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Dimension Measurementof Test Disks for RDDSl
KEK
YWATANABE
1. Measurement method
l ZEISS CMM General view , specification etc.
2. Performance of CMM measurement
3. Measurement procedure of test disks
4. Typical measurement results
& comparison to SLAC contour measurement
5. Results
6. Discussion
n
ZEISS UPMC-850 CARAT
l Measurement volume
X axis 850mm, Y axis 1200mm , Z axis 600mm
l Maximum weight
1500kg
l Measurement accuracy (VDI / VDE 2617)
Every axis Ul 0.5+L / 900 pm =+ -0.5 pm /60mm
Space u3 0.8+L / 600 pm
l Probe head
Universal probe head
l Probe(for Universal probe head)
Diameter 4 lmm
Length 16mm
l CNC program
From alignment to measurement & data output
Measurement of reference gauges1. Block gauge
*Industrial standard gauge grade 00
(JIS grade00 6Ot-0.00012 Parallelism 0.00006)
* CMM agreed within 1 pm in X,Y
2. Reference cylinder (made of copper)
* Made by KEK
* OD @61.000 ID @ 22.000
* KEK CMM agreed with Mitsutoyo within 0.6 pm
* Want to compare with SLAC CMM
Should be studied once more after maintenance of CMM
1. Measurement of Block Gauges (Probe @ 3,pressure 0.2N)
Gauges length z X Y
60mm 60.0017 60.0009 60.0003t- 0.00015 * 0.0002 -t 0.0003
z-z x-x Y-Y
1 1 1 1
2. Measurement of Reference Gauges
Made by
KEK
KEK
KEK
REFl
REF2
REF3
oD(61.000/zo”c) ID(Z1.996/20°C)
KEIK-CMM Mitsutoyo KIZK- CMM Mitsutoyo
20°C 19.8”C 20°C 19sc
61.0023 2 1.9969
to.1 kO.1
61.0013 21.9991
61.0017 61.0013 21.9985 2 1.9990
to.1 61.0012 to.1 21.9991
61.0013 21.9992
61.0018 61.0014 21.9993 21.9993
kO.2 61.0014 -to.1 21.9991
Disk measurement method1. Temperature
* Room temperature 20°ct2”c
* Disk surface temperature (Before & after CMM all+O5”c)
2. Measurement condition* Probe diameter 4 lmm
* Probing pressure 0.2N(variable 0.05N to 1N)
* Probing speed lmm/sec(set at almost minimum)
3. Probe calibration* Calibration sphere Ceramics 4 15 6 points calibration
Vacuum chuck
.
.
.
Material A15052
Vacuum area 4x46 Pressure -1kg
Disk does not move by proving (Pressure>>Probing Pressure)
Top surface is machined by Ultra-precision lathe before each batch
Merit 1. Stability of disk against pressure
2. Less distortion due to fixing
3. Full of experience in turning lathe machining
1. The thickness cannot be measured directly
2. Both sides cannot be measured at once
. Demerit
n
Measurement process of rough machining disk
Alignment
HOM @
HOM @
Measurement
. OD
. P- 2a
* Zb(Z-0.1)
* k!l
- !s* HOM 0 d
. HOM 0 d
. HOM @ d
* HOM @ d
. Slit 0 3mm
1.5mm
h
. Slit 0 3mm
1.5mm
h
* Slit 0 3mm
1.5mm
h
. Slit @ 3mm
1.5mm
h
. Slit 0 Depth +-
* Slit @ Depth +-
. Slit @ Depth t -
. Slit 0 Depth -+
SURFACE
CIRCLE
CIRCLE
CIRCLE
4point
4point
3point
3point
ZEROPOINT,TR.SPACE
ZEROPOINT
ADR PROG23
CIRCLE 4point
POINT 4point (Surface of
CIRCLE 4point Vacuum Chuck)
CIRCLE lpoint
POINT 4point
POINT lpoint
CIRCLE 4point
CIRCLE 4point
CIRCLE 4point
CIRCLE 4point
POINT Zpoint
POINT Zpoint
POINT lpoint
POINT Zpoint
POINT Zpoint
POINT lpoint
POINT Ppoint
POINT 2point
POINT lpoint
POINT Spoint
POINT Ppoint
POINT lpoint
POINT +- lpoint
POINT i: lpoint
POINT t lpointPOINT * lpoint
-3-
III CMM measurement point (rough cut cell!
Xaxts
-
Measurement process of final machining disk
Alignment
HOM @
HOM 0
SURFACE
CIRCLE
CIRCLE
CIRCLE
lpoint
lpoint
lpoint
4point
ZEROPOINT,TR.SPACE
ZEROPOINT
SYMMETRY
ADR PROG23
. OD
* P. 2a
. 2b(Z-0.1)
* Zb(Z-0.3)
. g1
. @
. Slit @ Depth
. Slit 0 Depth
. Slit @ Depth
. Slit 0 Depth
CIRCLE 4pointPOINT lpoint
CIRCLE lpoint
CIRCLE 4point
CIRCLE 4pointPOINT lpoint
POINT lpoint
POINT 2pointPOINT 2point
POINT Spoint
POINT 2point
L%lrface of
Vacuum Chuck)
-4.
Xaxis
Vccwm cnuch
Time of measurement
* Setting 5 minutes
* Edit of program 2h / 1 type
* Alignment 1 Rough : 20 minutes / disk
and
Measurement Final : 10 minutes / disk
* Output data 2 minutes
Comparison of typical data of #102,#153Those taken by KEK and SLAC
a,b,gLgWDall consistent within 2-3 pm
except #102B
12
-B11
10
9
8
7
E
5:b
L
tY
1
t
-.___. ;,___. ---
ILI I I I I I
I- 4 - 3 - 2 - 1 0 1
121.9,bm Nom. curve : Act. curve: Tolerance y.
Dscrptlon: RODS TEST CELL X102 Element : PROFILE-CURVSer. No. : TEST/003 File No. : x**)c% Department: MET-06Qcustomer : JUWEN WAN6 Draw. No.: PF-290-287-39 E
X Y Z Nr.Farm . . . . . . . . . 0.01313 Min. Deviat.: -0.00848 0 . 6 3 2 5 . 7 9 0 0 . 0 0 0 7 9Lower Toler. :-0.00400 Max. Deviat.: 0 a00464 -1.467 10.154 0.000 157Upper Toler. : 0.00400Error Magnif.: 30No. of points: 168
M E TInspectionSLAC Department- 060 -Established 1962
-----53.1999 5:17Ptl SLAURRD-Q 650 926 5368 NO.409 P.2
,21.9-,.m Nom. curve :
:Talerance :---------
Dscrptlon; RODS Xst CELL +I53 - ; i ~Elemnt : PRoFILEJUR~
SBr. NO. : T-NO.1JUWCN HAF&
File No. :, ?t-wrX ;, oepartment:'HEl~Ol3QCustolner : Draw. No.: PF-290~2/37-?$ E
,;. ..,;k Y- . . z NP.
Form * 0.61678 Min. Oeviat.: -0.Oi40E1 ,, ib.644 2,868 -3.734 e8e . , . . . . . .Lower Toler. :-0.00400 Wax. Oeviat.! ‘.Q .00270 A ise, . 3.612 -4.702 ii5Upper .Toler. : 0.00400Error Hagnif.: :. 30No. of.points: _. ice-. I' .
. .
c4
gw
5
434;--
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Concentricity of 2a,2b with respect of OD
‘center point of OD, 1 . . . .I. ._ .“,-.~*~-
P.I^ .” . _. ., ,. ._ . . .., ̂,. I_ ,._
I
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ceriter point of 2a.I_I___..-.^ ^~,._iI.._.. .~ .^ ...^.....I _._ +-)&)&.
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! -0.004
:enter point of 2b(O.l)
0.004 cb
0.002 c
L---h-o.bos -0.004
!0.004 O.o;oS
-0.002 1
-0.004 i
..,__ ""-.. " ._ .", -. +-j&j& L . ". _.^ ..^. __ ..^
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TA 0 . 0 0 66.-:F 0 . 0 0 4f:iigE 0 . 0 0 2
-0.002
TESTRDDS gl (final)
Most data are with larger than design by 4 to 10 microns.
l gl -x+n gl -Y+
/ A d - X -l & J ,
Cell No.
,.
I..
,.
40 l-801
“6-601
C-IL-EOZ
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1 %
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- et-100
1 qz-100
-2.96
-2.97
-2.98
z -2.992$ - 3
8u -3.01
-3.02
-3.03
-3.04
-3.05
TESTRDDS depth of 3mm slits (final) Slit are with +20um except #102 rough machined diskThose may change due to final machining
---- 6 depl-1n depl-2
A dep2-1l dep2-2m dep3-1
l dep3-2o dep4-1A dep4-2
Cell No.
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0p :
.-s :...........:“’/...........>;._...........
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TESTRDDS-3mm slit width(rough=final)
Scattering is within Z!I 1 Oum for each lot
3.01
z25 3s?3
2.99
.2 . 9 8 .. . . . . . t . . . . . . Tt . . . . ~.:.:.-- . . .. 2Tr . . ...‘... ~.2...‘P*...‘..m .. . . . ...’
2 . 9 7
-t slit3-1 W
+- slit3-2W-+ slit3-3W
slit3-4W
0.04
0.03
0.02
0.01
t-0.03
-0.04
-0.05
-0.06
Position of 3mm slits
Within ?I 1 OumThose #102 may be due to training stagein CMM or machining?
6 slit3 ldiff axis
w slit3-2diff axisA slit3-3diff axis
slit3 4diff axis
cell No.
..........................
...........................
I..............................
.......................
...._......
.......................
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.......................
.......................
- “!xO
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- "8431
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1 “P-ZGO
~
ez-ZGO
.“11-100
If “6-100
j
eL- 100
“z;- 100
“E- 100
--t
“C-100
0.04
0.03
0.02
0.01
z‘i: 08
a=O -0.01B5gj -0.02
ii
-0.03
-0.04
-0.05
-0.06
Position of 1.5mm slits
Same as 3mm slit_._ __.. _-..-..- .__ . .._. _. .^ . ..,,.. ,.- ., .__ ..~ .._ _ ._.: . . . ..-- .._ . -.- -.
4 slitl.5-1 diff axisn slitl.5-2diff axisA slitl.5-3diff axis
slitl.5-4diff axis
-2.98
- 3
-3.02
zY8= -3.04
-3.06
-3.08
TESTRDDS-3mm slits depth(as of rough machining) Slit are within + 20um except #102 rough machined diskthose may change due final machining
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*.........................................................................................*.........................*...*.........*......................................................l depl-1
n depl-2
dep2-1
dep2-2
⌧ dep3-1
l dep3-2
-t dep4-1
- dep4-2
Cell No.
Conclusion
1. We can measure disk using ZEISS at KEK
with precision of about 1 pm in diameter , width , depth etc.
2. Precision of thickness measure is bad. About several pm
3. One disk can be measured using the present method
in 2-hours programming and O.&hour measurement for
rough and final in total
Development of the measuring RDDSl
fl We need to establish a fixture by
Re-designing the chuck to measure thickness
Studying of fixture to set disk vertically
To precisely measure thickness
To measure both sides at once
fl Software for 200 different disks
Present CMM is Difficult to edit program for each discrete data
Very time consuming to program
Should we investigate the usage of other machine?