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Mich Met Intro2009

Introduction to Michigan Metrology

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Mich Met Intro2009

  1. 1. 3D Surface MicroTexture/Wear Measurement, Analysis, Inspection Services <ul><li>Solving Problems related to “Squeaks, Leaks, Friction, Wear, Appearance, Adhesion…” </li></ul><ul><ul><li>Friction Control </li></ul></ul><ul><ul><li>Sealing / Fluid leakage </li></ul></ul><ul><ul><li>Component Wear </li></ul></ul><ul><ul><li>Noise, Vibration, Harshness </li></ul></ul><ul><ul><li>Sensor Failure </li></ul></ul><ul><ul><li>Surface Finishing </li></ul></ul><ul><ul><li>Component Appearance </li></ul></ul><ul><ul><li>Coating Adhesion </li></ul></ul><ul><ul><li>……… .. </li></ul></ul>Brake Rotor Surface Texture Michigan Metrology, LLC
  2. 2. <ul><li>About the Company: </li></ul><ul><li>Established in 1994 by Donald K. Cohen, Ph.D. </li></ul><ul><li>“ 1000’s of projects for 1000’s of companies” </li></ul><ul><li>20+ years focused on Surface Metrology </li></ul><ul><li>Chairman ASME/ANSI B46.1, National Standard </li></ul><ul><li>Co-inventor of the WYKO RST 3D Surface Profiler </li></ul><ul><li>15 patents/26 publications in optics and surface profiling </li></ul><ul><li>Former VP of Engineering, WYKO Corporation </li></ul>
  3. 3. <ul><li>Automotive and related applications: </li></ul><ul><li>Brake Noise .. Rotors/Pads </li></ul><ul><li>Fluid handling .. ABS/Fuel Control </li></ul><ul><li>Sensor Wear….. “Drive by Wire” Fuel level/Air Bag </li></ul><ul><li>Seal leakage ….. Cranks, Axles </li></ul><ul><li>Transmission… Gears/Clutches </li></ul><ul><li>Engine … Bearings, Bores, Pistons... </li></ul>Shaft Texture
  4. 4. <ul><li>General applications: </li></ul><ul><li>Biomedical … Implants/Stents/Wires </li></ul><ul><li>Materials… Films, Foils, Coatings, Paint </li></ul><ul><li>Finishing …. Plating/EP/Coating Quality </li></ul><ul><li>Printing ... Paper/Plates </li></ul><ul><li>Electronic ... Switches/Sensors </li></ul><ul><li>Optical .. Mirror inspection </li></ul>Polymer Film Hip Implants
  5. 5. WYKO NT8000 Vertical Scanning Interferometer (VSI) Instrumentation: 10 X
  6. 6. Measurement Capabilities: Measurement Area - 0.15mm x 0.1mm to 7mm x 5mm + w/Stitching Lateral Resolution - 2.5 microns - 20 microns Height Resolution – 6 nm / 0.2 nm Printing Plate Fuel Regulator Component
  7. 7. Analysis Capabilities: Surface: “The boundary that separates an object from another object, substance, or space…” Texture: “The composite of certain deviations that are typical of the real surface. It includes roughness and waviness…” X Y Z “ Surface Roughness”, Ra is the average of the absolute value of profile heights over a given length (area). L 2D 3D Surface Texture (Surface Roughness, Waviness and Lay) ANSI/ASME B46.1, 1995, American Society of Mechanical Engineers, NY, New York 10017.
  8. 8. “ Hard to reach areas” Problem : ABS component ball seat – high leak rate Solution : Quantify the texture / machining problems / coining problems. Measured Surface Failed Leak Test Passed Leak Test 0.5mm Sa = 60 (micro inch) Sa = 16 (micro inch) Applications:
  9. 9. <ul><li>Once the surface is measured, need to develop parameters .. etc. </li></ul><ul><li>Probably >100, 2D parameters introduced in the literature / standards over the years </li></ul><ul><li>Recently “S” Parameters – 3D parameters 14+ …. </li></ul><ul><li>The parameters quantify “information” </li></ul><ul><li>Height ----- “Amplitude parameters” (e.g. Ra, Sa) </li></ul><ul><li>Spatial ----- “Spacing parameters” (e.g. Sm) </li></ul><ul><li>Height & Spatial ----- “Hybrid parameters” (e.g. R  q, Str.) </li></ul><ul><li>Functional – “Bearing Area Curve” (e.g. Rpk, Rvv,Spk,Sk) </li></ul>Analysis Capabilities: Ra Rpk Rtm ARa ACV  q
  10. 10. “ Statistical Based” … Amplitude Parameters .. Rq, Rsk, Rku Calculate the “moments” of the distribution: (Sq) Rq = “RMS”, = (Ssk) Rsk = Skew , Skewness (Sku) Rku = Kurtosis = Analysis Capabilities:
  11. 11. Amplitude Parameters .. Rq, Rsk, Rku Application: Bearing issues, lubricant retention Mfg. Process, tool wear etc. Limitation No spatial information Analysis Capabilities: Rq=3, Rsk = 0, Rku=3, Gaussian Surface Rq=12, Rsk = -1, Rku=8, Negatively Skewed Rq=12, Rsk = 1, Rku=8, Positively Skewed Rq=4, Rsk = 0, Rku=1.5, Slowly Varying Rq=4, Rsk = 0, Rku=10, Extreme Peak/Valley
  12. 12. Quantify by parameters such as Rsk Problem : Plastic molded component – leak paths at sealing locations Solution : Quantify the component surfaces –refine the mold/process Non Contact – Soft Materials Leaking Sealing Surface Improved Mold/Process 1 mm Applications: Ssk < -2.00 Ssk ~ 0.00
  13. 13. Spacing Parameters Rsm, PCL Rsm = The Average of all Smi PCL= Peak Count Level...Threshold Peak = When profile intersects lower and upper PCL Pc = Peak Density....peaks/unit length Application: Coatings/appearance, sealing (with Rz) Mfg. Process (e.g. feed-rate / vibration, forming…) Limitation “ User” determined (arbitrary?) thresholds (sometimes set to Ra) Definition of a “crossing (with noise)” causes repeatability problems Analysis Capabilities: Sm4 Sm3 Sm2 Sm1 PCL Peak 3 Peak 2 Peak 1
  14. 14. Tradeoff parameters such as Ssk, Pc -- Symmetry and Spacing Problem : Optimize Clutch plate texture – shudder vs. durability Solution : Quantify the component surfaces –Define/Design the surface Sa not enough, needed parameters such as Ssk, Pc to control function. Quantify Texture – Surface Engineering Applications:
  15. 15. Hybrid Parameters...Slope, R  q,  q (Sdq) R  q = 2  Rq/R  q Slope “ Average Wavelength Weighted By Amplitude”  q=4  q=2 Application: Appearance, coating application Dynamic surface interactions Limitation Very sensitive to measured lateral resolution Analysis Capabilities: Low  q High  q
  16. 16. Sa: In spec Sdq: Low Sa: In spec Sdq: High Quantify Texture – Process Control Problem : Brake Rotor Ra “inspec” …some work ..some have NVH issues Solution : Quantify the surfaces – Spec additional texture parameters  q Solution : Identify cause of texture variation..(materials? tools? setup?) Applications:
  17. 17. “ Functional” Bearing Area Parameters .. Rpk, Rk Rvk.... (Spk) Rpk = “Peak Height” .. First Region of contact (Sk) Rk = “Core Height”... “working” Region ..”Base” (Svk) Rvk = “Valley Depth” ... “Lubricant Retention Region” Mr1 = “1st Material Ratio”... “Peak Material” Mr2 = “2nd Material Ratio” ... “Valley Material” V 0 = Rvk(100-Mr2)/200......”Retention Volume” Application: Bearing systems, machining operations, wear studies, Lubricant issues Limitation No spatial information Analysis Capabilities: D C B A t p = 100% x (A + B + C + D )/L t p Peaks “ Core ” Valleys 100% 50% 0% Min Ht Max Ht 40% Rvk Rk Rpk Mr1 Mr2
  18. 18. Bearing Area Analysis: Lube Retention - Svk Load Distribution- Spk Quantify Texture – Cylinder Bore Honing Process Control Applications:
  19. 19. Problem : Warranty….Excessive wear/field failure Solution : Quantify the component surfaces – Solution : Quantify the wear rate under test Profile Along Worn Contact Fuel level Sender Wear EGR Sensor Wear Quantify Wear Wear Depth = 12 um Applications:
  20. 20. Full Conventional Stylus Analysis, Cutoffs, etc. Plant Floor Correlation – Simulate Stylus Based Gages Applications:
  21. 21. Analysis Capabilities: The Next Generation – ISO 25178-2
  22. 22. <ul><li>Services Provided: </li></ul><ul><li>3D MicroTexture Measurement/Analysis (3DMA): </li></ul><ul><ul><li>Measure the surface in 3D at ~9 locations </li></ul></ul><ul><ul><li>Reports include, </li></ul></ul><ul><ul><li>Hardcopy: Report, Graphics, Spreadsheet, Reference Section/Glossary </li></ul></ul><ul><ul><li>Softcopy (CD): Report, Graphics (PowerPoint), Spreadsheet (Excel) </li></ul></ul>
  23. 23. <ul><li>Services Provided: </li></ul><ul><li>3D MicroTexture Measurement Inspection (3DMI) </li></ul><ul><ul><li>Measure the surface in 3D at ~3 locations </li></ul></ul><ul><ul><li>Reports include, </li></ul></ul><ul><ul><li>Hardcopy: Summary, Graphics, Spreadsheet, Reference Section/Glossary </li></ul></ul><ul><ul><li>Softcopy (CD): Summary(Word), Graphics (PowerPoint), Spreadsheet (Excel) </li></ul></ul>
  24. 24. <ul><li>Services Provided: </li></ul><ul><li>Surface Metrology Engineering Services (SMES) </li></ul><ul><ul><li>Training/Seminars </li></ul></ul><ul><ul><li>Expert Witness </li></ul></ul><ul><ul><li>Consulting </li></ul></ul>
  25. 25. 3D Surface MicroTexture/Wear Measurement, Analysis, Inspection Services Solving problems related to squeaks, leaks, friction, wear, appearance, adhesion… providing… Michigan Metrology, LLC
  • AmrHamad3

    Apr. 28, 2016
  • lala_suhaila

    Jul. 6, 2010
  • michmet

    May. 17, 2009

Introduction to Michigan Metrology

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