• With the advent of NC machine tools, the demand has
grown for means to support these equipment
• Growing need to have an apparatus that can do faster
first piece inspection - 100% dimensional inspection
• CMM plays a vital role in the mechanization of the
inspection process
• Relatively recent developments in measurement
technology
• Can even be used as layout machines before machining
and for checking feature locations after machining
• Also called measuring machines
CONTD..
• Consist of a platform on which the workpiece being measured
is placed and moved linearly or rotated
• A probe attached to a head capable of lateral and vertical
movements records all measurements
• They are equipped with digital readout or can be linked to
computers for online inspection of parts.
DEVELOPMENTS IN CMM
• 1950s:
– Utilization of diffraction gratings to measure movement
of m/c table
– Application of friction free linear bearings to m/c slides
for automatic control
• Later developments:
– Replacement of tapered probe with touch trigger probe
– Application of computers to control, compute and record
• Low friction air bearings, mounting for vibration
isolation, counter balance for over-hanging arm
DESCRIPTION
• CMMs are built rigid and are very precise.
• Versatile in their capability to record measurement of
complex profiles with high sensitivity (0.25 μm) and
speed
• These machines can be placed close to machine tools
for efficient inspection and rapid feedback for correction
of processing parameter before the next part is made.
• They are also made more rugged to resist environmental
effects in manufacturing plants such as temperature
variations, vibration and dirt.
FEATURES
• To give maximum rigidity to machines without excessive
weight, all the moving members, the bridge structure, Z-axis
carriage, and Z-column are made of hollow box construction
• A map of systematic errors in machine is built up and fed into
the computer system so that the error compensation is built
up into the software
• All machines are provided with their own computers with
interactive dialogue facility and friendly software
• Thermocouples are incorporated throughout the machine and
interfaced with the computer to be used for compensation of
temperature gradients and thus provide increased accuracy
and repeatability
MAIN STRUCTURE
• The machine incorporates three coordinate axes so that
precise movement in x, y, and z directions is possible
• Each axis is fitted with a linear measurement transducer
• The transducers sense the direction of movement and
gives digital display
• Basic configurations:
– Cantilever
– Bridge Type
– Column Type
– Gantry
– Horizontal
Gantry
CANTILEVER
• This construction combines easy access and relatively
small floor space requirements.
• It is typically limited to small and medium sized
machines.
• Parts larger than the machine table can be inserted into
the open side without inhibiting full machine travel.
BRIDGE
• This arrangement over the table carries the quill (z-axis) along
the x-axis and is sometimes referred to as a travelling bridge.
• This construction provides better accuracy, although it may
be offset by difficulty in making two members track in perfect
alignment.
• This is by far the most popular CMM construction.
COLUMN TYPE MACHINE
• Commonly referred to as a universal measuring machine
rather than a CMM.
• These machines are usually considered gage room
instruments rather than production floor machine.
• The constructional difference in column type with the
cantilever type is with x and y-axes movements.
GANTRY TYPE
• In this arrangement, arms are held by two fixed supports
• Other two arms are capable of sliding over the supports
• This is particularly suited for very large components and
allows the operator to remain close to the area of
inspection.
HORIZONTAL ARM
• The open structure of this arrangement provides optimum
accessibility for large objects such as dies, models, and car bodies
• Some horizontal arm machines are referred to as layout machines
• In some horizontal machines the probe arm can rotate like a
spindle to perform tramming operations
Mounting Options Bearings
• no-contact air bearing and
• Benchtop • hard contact bearings
• Freestanding
• Handheld
• Portable Drives
• Linear Motor Drive
• Leadscrew Drive
• Friction Drive
• Belt Drive
• Rack-and-Pinion Drive
PROBING SYSTEM
• It is the part of a CMM that sense the different parameters
required for the calculation.
• Appropriate probes have to be selected and placed in the
spindle of the CMM.
• Originally, the probes were solid or hard, such as tapered
plugs for locating holes.
• These probes required manual manipulation to establish
contact with the workpiece, at which time the digital display
was read.
• Nowadays, transmission trigger-probes, optical transmission
probes, multiple or cluster probes, and motorized probes
are available.
INDUCTIVE TRANSMISSION PROBES
• Inductive and optical transmission
probes have been developed for
automatic tool changing.
• Power is transmitted using
inductive linking between
modules fitted to the machine
structure and attached to the
probe.
• The hard-wired transmission
probe shown is primarily for tool
setting and is mounted in a fixed
position on the machine
structure.
OPTICAL TRANSMISSION PROBE
• It allows probe rotation between gaging moves,
making it particularly useful for datuming the probe.
• The wide-angle system allows greater axial
movement of the probe and is suitable for the
majority of installation.
MOTORIZED PROBE
• With the motorized probe, 48 positions in the horizontal
axis, 15 in the vertical axis can be programmed for a
total of 720 distinct probe orientations
• It shows that with a range of light weight extensions, the
head can reach into deep holes and recesses.
• The second diagram shows that head of the probe is
sufficiently compact to be regarded as an extension of
the machine quill.
• This enables the inspection of complex components that
would otherwise be impossible or involve complex
setups.
MULTIPLE STYLUSES PROBE HEADS
• Wide ranges of styli have been developed to suit many
different gaging applications.
• The selection of stylus is done based on the application
for which the probe is to be used.
MACHINE CONTROL AND COMPUTER
HARDWARE
• The control unit allows manual measurement and self
teach programming in addition to CNC operation.
• The control unit is microprocessor controlled.
• Usually a joystick is provided to activate the drive for
manual measurement.
SOFTWARE
• In a CMM, the computer and the software are an inseparable
part.
• They together represent one system. The efficiency and cost
effectiveness of a CMM depend to a large extent on the software.
SOFTWARE FOR 3D GEOMETRY ANALYSIS
The features that the CMM software should include :
• Measurement of diameter, center distances, lengths, geometrical
and form errors in prismatic components, etc.
• Digital input and output commands for process integration.
• Parameter programming to minimize CNC programming time of
similar parts.
• Program for the measurement of spur, helical, bevel and hypoid
gears.
• Online statistics for statistical information in a batch.
• Measurement of plane and spatial curves.
• Data communications.
• Interface to CAD software.
CMM IN CAM
• CMM is a very essential and useful tool in CAM.
• The old standards in communication in CAM were capable of
only unidirectional communications - whether the design
conforms to the specification could not be known from these
standards.
• Dimensional Measurement Interface System (DMIS) is a new
standard in communication used in CAM.
• It provides a bi-directional communication of inspection data
between manufacturing systems and inspection equipment
to see what has to be made and what has been made.
• CMMs enable DMIS bi-directional communication.
CNC MACHINE TOOL, CAD SYSTEM AND A
CMM - INTERRELATION
CONTD..
• The data-collecting unit in a CMM is the probe - selection of
probe and its positioning is very crucial.
• Instructions must be given to CMM system of the speed for
positioning the probe, the path to be followed by the probe, angle
at which the probe approaches etc.
• After a part has been produced on the CNC machine, finished part
would be checked on a CMM with its inspection program.
• Then, the data about the checked part is sent back to the
computer, where the original part geometry is stored.
• The part geometry as designed is compared with the part
produced and the resultant deviation could be identified.
• It helps in identifying problems in manufacturing.
TAKING MEASUREMENTS WITH CMM
• Basic concept: Measure the shape and dimensions of the
measurand and compare the measurements with the desired shape.
• As a last step the data is post processed and displayed to the user.
Probe calibration
• Before a part can be measured the stylus needs to be calibrated with
a metrology artifact. For a 3D probe head the artifact is typically a
cube or a sphere of known dimension.
• The calibration procedure relates the probe dimensions to the
measurements taken by the machine and later allows the computer
to back out the actual part dimensions.
CONTD..
• Defining a part coordinate frame
• Taking measurements
CONTD..
• Processing and evaluating the measurements
SPECIFICATIONS
• X,Y,Z measurement • Mounting Options
length • Probe/Sensor type
• Resolution • Operation
• Workpiece weight • Application
• Control features
• General
applications
ADVANTAGES
Flexibility
• CMMs are essentially universal measuring machines and need not be
dedicated to any particular task
• They can measure almost any dimensional characteristic of a part
configuration, including cams, gears and warped surfaces.
• No special fixtures or gages are required
• Because probe contact is light, most parts can be inspected without
being clamped to the table
Reduced Setup Time
• Part alignment and establishing appropriate reference points are very
time consuming with conventional surface plate inspection techniques
• Software allows the operator to define the orientation of the part on
the CMM, and all subsequent data are corrected for misalignment
between the parts-reference system and the machine coordinates
CONTD..
Single Setup
• Most parts can be inspected in a single setup, thus eliminating the need
to reorient the parts for access to all features.
Improved Accuracy
• All measurements in a CMM are taken from a common geometrically
fixed measuring system
• This eliminates the introduction and the accumulation of errors that can
result with hand-gage inspection methods and transfer techniques.
Improved Productivity
• The above-mentioned advantages help make CMMs more productive
than conventional inspection techniques.
• Furthermore, productivity is realized through the computational and
analytical capabilities of associated data-handling systems, including
calculators and all levels of computers.
CONTD..
Reduced Operator Influence
• The use of digital readouts eliminate the subjective interpretation
of readings common with dial or vernier type measuring devices.
• Operator “feel” is virtually eliminated with modern touch-trigger
probe systems, and most CMMs have routine measuring
procedures for typical part features, such as bores or centre
distances.
• In computer assisted systems; the operator is under the control of
a program that eliminates operator choice.
• In addition, automatic data recording, available on most machines,
prevents errors in transcribing readings to the inspection report.
• This adds upto the fact that less skilled operators can be easily
instructed to perform relatively complex inspection procedures.
KEY WORDS
• Tramming: Refers to indicating a cylindrical surface of a part in such a
manner as to centralize the surface with the spindle of the machine.
• Stylus: A pointed instrument used as an input device in the probe of a CMM.
• Axial Length Measuring Accuracy: It is defined as the absolute value of the
difference between the reference lengths of gauges, aligned with a machine
axis, and the corresponding measured results from the machine.
• Length Measuring Accuracy: It is defined as the absolute value of the
difference between the calibrated length of the gauge block and the actual
measured value.
• Probe: It is the sensory part of a CMM responsible for sensing different
parameters required for the measurement.
• DMIS: Dimensional Measurement Interface Specification is a new standard in
communication being used in CAM. It provides a bi-directional
communication of inspection data between CAD system and inspection
equipment so as to see what has to be made and what has been made.
COMMON APPLICATIONS
• Dimensional measurement
• Profile measurement
• Angularity or orientation
• Depth mapping
• Digitizing or imaging
• Shaft measurement