alicona focusvariation3 e small resolution

The magazine about Alicona-m

etrology

InfiniteFocusSL

HOW TO MEASUREFORM ANDROUGHNESS WITH ONLY ONE SYSTEM

TRACEABLE

ROUGHNESS MEASUREMENT

Eng l i s h ed i t i o n 3 , 2 012 / 2013

FASTINTUITIVE

MEASUREMENT

OPTICAL 3D MEASUREMENT

IN PRODUCTION

2 alicona

InfiniteFocus X-Large

IF-EdgeMaster

IF-SensorR25

IF-ToolPrecisionIF-Portable

InfiniteFocusSL

alicona 3

Recommended: 3D measurement technologyWhich measurement technology should I use? Which device and which providerare the best choice for performing my measurement task?

In the age of multimedia and information overload, it is clear that especially thosesuppliers who were recommended the most, are also trusted the most. Thus,every year we have our customers speak for us and have them present our mea-surement systems including information about applications and benefits. The la-test statements are published in the new, third edition of FOCUSvariation.Common applications in different industries give an idea of where and how touse the Focus-Variation technology.

One aspect that our customers very often associate us with, is reliability. This cle-arly reflects the standards that our company sets itself. A large emphasize is puton being a dependable and competent partner, offering 3D measurement devi-ces that deliver reliable results. More than a mere determination of the "Ra" valueis necessary in order to generate added value from a measurement. For this rea-son our measurement systems enable easy automation, area based measure-ments as well as simple and intuitive operation. Users gain traceable andrepeatable results and benefit from multiple use at no additional cost. All Aliconameasurement systems for quality assurance in research and production arebased on these principles. This also applies to the new, quick InfiniteFocusSL sy-stem from the InfiniteFocus line. Come and see yourself how fast and simple 3Dmeasurement can be!

Maybe you will be the next one to recommend us.Yours faithfully,

Dr. Stefan Scherer, Alicona CEO

Dr. Manfred Prantl, Alicona CEO

InfiniteFocus

8 – 41 InfiniteFocus

8 – 9 System description

10 – 11 What makes InfiniteFocusdistinctive: Features

12 – 27 InfiniteFocus in use: References MakinoSuttonToolsCassidian (an EADS group) Komatsu Seiki KosakushoGF AgieCharmillesRohde & SchwarzProfinAtomic

28 – 31 Measurement modules based on Focus-Variation

32 Measure from every position: Technology of “Real3D”

33 InfiniteFocus Accessoires

34 – 35 InfiniteFocus X-Large Systems

36 – 37 Technical Specification: InfiniteFocus

38 – 39 InfiniteFocusSL: As fast and intuitve as 3D measurements can beNew profiler for fast, simple and traceable 3D surface measurement

JANUARY 2012/2013

12-27

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4 alicona

38

HOW TO MEASURE FORM ANDROUGHNESS WITH INFINITEFOCUS

Table of content

50-55

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61

TOOL MEASUREMENT

42 – 45 Measurement of drills, miller cutters, inserts etc.: IF-EdgeMasterSystem description, technical specification and case study

46 – 47 Measurement of hob cutters: IF-EdgeMasterHOBSystem description, technical specification and case study

48 – 49 Measurement of taps: IF-ToolPrecisionSystem description

QUALITY ASSURANCE

IN PRODUCTION

52 – 53 Stable 3D measurement in production: IF-SensorR25System description,technical specification

54 – 55 Measure micro structured surfaceson large components: IF-PortableSystem description, technical specification

TECHNOLOGY

58 – 59 Traceable roughness measurementsFocus-Variation as an ideal technique to measure roughness

59 – 60 Focus-VariationFunction & Features

61 Focus-Variation from the point of view of a tool research associationHeinz-Wolfgang Lahman (GFE) about Focus-Variation

62 AccessoriesGrips, standards and other accessories for all Alicona measurement systems

40

59

6 alicona I Form and roughness measurement

As fast and easy as 3D measurement can be

Form and roughness measurement I alicona 7

Measure form and roughnesswith only system » InfiniteFocus» InfiniteFocusSL

8 alicona I InfiniteFocus

THE SYSTEM

InfiniteFocus is an optical 3D measurement device that is universal, flexible and applicable in manyindustries. It combines the functionalities of a surface measurement system and a micro coordinatesystem in one measurement device. Even when measuring complex forms and large measurementareas, operators achieve a vertical resolution of up to 10 nm.

THE BENEFITS

Users perform high resolution measurements of even complex components with steep flanks andvarying material properties. This also applies to polished components or forms with small radii andangles. Every measurement provides color information registered to the 3D data.

THE APPLICATION

Typical applications are the cutting edge measurement of drills, milling cutters etc. as well as qualityassurance of micro precision components in the automotive industry, aerospace industry, medicaltechnology or micro die casting industry. Other applications are paper and print industry, microelectronics and forensics.

THE EXPERIENCE

„We use InfiniteFocus to measure micro end mills. Here, the option of full form measurement is a keybenefit. In our view Alicona has no competition in this field! Also, the system is remarkably easy to useand extremely robust – from my point, InfiniteFocus is an unbreakable device.”

Frank E. Pfefferkorn, Ph.D.Associate Professor, Mechanical EngineeringUniversity of Wisconsin-Madison

INFINITEFOCUSHOW TO MEASURE FORM AND ROUGHNESS IN ONE SYSTEM

InfiniteFocus I alicona 9

InfiniteFocus stands out with high flexibility and universal use.

Users from various industries and various applications and/or in-

homogeneous material benefit from a robust measurement device

with high usability, high measurement speed, registered color informa-

tion and traceability.

» High vertical resolution that remains constant even across a

large vertical scanning range (Z)

» Technology that delivers a measurement point density of over

100 mil measure points including an estimation of

measurement uncertainty for every 3D point

» Automatic deviation from target geometry

» Options for automation and offline licenses for an optimal

and resource-friendly use

» Complete form measurement of drills, mills etc. with the

“Real3D” rotation unit

» Ability to change objectives without calibration, upon request

also automatically

» Various standards and calibration tools to verify traceability

» High degree of robustness without wear or maintenance

Measure small radii and angles even across large measurement volumesMore than 100 mil measurement points ensure a meticulously detailed measurement. This is how components and tolerances within the µm or sub-µm range

are measured. The high measurement point density of Focus-Variation enables operators to gain a consistently high lateral and vertical resolution even across

large measurement areas. Traceable measurement is also provided of small radii, angles and roughness which are often difficult to access.

WHAT MAKES INFINITEFOCUSDISTINCTIVE

10 alicona I InfiniteFocus USPs

Form and roughness measurement with only one system Usually, when measuring roughness a surface measurement system is used whereas for dimensional accuracy or verifying tolerances a coordinate

measurement system is used. InfiniteFocus offers the functionalities of both device types combined into one system. Consequently quality assurance becomes

more cost-effective, is easier to execute and delivers results more efficiently.

Measure steep flanksIn contrast to other techniques, light coming from different directions is used to positively influence a measurement. In addition, the measurement

of the maximum flank angle is not restricted by the numerical aperture. Depending on the surface users measure flanks of up to approximately 90°.

This is achieved via add-ons such as optional ring light or polarization to support the measurement of complex geometries.

Measure components with varying surface finishes or coatingInfiniteFocus is based on an intelligent lighting technology. The patent pending SmartFlash technology allows quick and intuitive measurement of materials with

varying surface characteristics or reflection patterns. Modulated light provides optimal illumination throughout the whole measurement area. Operators measure

glossy, ground, rough, reflective and diffuse components.

Full form measurement with the Real3D technology Meaningful quality assurance requires area based measurements. Due to various hard and software modules, the Real3D technology enables full form

measurement of components. Individual measurements from various directions are automatically reassembled for a complete 3D view. This way operators

also measure complex contours and surfaces that can hardly be measured optically in the conventional way.

Measure even large and heavy componentsThe robust technology of Focus-Variation combined with the vibration isolation frame of InfiniteFocus allows the measurement of roughness plus form

on heavy and large components. The spectrum of measurable surfaces goes hand in hand with the respective weight classes up to the dcm2 range.

A technology that measures form and roughness.A flexibility that allows almost unlimited application.A resolution that remains constant over the whole measurement range. And an ease of handling that makes InfiniteFocus a popular measurement device that is widely used.

InfiniteFocus USPs I alicona 11

12 alicona I InfiniteFocus References

Source: Makino

InfiniteFocus References I alicona 13

Makino uses InfiniteFocusto verify the machining performances of its precision micromachiningcenter iQ300

With InfiniteFocus being used in internal

testing facilities, Makino meets the re-

quirements of customers in terms of qua-

lity assurance throughout high resolution

3D measurement of manufactured com-

ponents. Both geometry and surface fi-

nish are verified. In addition, InfiniteFocus

is increasingly used for integrated tool

compensation.

MACHINE TOOL MANUFACTUREVISIBLE PRECISION

One system useable by both manufacturer and his customersMakino is well known as a leading supplier of vertical and horizontal machining centers. “Our ma-chines are in use whenever highest precision is required”, states the manufacturer. InfiniteFocus isused to verify how precise and accurate the machining centers manufacture. Users of Makinoapply the optical 3D measurement system to verifiy surface finish and machining results ofproduced workpieces.

All kinds of micro precision components

Makino measures micro components that have

been manufactured for further use in various

industries, including tool making, automotive,

die casting or aerospace industry. Regardless

of industry or specific application, these usually

miniaturized components often have complex

geometries with challenging forms. Both tool

machine manufacturer and users emphasize

on verification of dimensional accuracy and

achieved surface finish of machined compo-

nents. This is both achieved with InfiniteFocus

since the optical system combines the capabi-

lities of a form with those of a roughness mea-

surement device in one system.

However, quality assurance with InfiniteFocus

starts at an earlier stage than measuring the

final manufactured component. Makino also

offers the optical measurement system to

perform integrated tool compensation. Measu-

rements with InfiniteFocus make even minimal

changed machining parameters clearly visible

and transparent, which optimizes manufactu-

ring and accelerates the achievement of tole-

rances in the µm–range.

“We expect from our partners highest qua-

lity in terms of products and service, which

includes high expertise as well as qualified

and quick responses to our needs. With Ali-

cona we have found a reliable partner in all

fields. Our requests that we address for in-

stance to the departments Support and Ap-

plications are followed up quickly, competent

and friendly. This is valid for both the Euro-

pean headquarters and the local contact in

Japan.”

Extension of worldwide services

In near future Makino plans to extend its

global services in the fields of Reverse

Engineering and 3D Scanning. Also,

InfiniteFocus is supposed to be offered

as integrated measurement technology

for automated tool compensation.

Toshihiko TadaApplication Technology Developing Group

Micro Machining Team

Makino

WhereWHERE INFINITEFOCUSALSO IS USED

WhatABOUT

WhatIS MEASURED

WhatTHE CUSTOMER STATES


Source: Sutton Tools


Complete form measurementof drills, end mills and taps

Research and development is a major

focus for Sutton Tools. Being equipped

with state-of-the-art technology is

part of the company’s philosophy to

develop and deliver advanced manu-

facturing technology. As a result,

using InfiniteFocus with the Real3D

option is a logical step: 360° tool

measurement provides completely

new perspectives and insight into the

tool geometry, leading to more advan-

ced products than previously thought

achievable.

CUTTING TOOLSNEW PERSPECTIVES – NEW INSIGHTS

Increased cutting speed and longer durability Sutton Tools has a clear idea of what they expect from their products. “Our goal is to fulfill and evenexceed our customer’s expectations with performance and process reliability of our tools”, says theAustralian manufacturer. In order to reach this goal, InfiniteFocus is used in combination with therotation unit “Real3D”. The complete form measurement of drills, end mills and taps shows howmuch impact even smallest surface characteristics can have.

Form, roughness and contour

With the optional rotation unit Real3D,

InfiniteFocus measures surface charac-

teristics such as clearance, diverse flank

angles or thread pitch. The tool’s auto-

matic 360° rotation allows complete

form measurement from all directions.

This provides significant advantages in

tool optimization.

Further applications are wear measure-

ment or the measurement of form devia-

tions to a CAD dataset. Especially in tool

design Sutton Tools benefits from the

detailed visualization including true color

information. However, the system is not

limited to the measurement of only one

tool or tool type. The large vertical travel

range enables the handling of varied tool

forms and sizes.

“InfiniteFocus with Real3D is the most efficient

measurement system we know. No other device

can deliver such a detailed visualization nor could

it possibly measure both, geometry and surface

quality. This makes development and manufac-

ture processes run significantly faster. In addition

InfiniteFocus has proved to be the ideal instrument

for strategic benchmarking within this branch. The

results of the respective comparisons help us to

stay ahead of the competition as it allows us to re-

spond quickly and directly to market requirements.

Our research confirms that we work with the most

state-of-the-art technologies and procedures

worldwide.”

To understand and make useof the relation between toolgeometry, material and surface finish

Regardless of the surface finish, compo-

nents are measured at every stage of

manufacture and development. This pro-

vides Sutton Tools with new insights and

assessment criteria in tool development.

Steve DoweyTechnical Manager

Sutton Tools

WhatABOUT

WhatIS MEASURED




Source: Cassidian


AEROSPACE AND AERONAUTICSERROR ANALYSIS

Reduction of material and labor costs

Initially Cassidian intended to purchase a measurement device for failure analysis. It did nottake the areospace and defence enterprise long to realize the great potential InfiniteFocus hasto offer in different areas and today this potential is fully exploited. Typical applications otherthan failure analysis are incoming goods inspection and the verification of high surface qualityfor customers.

Incoming goods inspection, failure analysis and avoiding customer complaints

High resolution measurement of geometry and

surface finish is performed to verify the manufac-

turer's information and identify defects prior to

further processing. The surface quality of compo-

nents is determined with a numerical measure-

ment in order to avoid unsuitable and expensive

materials in production. A thorough report that in-

cludes practically oriented visualization and mea-

surement results that are easy to read, verifies

compliance with the agreed specifications and

the stipulated surface finish. Since this was intro-

duced customer complaints at final inspection of

aircraft are reduced to a minimum.

Titan, high strength steels and fibre composites

Varying components, many of which have

complex forms are measured. The measu-

rement of these various components include

radii, threads, diverse angles and roughness.

Since Cassidian uses InfiniteFocus, surface

characteristics are measured, that in the

past, were either difficult to access or could

not be accessed at all. These include root

of a thread and thread flanks of gear drives.

Surface damage of various sizes and di-

mensions are measured, even on round

components.

"Due to its high flexibility, Infinite-

Focus had paid for itself within the

first year.

Initially the system had been pur-

chased for failure analysis and for

measuring the depth of surface

damage. However, it became ap-

parent very soon that the measu-

rement device can be universally

used. Today we operate across

departments which makes both,

quality assurance and develop-

ment more comprehensive and at

the same time easier and more

efficient."

Gregor HeichlerProject engineer in the area of non-destructive material testingCassidian

For the development of a new material in polymer technology

The objective is to develop a material of appropriate strength for an optimal adhesion of surfaces. Analysis

with InfiniteFocus, using area based measurement, shows which surface treatment and/or which surface

parameters improve strength of adhesion.

WhatABOUT

WhatIS MEASURED




Source: Alicona


Quality assurance in stamping

Komatsu Seiki Kosakusho manufacture high qua-

lity, small and accurate mass produced products

for wrist watches and injector parts for automobile

engines. High resolution and reliable measure-

ments are not the only requirement for the pro-

ducts, also the data have to be comparable

between the finished products and the stamping

tools.

MICRO PRECISION STAMPINGHIGH PRECISION IN LARGE VOLUME PRODUCTION

Injector nozzles which provide best possible combustionKomatsu Seiki Kosakusho manufactures micro precision tools and products for the automobile, elec-tronics, and medical device industries. High emphasis is placed on high quality components evenwith a monthly production rate of more than 1,000,000 units. The measurement of stamping tools isthe first business area where the Alicona InfiniteFocus is used. The high repeatability and resolutionof the flexible 3D measurement system is very suitable for the precise and accurate manufacturing.This provides innovation to maintain competitive advantage.

Small stamped holes and tool condition

Small holes in gasoline injector nozzles

and its tools for production are measured.

The diameter of small holes is Ø 0.12mm

and the length is 0.2mm, and these are

produced by micro piercing. The whole

condition at entrance and exit is one of the

important control criteria for the quality

and production departments. InfiniteFocus

can easily measure the hole condition wit-

hout any damage, and it shows 3D analy-

tical images for both the operators and

managers. Also we are able to establish a

correlation between tool life and product

quality. This allows us to develop compe-

titive cost analysis and continuous impro-

vement by measuring tool wear and the

wear process in mass production.

“Alicona is a very valuable and powerful

partner in both service and technical inno-

vation with new developments that offer

benefits. It provides benefits and trust bet-

ween our customers and us.

New software-developments increase the

range of possible applications into micro

and nano scale. I am, thus, very confident

with InfiniteFocus and Alicona.”

Development of newmaterials in the academic area

For the last 10 years Komatsu Seiki Kosa-

kusho has been working on the development

of grain size controlled material to provide sta-

ble stamping and cutting conditions for micro

and nano scale products. The micro or nano

structured geometry needs to be measured by

non-contact methods, and in high resolution,

without any damage on the limited number of

development samples. Also, the data created

by InfiniteFocus is used for academic papers,

books, and presentations in seminars and

education.

Takafumi KomatsuExecutive Director

Komatsu Seiki Kosakusho

WhatABOUT

WhatIS MEASURED




Source: GF AgieCharmilles


With InfiniteFocus GF AC also offers a solution for digitalizingsurfaces

Having Alicona as a partner, GF AgieChar-

milles is a qualified supplier for the entire

production chain. This includes the digitali-

zation of natural surfaces and quality assu-

rance of the final machined component.

LASERTEXTURINGTEXTURING, ENGRAVING AND MICRO-STRUCTURING

How to strengthen the market position as complete supplier A joint project by Alicona and GF AgieCharmilles has shown that InfiniteFocus enables thesupplier of precision machines to offer a complete solution for the entire production chain inthe field of laser texturing. InfiniteFocus is used to scan and digitalize natural surfaces. Thistexture is then applied to mold components via laser texturing by GF AC. This competitive ad-vantage is to be extended to the business areas EDM and milling technologies.

Materials such as leather, silkor other surfaces

The 3D data of the measured surface,provided by InfiniteFocus, are transferredas Grayscales data file and finally applied tothe final parts via laser. The high resolu-tion 3D measurement is the basis ofbeing able to produce a mold componentwith a surface texture that looks andfeels as close as possible to the origin ma-terial, thanks to GFAC laser technology.

“Our machines for mold and tool making

are widely used for manufacturing high

precision micro components. There is cur-

rently no other measurement device for our

customers I can think of that is more suit-

able for the measurement or the quality

assurance of machined workpieces. In

return, measurements from InfiniteFocus

demonstrate the high precision and quality

of our machines.”

EDM and milling technology

GF AgieCharmilles increasingly manufactures in the micrometer through to the nanometer range.

With InfiniteFocus, GF AC verifies the accuracy of its precision machines through high resolution

surface measurement of the machined workpieces. Both measurement of dimensional accuracy

and surface roughness measurement are performed. Particularly in tool design GF AC also

benefits from the ability to measure geometries with complex forms.

Jean-Paul NicoletHead of Marketing and Sales Support for new technologies

GF AgieCharmilles

WhatABOUT

WhatIS MEASURED




Source: Rohde & Schwarz, plant Teisnach


MICROPRECISION VERIFICATION OF TOOL AND WORKPIECE

InfiniteFocus for 3D measurement in all areas of manufacturing For Rohde & Schwarz quality assurance is a value-added process. The insights in micro precisionmanufacturing that have been gained with InfiniteFocus, have helped to increase process reliability,safe production costs and optimize the workflow. Applications reach from tool release to the 3Dmeasurement of turned and milled components.

Quality assurance for a realnet output ratio in all areasof manufacturing

InfiniteFocus is used for a wide range of

applications over the whole parts spec-

trum. These applications reach from

quality assurance of dies in forming

technology over to 3D measurement of

turned and milled components. The 3D

measurement device is used as an inte-

gral part of the process chain in the pro-

duction of mechanical components.

Stamping dies for tool release, microcomponents and workpieces with varying surface finish

For the production of miniature switches, Rohde &

Schwarz produces a stamping die which is further

used to engrave a defined relief onto a sheet sur-

face. Before the stamping die is used in series pro-

duction for the first time, the form of its surface is

measured. It has a pyramid-shaped structure with a

total area of 70µm x 70µm and a height of 35µm.

With InfiniteFocus Rohde & Schwarz verifies the

right distance between the individual paths by mea-

suring pits and peaks. Also diverse angles are mea-

sured and the proper partition is determined.

Another standard application is the measurement of

miniaturized components with complex forms. Often

these components have steep flanks with functional

characteristics such as incisions or indentations.

InfiniteFocus measures these fine, highly precise

structures quickly, effortlessly and in high resolution.

Another application is electroplating. In this proce-

dure components are being coated with e.g. gold

and silver. The intelligent illumination technology of

InfiniteFocus delivers high resolution results regard-

less of lightning conditions and varying reflective

properties.

“The measurement system's fle-

xibility and its universal applicabi-

lity are a great benefit for us. After

less than a year InfiniteFocus had

already helped us to increase

process reliability, optimize pro-

duction processes, save produc-

tion costs and improve workflows.

We can get into production more

quickly and involve far less em-

ployees.”

Gerhard KokottHead of quality management at the Rohde & Schwarz plant Teisnach

»

»

»

Various materials in numerous manufacturingsegments

These include: printed circuit boards

(PCB boards), drill holes including inter-

nal geometries, galvanized and/or sput-

tered surfaces (e.g. components with

thin film technology), height levels on ca-

libration disks, teflon coated surfaces,

materials made of pure iron, nozzles

from the sheet metal processing area,

roughness measurements at milled

components etc.

WhatABOUT

WhatIS MEASURED




Source: Profin


CUTTINGEDGEPREPARATIONMEASURABLE SURFACE QUALITY

Micro cutting edges for smallest production tolerances Manufacturing micro cutting edges is all about highly precise contours, edges and areas. TheSwiss enterprise Profin is also aware of that and therefore the expert for precise processing ofcutting tools and precision components operates with InfiniteFocus which measures form but alsosurface quality.

Measurement of form andsurface quality

Machine tools by Profin facilitate edge

roundness in µm range plus quality im-

provement of the cutting edge's chip

and clearance surface. InfiniteFocus is

used for quality assurance of the pro-

cessing result and for continuous deve-

lopment of machine tools. Area based

roughness measurement enables Profin

to numerically verify the surface state of

components.

Micro tools after edge preparation:indexable inserts, end mills, drillsor saw bands

With InfiniteFocus Profin tests whether the tra-

ditional requirements regarding surface finis-

hing e.g. high precision deburring, edge

roundness within µm range or refining proces-

ses of polished workpiece conform to the defi-

ned specifications. A particular emphasis is put

on the measurement of chipping, form, radius

and roughness of the tool's cutting edges.

“We were looking for a 3D measure-

ment device that would not only eva-

luate form but also surface. Alicona

was the only provider that succee-

ded in presenting such a measure-

ment device. Every other system we

evaluated featured only one functio-

nality. The devices were either mea-

suring form or surface but never

both. With InfiniteFocus we now have

a system for form measurement and

for evaluating the surface.”

Dr. Peter FrankHead of Profin development

Verification of high surface quality

Furthermore InfiniteFocus is used for a numerical verification of the benefits that come with the

Flakkoting technology developed by Profin for cutting edge preparation. The machined tools' high

surface quality clearly demonstrates the detailed visualization including true color information

and the significant 3D measurements.

WhatABOUT

WhatIS MEASURED




Roughness measurementof injection molding components

A surface roughness that is either too

high or too low might affect a medical

product’s proper functionality. Infinite-

Focus is used to verify surface finish

of these items and thus helps to

achieve error free functionality. This

enhances the patient comfort and the

hospital saves money.

INJECTION MOLDING SAFETY IN PHARMACEUTICS AND MEDICAL ENGINEERING

Safe administration of medication via 3D measurement Since the surface roughness of injection molded components may influence the functionalityof medical products, one of the leading pharmaceutical companies uses InfiniteFocus to performenhanced quality assurance. The use of the high resolution form and roughness measurementsystem results in safer administration of medications and minimizes the risk of injury for hospitalstaff.

Polymer components whichare used in devices andcombination products

These products offer, apart from the ad-

ministration of medications, diverse

safety features. Among other things they

include syringes with an additional

needle protection device made of polymer.

This protection is put over the syringe

after the injection in order to prevent

needlestick injuries by contaminated

needles. The polymer’s surface

roughness being too low could, in the

worst case, even lead to a leaking con-

tact between needle protection and

needle. Protection against an infection

caused by a contaminated needle would

no longer be provided then.

Roughness measurement by InfiniteFocus

is performed in combination with form

measurement. By measuring the syrin-

ge’s form or/and glass cone on the sy-

ringe, the matching sealing plug’s

perfect fit is verified.

“In the past, roughness was traditionally measured

profile based. The results were correspondingly

uncertain and of no great significance since pro-

file-based roughness measurements only deliver

information about a small segment of a surface.

Due to the area based roughness measurement

with InfiniteFocus, we now gain reliable feedback

regarding the product's secured functionality. On

top of that we benefit from the great user friendli-

ness and the intuitive handling. The easy handling

allows several employees to use the system in va-

ried areas only shortly after a quick introduction.”

Cédric GyselAssociate Scientist

in pharmaceutical development

WhatABOUT

WhatIS MEASURED



InfiniteFocus for ensuringthe proper tuning of running base and edge

While the surface is decisive for slide

characteristics, the edge geometry

guarantees turning compliancy and

optimum edge grip. Information about

the exact values of the grinded running

base makes it possible to adapt pro-

duction parameters to suit the accor-

ding requirements even better.

TUNING OF A SKI´S RUNNING BASE AND EDGESOPTIMUM EDGE GRIP ON THE SLOPE

Determine slide characteristics of skis via roughness measurement "We were looking for a suitable measurement device to measure both, edge geometry and runningbase roughness of our skis", Atomic states. Eventually the supplier of winter sports came acrossInfiniteFocus. Area based roughness measurements of the running base allow to draw conclusionsabout the slide characteristics of the skis.

Surface roughness and edge geometry

A grinding process gives the running

base its surface roughness. Whether a

result is correct, is easily determined by

a “well defined surface pattern”, as Ato-

mic puts it. The result is also verified by

the area based roughness measure-

ment. Additionally, roughness measure-

ment allows to draw conclusions on

friction and thus on the ski's glide cha-

racteristics.

Another main focus of quality assurance

is the measurement of edge geometry.

This includes various edge angles or an-

gular distribution, edge roughness and

the chipping at the edge’s point.

“In the past, roughness and geometry of our skis

were measured separately. Not only did we have to

face complex sample preparation but also inade-

quate results. For example, when we had to mea-

sure larger areas, it was inevitably to do step by

step measurements and put them together to a

final area model afterwards. Today we measure

both, roughness plus geometry with only one sy-

stem. This helps us to even gain results of large

measurement areas in an up to now not known

quality!”

Harald ScheiklHead of the test lab “Gliding”Atomic

Source: Atomic

WhatABOUT

WhatIS MEASURED


28 alicona I InfiniteFocus measurement modules

All measurement modules installed in InfiniteFocus provide in-depth information of the measured objects geometry´s coordinate system.In addition, a variety of form removal utilities are available for form and roughness measurement. This allows simple, accurate and repeatablesurface measurement on simple and complex components. All measurement modules are designed by Alicona and are optimally tailored toeach other, ensuring user friendly operation.

PROFILE-FORM MEASUREMENT Form measurement along a user defined profile

Radii, angles, height steps and normal distances are measured automatically or manually. In addition, the profile-form measure-ment enables the verification of surface parameters such as circum-circle and in-circle plus a series of further thread parameters. Cuttingedge measurement can also be performed and users measure radius, basket arch form – both “waterfall” and “trumpet” type – wedgeangle and bevel lengths.

ROUGHNESS MEASUREMENTClassic profile-based measurement of Ra, Rq, Rz conforming to ISO 4287, 4288

Roughness is measured with comprehensive parameter evaluation of roughness, waviness and frequency. Statistical evaluationsand the bearing ratio curve or spectral analysis are graphically visualized.

MEASUREMENT MODULES BASED ON FOCUS-VARIATION

InfiniteFocus measurement modules I alicona 29

A simple to use “tab-windows” system guide a user through the application and the 3D measurement of various surface para-meters. Advanced graphic visualization, including registered color information, enhances the options to characterize surfaces anda series of export functions increase user friendliness. Also complex parameters are visualized and measured from different per-spectives.

AREAL SURFACE TEXTURE MEASUREMENTSurface measurement according to ISO 25178

Surface roughness, in this module, is measured area based instead of profile based. Statistics include bearing area curve, fractal dimension,autocorrelation, gradient distribution, local homogeneity and spectral distribution. A specially designed filter allows form removal to verifyroughness on large measurement fields.

VOLUME MEASUREMENT Quantification of pits and peaks

The volume of features are measured according to a user defined border. The easy positioning of cutting layers or cutting surfaces pro-vide a universal tool.

30 alicona I InfiniteFocus measurement modules

2D IMAGE MEASUREMENT Evaluation of 2D geometries

In the 2D view of the measured surface features such as circles, straight lines, angles, parallel lines, distances, ellipses, rectangles etc. canbe measured.

AUTOMATIONProgrammable solution for repeating measurement tasks

InfiniteFocus measurement applications are programmable, from a simple profile form measurement to more complex hardwarecontrol.

MEASUREMENT MODULES BASED ON FOCUS-VARIATION

InfiniteFocus measurement modules I alicona 31

Modular software design

The Alicona software design for 3D surface

measurement is based on a modular con-

cept which provides a wide range of benefits.

» the generation of a 3D data set and

the 3D measurement of another

already existing data set, are

performed independently of one

another. Meaning, while one

component's 3D data set is created,

the operator simultaneously

measures another already existing

data set without any restrictions.

» the software modules can be

supplemented as required. All Alicona

measurement systems are based on

the principle of individually adding

further application specific modules.

This way, operators have the

possibility of e.g. adding modules

for edge measurement to

InfiniteFocus. These modules are

standard features of the tool

measurement device IF-EdgeMaster.

» all measurement modules have been

developed by Alicona and share a

consistent operation. Thus the

practical application of a new module

is possible immediately and

intuitively.

CONTOUR MEASUREMENTUsers measure angles, distances, circles, incircles, circumcircles, thread pitch etc. from every position. Inaddition, the contour measurement module includes roundness measurement. Even complex profiles of e.g.along a helix are measured.

DIFFERENCE MEASUREMENTDifference measurement is used to numerically compare two different geometries. A typical application is themeasurement of wear before and after use of a cutting tool. Also, users measure form deviations to aCAD-dataset or reference geometry. The module is also used in the field of Reverse Engineering.

FORM MEASUREMENTOperators measure regular geometries and curved surfaces. Automatic fitting of spheres, cones and cylindersallow the visualization and form measurement of tools and other components. Also, deviation from targetgeometry becomes clear.

32 alicona I InfiniteFocus Real3D

InfiniteFocus is not limited to a view from one perspective when performingmeasurement. If required, a component is measured in 3D from differentperspectives. This can either be achieved manually by the operator posi-tioning the respective part or automatically by using the appropriate hard-ware add-ons. In both cases the individual measurements from variouspositions are automatically merged into a complete 3D data set. The

"Real3D" technology allows the component's visualization from differentangles plus a measurement of contour, difference and form. This way, sur-face parameters that are normally difficult to access are measured quicklyand effortlessly. Measuring with the Real3D technology is essentially moreuser friendly and more accurate than it can be achieved with conventionalstitching techniques on the basis of mechanical rotation or transmission

MEASURE FROM EVERY POSITION

The InfiniteFocus combined with the optional rotation unit Real3D, re-

present a genuine competitive advantage in, for example, the tool indu-

stry. Drills, milling cutters etc. are automatically rotated around 360°

allowing operators to perform full form measurement of their tools in

3D. Therefore surface characteristics such as diverse flank angles,

thread pitch, undercuts and clearance are accessed and measured. A

number of various adapters enable the 360° rotation of components

without rotational symmetry.

Measure components around 360° with a rotation unit

The Real3D technology automatically merges individual measurements from various directions into a complete 3D data set.

InfiniteFocus Accessories I alicona 33

INFINITEFOCUS ACCESSORIES

1-2 IF-GUIDEComponents are continuously equally positioned and aligned to simplifyautomated measurements.

3 VACUUM-PLATEUsed to vacuum clamp the specimen when measuring. Especiallyuseful for thin-walled or sensitive material, e.g. sheets, paper or rubber.

4 SPACER-PLATEHeigth extension for the X/Y stage. Especially for roughness measure-ments a stable positioning can be ensured. The Spacer-Plate isavailable in two different heights: 17.5mm and 35mm.

5 RINGLIGHT Additional light source for improved illumination. Especially useful onvery complex surfaces.

6 ROTATION-TABLEHardware for aligning components along X or Y axis of the system.Ideal for the measurement of horizontal or vertical grooves.

1 2

3

4

5

6

CUSTOMIZED MEASUREMENTSWITH INFINITEFOCUS X-LARGE

InfiniteFocus X-Large InfiniteFocus is easily

adjustable and functionalities can easily be exten-

ded depending on application and measurement

task. Its core technology, Focus-Variation, can

be “transformed” into another hardware wit-

hout losing any of its variety. Area based mea-

surement with high measurement point

density, high repeatability, several options for

automation as well as high resolution measu-

rements even across large measurement vo-

lumes are key benefits that all X-Large variants

of InfiniteFocus have in common. The systems dif-

Special measurement tasks need special measurement solutions. This is why Alicona offers the X-Large

series of InfiniteFocus to characterize surfaces that are not suitable for the standard measurement system

due to shape, size or weight of components to be measured. X-Large devices have a different look but

offer the same benefits as the standard system: high vertical resolution of even complex forms with steep

flanks, measurement of surfaces with varying material and reflection properties and registered color in-

formation with each measurement.

fer in possible XY-travel ranges and a max

measurable weight of components. The cur-

rently available spectrum of InfiniteFocus X-

Large solutions includes travel ranges from

(mm) 200 x 200 up to 1000 x 1000 with a

max measurable weight of up to 20 kg. Howe-

ver, on request an increased weight of com-

ponents is achievable. This flexibility is also

valid for possible applications as each solid

34 alicona I InfiniteFocus X-Large

material is measurable as soon as there is a

minimum surface roughness of only a few na-

nometers. Typical applications are e.g. the au-

tomatic defect analysis of large measurement

fields or form measurement of laser structured

geometries on printing plates.

CUSTOMIZED MEASUREMENTSWITH INFINITEFOCUS X-LARGE

InfiniteFocus X-Large I alicona 35

MEASUREMENT WITH EXTRASBoth the InfiniteFocus standard system and the

X-Large series for the characterization of measu-

rement fields larger than 10cm x 10cm are easily

adoptable to particular environments and/or new

conditions. This means that not only the hardware

can be changed to meet new requirements, but

also the software is extendable individually

throughout new software modules. Instead of

purchasing a new measurement system because

of new or additional measurement tasks which

change former conditions to perform quality as-

surance, Focus-Variation allows the quick and

simple implementation of new software modules.

This is valid for both already available software

modules as well as new modules on request. See

what is possible with Focus-Variation – there are

packages on-hand for the groove measurement

of golf clubs, the measurement of diamond

particles, valve inspection, conrod and cams

measurement etc.

Dimensions 810mm x 640mm x 780mm

Weight of system 120kg

Max. lateral travel range (x/y) 200mm x 200mm

Max. vertical travel range (z) 100mm

Max. sample height 100mm*

Max. sample weight 20 kg

SPECIFICATION INFINITEFOCUS XL200






Max. sample weight 200 kg

Max. sample dimensions 1100mm x 1500mm

SPECIFICATION INFINITEFOCUS XL 1000






Max. sample weight 10 kg**

SPECIFICATION INFINITEFOCUS XL 500

* can be extended** load must be centered

* can be extended

* can be extended

36 alicona I InfiniteFocus Specification

TECHNICAL SPECIFICATION

SOFTWARE

GENERAL SPECIFICATION

SPECIMEN

OBJECTIVES

Measurement modules and utilities

Standard: ProfileFormMeasurement (height, angle…), ProfileRoughnessMeasurement (Ra…), SurfaceTextureMeasurement (Sa, fractale dimension…), VolumeMeasurement, 3D-Editor, FormRemoval; Optional: 3DFormMeasurement, DifferenceMeasurement, ContourMeasurement, EdgeMeasurement;

Automation IF Automation (built-in script editor), .NET Remoting interface

Visualization 2D-image and high resolution 3D visualization

Database intuitive, graphical database

Import/Export Simple export to STL and VRML, import of CAD-data with STL format, QDAS export, variety of reporting functionalities

Available in German, English, Korean, Japanese

Objectives 2,5x 5x 10x 20x 50x 100x

Lateral sampling distance µm 3.52 1.76 0.88 0.44 0.18 0.09Min. lateral resolution µm 58.71 23.48 11.74 8.8 6.4 4.4Max. lateral resolution µm 6.92 3.49 1.75 0.88 0.64 0.44Min. repeatability (vert.) µm 0.8 0.12 0.03 0.015 0.008 0.003Max. scan height (approx.) mm 8 22 16 12 9 3.2Scan speed* µm/s 2300 400 100 50 20 10Best vertical resolution** nm 2300 410 100 50 20 10Vertical dynamic 3400 52000 160000 250000 430000 380000Working distance mm 8.8 23.5 17.5 13.0 10.1 3.5Field of view X µm 5716 2858 1429 715 286 143Field of view Y µm 4351 2175 1088 544 218 109Max. extended field of view Y mm² 10000 10000 10000 4500 700 150Max. uni-directional scan extension mm 100 100 100 100 100 100

Specimen surface texture surface topography Ra above 10-15nm with a Lc of 2µm, surface structure dependent

Max. height of specimen 100mm up to 240mm

Max. weight of specimen 35kg, more on inquiry

Maximum slope angle up to 85°

Sample preparation none

Measurement principle non-contact, optical, 3 dimensional, based on Focus-Variation

Measurement result 2-100mio 3D points in registered true color information (maximum is dependent on the used measurement module)

Maintenance maintenance free

Illumination white LED coaxial light, high power, controllable; Optional: white LED ring light, controllable, polarization

Nosepiece 6 objectives manual or motorized

Travel range X:100mm, Y:100mm, Z:100mm

Weight 95-100kg, depending on equipment

Size measurement system WxDxH 710mm x 540mm x 628mm (up to 868mm)

Temperature range possible: 5° - 40°C, calibrated for: 18° - 22°C (other temperature ranges can be calibrated)

Temperature gradient less than 1° per hour

Power supply 900W;110-230V~; 50-60Hz

Size ControlUnit WxDxH 540mm x 682mm x 360mm

InfiniteFocus Specification I alicona 37

(1) Sensor head and stiffened sensor ribs (2) passive vibration damping and x-/y-stage (3) manual nosepiece (4) motorized nosepiece (5) 2.5x, 5x, 10x, 20x, 50x and 100x objective (6) ring light

(7) polarization disc for ring light (8) polarization for coaxial light source (9) height extension* for larger specimens (10) ClampingSet (11) InsertGrip (12) AdvancedInsertGrip (13) RotationTable

(14) RotationGrip (15) Real3DRotationUnit

*) can only be changed by certified Alicona service engineers

RANGE OF RESOLUTION AND APPLICATIONS

The entries in the table are traceable values.*) The minimum measurable values are dependent on the structure of the specimen.

Roughness Measurement U = 25nm at Ra =100nm U = 40nm at Ra = 500nm

Height Measurement MPE z = 300nm at z = 10µm MPE z = 400nm at z = 100µm MPE z = 500nm at z = 1000µm

ACCURACY

Information about measurement conditions is given by request

Objectives 2,5x 5x 10x 20x 50x 100x

Min. measurable height nm 2300 410 100 50 20 10

Max. measurable height (approx.) mm 8 22 16 12 9 3.2

Step height accuracy (1mm height step) % - 0.05 0.05 0.05 0.05 0.05

Max. measurable area mm² 10000 10000 10000 4500 700 150

Max. measurable profile length mm 100 100 100 100 100 100

Min. repeatability nm 800 120 30 15 8 3

Min. measurable roughness (Ra)* nm 7000 1200 300 150 60 30

Min. measurable roughness (Sa)* nm 3500 600 150 75 30 15

Min. measurable radius µm 20 10 8 5 2 1

Min. measurable vertical angle ° 20 20 20 20 20 20

38 alicona I InfiniteFocusSL

INFINITEFOCUSSLAS FAST AND INTUITIVE AS 3D SURFACE PROFILER CAN BE

THE SYSTEM

InfiniteFocusSL is a cost efficient optical 3D profile measurementsystem for easy, fast and traceable 3D measurement of form andfinish on micro structured surfaces. Users are able to measure formand roughness of components with only one system. In addition,color images with high contrast and depth of focus are achieved.The robust frame and the intelligent illumination technology providefast and high resolution measurement in laboratory and productionnear environment.

THE BENEFITS

InfiniteFocusSL is particularly attractive due to its cost effectiveness,measurement speed and usability. The long working distance of up to33mm in combination with the above average measurement field of50x50mm allows a wide range of applications. Measurements areachieved within seconds, and features, such as a coaxial laser for quickand easy focusing enhance its usability.

THE APPLICATIONS

Applications range from cutting edge measurement in tool industryto quality assurance and surface finish measurement of micro com-ponents and features on surfaces. InfiniteFocusSL is used inthe automotive, aerospace, mold and medical device indu-stries. Users also measure difficult to access surface positi-ons including steep flanks or the roughness on, for example,the tooth root of a gear.

InfiniteFocusSL I alicona 39

5x 10x 20x 50x 5x SX2 10x SX2 20x SX2 50x SX2

Sampling distance µm 2 1 0.5 0.2 2 1 0.5 0.2Min. repeatability (vertical) nm 120 30 15 8 180 45 25 15Max. scan height (approx.) mm 22 16 12 9 25 25 19 12Best vertical resolution1 nm 410 100 50 20 510 130 70 45Working distance mm 23.5 17.5 13.0 10.1 34 33.5 20 13Field of view X µm 4000 2000 1000 400 4000 2000 1000 400Field of view Y µm 4000 2000 1000 400 4000 2000 1000 400Max. extended field of view mm² 2500 2500 2500 1100 2500 2500 2500 1100Max. uni-directional measurement mm 50 50 50 50 50 50 50 50



Min. measurable radius µm 10 5 3 2 10 5 3 2

Min. measurable wedge angle ° 20 20 20 20 20 20 20 20

Min. measurable roughness (Ra) nm - 300 150 80 - 450 250 150

Min. measurable roughness (Sa) nm - 150 75 50 - 250 100 80

OBJECTIVES

Travel range X/Y manual option: 25x25mmmotorized option: 50x50mm

Vertical travel range Z 130mm (26mm motorized)

Illumination LED ringlight with 24 segments

Weight 15kg

Dimensions 195x316x418mm (WxDxH)


1) Vertical resolution can be adjusted in the IF-LaboratoryMeasurementModule2) SX are objectives with higher working distance

40 alicona I Tool measurement

Contactless cutting edge measurement in research and production

Tool measurement I alicona 41

Tool measurement » IF-EdgeMaster» IF-EdgeMasterHOB» IF-ToolPrecision

42 alicona I Tool measurement IF-EdgeMaster

THE SYSTEM

The IF-EdgeMaster is an optical 3D measurement device to automatically measure cutting tools.Typically, the system is used to measure cutting edges regardless of type, size, material or sur-face finish of the tool. Users measure radii > 2µm as well as rake, wedge and clearance angleof cutting edges. Both waterfall-type and trumpet-type are precisely measured. The robust tech-nology of Focus-Variation delivers stable and traceable measurements also in a production nearenvironment.

THE BENEFITS

The IF-EdgeMaster delivers fully automatic measurements and stable results even with externalvibration and external light. The system provides user friendly operation with high measurementspeed. High vertical resolution enables chipping measurement and, in addition, traceableroughness measurements at the rake face of an edge. A patent pending illumination technologyenables optimized illumination of surfaces with short exposure times, leading to fast measure-ments.

THE APPLICATION

Users benefit from high resolution measurements during the whole manufacturing process. TheIF-EdgeMaster is used to measure the green part of a tool as well as the highly polished com-ponent in its final stage. Typically, the measurement system is used to measure inserts, drills,millers etc. Advanced visualization including registered true color information allows transparentand provable quality assurance.

THE EXPERIENCE

“In addition to the large variety of measurement possibilities, it was the user friendly operation ofthe system that convinced us in the first place. These characteristics combined with the high mea-surement accuracy make this device an ideal tool for our production!”

Ulrich Weber

Special Tools Construction,

SIMTEK

IF-EDGEMASTER HOW TO MEASURE CUTTING EDGES OPTICALLY AND

REPEATABLE ALSO IN PRODUCTION

Tool measurement IF-EdgeMaster I alicona 43

A range of user friendly functions in hard and software supports

the high measurement accuracy, high measurement speed and

intuitive user guide.

» a coaxial laser, which enables best possible positioning and

focusing of a component

» a robust coarse drive for a quick start of the measurement

and an effortless change of specimen

» an optional motorized XY- measurement stage with integrated

axis control for the accurate measurement of various

components and geometries

» a ring light with individually controllable segments based on a

concentrator optics (patent pending). This provides an optimal

surface illumination with high contrast and short exposure

times

» a polarizer which is activated by motorization supports the

measurement of highly polished components or other

surfaces with high reflective properties

» a compact, lightweight control unit with integrated power

supply for mobile and handy use

» a robust, compact and specially designed Z-axis with

integrated 5nm resolution linear scale for maximum

measurement accuracy, planarity and straightness

» a vibration-isolating frame including sensors to monitor

vibrations, temperature and temperature gradients for best

possible use in a production near environment

IF-EDGEMASTER HOW TO MEASURE CUTTING EDGES OPTICALLY AND

REPEATABLE ALSO IN PRODUCTION

44 alicona I Tool measurement IF-EdgeMaster

Travel range X/Y manual option: 25x25mm, motorized option: 50x50mm

Travel range Z 130mm (26mm motorized)

llumination LED ring light with 24 segments

Weight 15kg










Sampling distance µm 2 1 0.5 0.2 2 1 0.5 0.2Min. repeatability (vertical) nm 120 30 15 8 180 45 25 15Max. scan height (approx.) mm 22 16 12 9 25 25 19 12Best vertical resolution1 nm 410 100 50 20 510 130 70 45Working distance2 mm 23.5 17.5 13.0 10.1 34 33.5 20 13Field of view X µm 4000 2000 1000 400 4000 2000 1000 400Field of view Y µm 4000 2000 1000 400 4000 2000 1000 400Max. extended field of view mm² 2500 2500 2500 1100 2500 2500 2500 1100Max. uni-directional measurement mm 50 50 50 50 50 50 50 50

OBJECTIVE DETAILS

1) The vertical resolution is automatically adjusted depending on the application.2) Objectives with larger working distances are available (5x objective: 34mm, 10x objective: 33.5mm, 20x objective: 20mm, 50x objective: 13mm). For detailed specifications please contact [email protected].

Tool measurement IF-EdgeMaster I alicona 45

Each batch with same tool lifetime

Simtek Precision Tools develops, manu-

factures and distributes high precision

tools for high demands. The product

range includes about 10,000 standard

tools for Turning, Grooving, Groove

Milling, Broaching, Thread Whirling, Po-

lygon Milling etc. One of the manufac-

turer´s key priorities is to deliver toolsthat with each batch have the same

geometry and perform identically to

offer process reliability to their custo-

mers. Cutting edge measurement is,

amongst others, performed with the

IF-EdgeMaster.

Exact cutting edge geometry for higher process reliability in production Practical 3D measurement in production has to be precise, quick and simple. The IF-EdgeMaster notonly offers repeatable and traceable measurements within a few seconds but also a very simple and in-tuitive user interface. Simtek Precision Tools uses these benefits for high resolution edge measurementand provable quality assurance.

Carbide inserts

The IF-EdgeMaster is mainly used for

the measurement of very small radii on

carbide inserts. In addition, negative and

positive bevels on the inserts are mea-

sured as they decrease signs of wear

and increase durability. Negative bevels,

for example, increase the cutting pres-

sure and at the same time protect the

cutting edge. Detailed visualization of

the measurements is used for transpa-

rent, provable quality assurance.

“In addition to the large variety of measurement

possibilities, it was the user friendly operation of

the system that convinced us. The IF-EdgeMaster

has an extremely intuitive user interface and is

very easy to operate. These characteristics combi-

ned with the high measurement accuracy make

the device ideal for our production!”

Ulrich WeberSpecial Tools Construction

SIMTEK Precision Tools

CUTTING TOOL INSERTSRADIUS AND BEVEL MEASUREMENT

WhatABOUT

WhatIS MEASURED


46 alicona I Tool measurement IF-EdgeMasterHOB

Travel range 66mm (26mm motorized)

Rotation table +/- 90°

Illumination LED ring light

Weight 18kg


Sample size Diameter 25-300mm

GENERAL SPECIF ICATION

OBJECTIVE DETAILS10x SX2

Sampling distance µm 1.1

Min. repeatability (vertical) nm 40

Max. scan height (approx.) mm 22

Best vertical resolution1 nm 100

Working distance2 mm 33.5

Field of view X µm 1760

Field of view Y µm 1320

10x SX1

Min. measurable radius µm 6

Min. measurable wedge angle ° 20

Uncertainty of angle ° 0.5

Max. Bevel length µm 500

1) The vertical resolution is automatically adjusted depending on the application.2) Objectives with larger working distances.


IF-EDGEMASTERHOB

IF -EdgeMasterHOB…

… is one of Alicona´s optical 3D tool measurement systems and a mar-

ket specific adapation of the optical cutting edge measurement device IF-

EdgeMaster. Due to a patent pending illumination technology and special

vibration isolation, the system is also suitable for the use in production.

In terms of hard- and software, the IF-EdgeMasterHOB is adjusted to

measure hob cutters. Users measure the edge geometry at the tooth

flank, the tooth root and tooth tip. This includes parameters such as radii,

wedge angle, basket arch form (“waterfall” and/or “trumpet” type) as well

as positive and negative bevel of the edge. In addition, the system provi-

des both chipping and traceable roughness measurement. Other typical

applications are wear measurement or the automatic comparison to CAD

data or reference geometry. A large vertical working distance allows ef-

fortless measurement of cutting edges even in areas that are hard to ac-

cess. Users measure hob cutters at every stage of manufacture,

regardless of surface finish or coating.

Tool measurement IF-EdgeMasterHOB I alicona 47

In-process measurementto produce hob cutters with equal cutting edgegeometry

Due to a new technology for cutting

edge preparation LMT Fette manufactu-

res hob cutters with an equal geometry.

This enables the supplier to offer tools

that provide identical lifetime in produc-

tion. The edge geometry of the hob cut-

ters is verified with high resolution and

traceable 3D measurements with the

IF-EdgeMasterHOB. The optical 3D mea-

surement system delivers repeatable re-

sults even at positions which have been

difficult to access before use of the

Alicona system.

Optimized cutting edge geometry for controlled tool lifetime in operation When LMT Fette introduced a new blasting technology for cutting edge preparation of hob cut-ters, a quick and reliable measurement system to support this process was necessary. In selec-ting the IF-EdgeMasterHOB, the manufacturer of precision tools chose another one of Alicona´s 3Dmeasurement systems. Quality assurance with the IF-EdgeMasterHOB enables the production of hobcutters with optimized geometry and identical tool-lifetime in operation.

Form and chipping

The IF-EdgeMasterHOB is used for hob

cutters in the model range 1-7. This

means that LMT Fette is able to measure

tooth sizes of up to 11mm with one ob-

jective. High emphasize is placed on the

edge measurement at the tooth flank, the

tooth root and the tooth tip. This includes

parameters such as radius, wedge angle,

basket arch form (waterfall-type and trum-

pet-type) as well as bevel length. In addi-

tion, the IF-EdgeMasterHOB is used for

measure chipping.

“Being able to measure the edge radius of both,

tooth tip and tooth flank over this broad range is,

as far as I know, not possible with any other sy-

stem. The high resolution 3D measurements with

the IF-EdgeMasterHOB enable us to offer tools

with dimensional accuracy, optimized surface state

and an equal geometry for increased process re-

liability. Also, the system´s user friendliness andthe independence from user influence are truly

impressive.”

Tobias SchulzHead of quality assurance in gearing

LMT Werkzeugtechnologie

HOB CUTTERSEDGE MEASUREMENT AT TOOTH FLANK,

TOOTH ROOT AND TOOTH TIP

WhatABOUT

WhatIS MEASURED


48 alicona I Tool measurement IF-ToolPrecision

IF-TOOLPRECISIONAUTOMATIC 3D MEASUREMENT OF TAPS

THE SYSTEM

The IF-ToolPrecision is a non contact, automatic 3D tool measurement system for areal basedand high resolution measurement of shank-tools. The system is optimized to measure taps. Itcombines all the functionalities of a coordinate measurement machine, a surface measurementdevice and a contour plus roundness measurement system. Users measure relevant parametersin the chamfer area, the flute and in the thread.

THE BENEFITS

The IF-ToolPrecision measures with a high measurement point density at high user friendliness.This is valid for the use in both research and single handed operation. There are no time con-suming calibration routines necessary as the insertion of the tool is very simple with auto cali-bration included. This both reduces measurement times and increases accuracy. Measurementreports include OK/NOT OK status, tolerances and visualization in registered true color information.

THE APPLICATIONS

The IF-ToolPrecision measures with a high measurement point density.Users benefit from a detailed and dense visualization which makes the sy-stem to an ideal tool in both tool design and reverse engineering. The 3Dmeasurement system is used for both, 3D digitalization of the tool and au-tomatic comparison with CAD data.

Tool measurement IF-ToolPrecision I alicona 49

THE EXPERIENCE “Before IF-ToolPrecision, there world-wide was no comparable system available– neither in function nor in precision.”

Michael AckermannBass GmbH & Co.KG

50 alicona I Quality assurance in production

Stable 3D measurement in production

Quality assurance in production I alicona 51

Quality assurancein production » IF-SensorR25» IF-Portable

52 alicona I Quality assurance in production IF-SensorR25

IF-SENSORR25 HOW TO ACHIEVE STABLE 3D MEASUREMENT

IN PRODUCTION

THE SYSTEM

Optical 3D measurement sensor

IF-SensorR25 is a solid optical 3D measurement instrument for automated formand roughness measurement in production. The sensor is integrated into a pro-duction line and delivers high resolution, repeatable and traceable results whenmeasuring surface characteristics in the µm or sub-µm range. This resolution canhardly be achieved by conventional 2D solutions or tactile techniques.

THE BENEFITS

A measurement procedure from development to production

The robust technology of Focus-Variation delivers high resolution results with highrepeatability in research and production. Therefore IF-SensorR25 is a platform thatenables the use of the same measurement process both in-line and in the lab.Standardized interfaces (QDAS) support an easy and quick integration into pro-duction allowing comparable in-line and lab measurements.

THE APPLICATION

Measurement of surface quality and finest form tolerances

IF-SensorR25 is a measurement system for quality assurance in serial production. Itis suitable for numerous materials including composite materials. Applications rangefrom tool to automotive industry, die casting industry and any form of precision manu-facturing. The modular design allows arbitrary extensions of hard- and software fornew and/or complex measurement tasks.

Quality assurance in production IF-SensorR25 I alicona 53


Sampling distance µm 2 1 0.5 0.2 2 1 0.5 0.2

Min. repeatability (vertical) nm 120 30 15 8 180 45 25 15Max. scan height (approx.) mm 22 16 12 9 25 25 19 12

Best vertical resolution1 nm 410 100 50 20 510 130 70 45

Working distance2 mm 23.5 17.5 13.0 10.1 34 33.5 20 13

Field of view X µm 4000 2000 1000 400 4000 2000 1000 400

Field of view Y µm 4000 2000 1000 400 4000 2000 1000 400







OBJECTIVE DETAILS

Travel range Z 26mm motorizedIllumination LED ring light with 24 segmentsWeight 4kg



1) Vertical resolution can be adjusted in IF-LaboratoryMeasurementModule.2) SX stands for objectives with larger working distances.

54 alicona I Quality assurance in production IF-Portable

IF-PORTABLEHOW TO MEASURE MICRO STRUCTURED

SURFACES ON LARGER COMPONENTS

THE SYSTEM

The IF-Portable is an optical 3D measurement device to measure form androughness on also larger components. The standard configuration allows the highresolution measurement of surface fields of up to (mm) 50x50x19. Typically, thesystem is used for near and or in production quality assurance. As an easy tohandle and portable system it is a flexible measurement station which can beused wherever it is needed.

THE BENEFITS

A key feature is the integrated revolving nosepiece to change objectivesand measurement resolution. This increases measurement precision aseach objective is pre-calibrated, avoiding error-prone readjustment or re-calibration processes. Also, easy automation of measurements increasesprocess reliability, production efficiency and usability.

THE APPLICATIONS

A large vertical scanning range enables the measurement of various geome-try types and forms. Amongst others, a key application is platen inspection inprint industry. Further fields of use are the measurement of turbine or rotorblades, steel and body type surfaces. Users achieve traceable measurementsin high repeatability.

Quality assurance in production IF-Portable I alicona 55

2.5x 5x 10x 20x 50x 100x

Sampling distance µm 4.4 2.2 1.1 0.55 0.22 0.11

Min. repeatability (vertical) nm 610 160 40 25 25 25Max. scan height (approx.) mm 8 22 16 12 9 3.2

Best vertical resolution1 nm 1717 428 106 60 60 60

Working distance2 mm 8.5 23.1 17.5 13.0 10.1 3.5

Field of view X µm 7040 3520 1760 880 352 176

Field of view Y µm 5280 2640 1320 660 264 132

RANGE OF RESOLUTION AND APPLICATION

2.5x 5x 10x 20x 50x 100x

Max. measurable area mm² 2500 2500 2500 2500 1000 210

Min. measurable angle ° 20 20 20 20 20 20

Min. measurable roughness (Ra) nm 5200 1300 320 180 180 180

Min. measurable roughness (Sa) nm 2600 650 160 90 90 90

OBJECTIVE DETAILS


1) Vertical resolution can be adjusted in IF-LaboratoryMeasurementModule

THE EXPERIENCE

“The form of a laser structured surfacegeometry is a crucial challenge whenit comes to measure a platen. Withthe IF-Portable system we have founda solution which really delivers preciseresults.”

Andreas Tillmannproject management Heidelberger Druck

Travel range X/Y 50x50mmTravel range Z 26mmIllumination LED coaxial light

Weight 9.3kg (dependent from configuration)


56 alicona I Technology & Accessories

Technology & Accessories I alicona 57

Technology & Accessories» Principle of Focus-Variation » Traceable roughness measurement» Focus-Variation from the perspective of a tool research association: A guest editorial

Based on the Focus-Variation technology, InfiniteFocus offers a high measurement sy-stem capability for measuring surface roughness. Roughness is measured profile basedaccording to ISO 4287/88 and area based according to ISO 25178. Due to unique techno-logy and system specific characteristics, operators perform repeatable and traceableroughness measurements down to 0.05 µm.

A high vertical and lateral resolution enables measurements of com-ponents with low roughness but also of highly textured surfaces. Thismeasurement performance is supported by the flexible lighting tech-nology which allows the measurement of steep flanks and materialswith varying surface characteristics. The large vertical travel rangewith a long working distance makes it possible to measure variedcomponent forms and types. Using standards of the PTB (PhysikalischTechnische Bundesanstalt, Braunschweig, the national metrology in-stitute providing scientific and technical services) and the DKD (Deut-scher Kalibrierdienst) for calibration and adjustment guaranteetraceable results.

RELIABLE ROUGHNESS MEASUREMENTMEANS TRACEABLE ROUGHNESS MEASUREMENT

The high vertical and lateral resolution ofInfiniteFocus is based on:» a robust measurement sensor with integrated granite

» a glass scale with a 2nm resolution

» specially developed lens

» a high quality and high resolution CCD sensor

» an optical vibration isolation

Area based surface parameters conforming to ISO 25178

» Height parameter (Sa, Sq, ..)

» Lateral parameter (Sdq, Sdr, ..)

» Functional parameter (Sk, volume parameter...)

» Features (Sda, ….)

58 alicona I Technology

The specimen is placed ontothe stage and is illuminatedwith modulated light. Thislight is transmitted throughthe optic and focusedthrough a beam splitter ontothe specimen. Coaxial illumi-nation is created.

As the distance betweenspecimen and objective isvaried the change of sharp-ness is measured. Depen-ding on the 3-dimensionalstructure of the specimensome areas are depictedsharp or not, the sharp datais used to construct the 3Ddataset.

Essential to the measure-ment result is the correct in-teraction of modulatedillumination with continuousvertical movement and thequality of the sensor measu-rement. This process isachieved with the Smart-Flash technology developedby Alicona.

For every position on the ob-ject the sharp regions aremeasured. The variation ofthe sharpness values is usedfor the measurement of the3D-postion. This is howdense 3D-datasets are crea-ted.

The light is reflected by thespecimen and projected onto a digital sensor in the pre-cision optic. Depending onthe objective selected variouslateral and vertical resoluti-ons can be achieved.

Due to the Alicona roughness standard the optical roughness measurementof InfiniteFocus guarantees traceable precision:» The standard that is traceable to the PTB is applicable for all optical techniques included in EN ISO.

» This roughness standard is suitable for optical as well as for tactile scanning and thus enables comparison to tactile

roughness measurements.

» Available roughness values: Ra 100nm, 500nm and 3000nm

Average roughness value Ra

Tactile measurement Optical measurement with InfiniteFocus Roughness standard 100 100nm 103nm

Roughness standard 500 503.5nm 501.3nm

Technology I alicona 59

PROVABLE PRECISIONOPTICAL ROUGHNESS MEASUREMENT WITH INFINITEFOCUS

How Focus-Variation works

InfiniteFocus is based on the principle of Focus-Variation. It is a robust tech-

nology with a high measurement point density including information about

measurement uncertainty. Focus-Variation is applied in both research and

production.

MEASUREMENT POINT DENSITY AND REPEATABILITY A large number of dense measurement points, also on larger areas, provides highlyrepeatable measurements. Alicona also automatically provides an estimation of the re-peatability of every single measurement value analyzing the variance of each measu-rement point in the Z-direction. This repeatability measure helps to evaluate the qualityof individual measurement points. This again allows measurement results that are easyto interpret. In addition it shows if and to which extend vibrations occurred during themeasurement.

TECHNOLOGY:FOCUS-VARIATION

INFINITEFOCUS:Dr. Manfred Prantl, Alicona R&D CEO

“Security and reliability are the cornerstones ineach development. We develop with high invest-ment in R&D, ensuring that we can tackle theneeds required in industry and science.”

» All Alicona measurement systems guarantee versatility and precision.

» The use of the measurement systems is easy to understand even though a variety ofdifferent settings is provided.

» All measurement results are traceable backto the PTB as well as to NPL. Additionally we have developed our own standard that allows the verification of the accuracy of optical roughness measurements.

InfiniteFocus provides highresolution and reproduciblemeasurement results in boththe lab and in rougher ma-nufacturing environments.

» The technology works reliably and is not affected by environmental influences such as temperature or ambient light. This is due to the large amount of data that is used for measu-ring every single z-value.

» InfiniteFocus is a high quality measurement device and generally insensitive to external influences. The system includes a vibration absorption construc-tion and is therefore vibration resistant.

» Various light sources minimize the impact of light.

» InfiniteFocus delivers an estimation of the measurement uncertainty for every 3D-point.

60 alicona I Technology

There is still a huge need in the research on the

problem, what impact typical parameters of a

cutting edge produce on the processing result.

During industry for quality assurance is mainly

focused on the measurement of a radius, chip-

ping, wear and micro cracks, research however

is dealing with a problem, which additional sur-

face parameters can be used for a functional

description of a cutting edge. Recent develop-

ments in metrology help us to move forward

with relevant activities. This is why, among

other factors, the impact of a form of the cut-

ting edge and its roughness is examined as to

their influence on the results of processing.

Here the Focus-Variation turns to be increa-

singly establishing itself as an appropriate tech-

nology. The area based, high resolution

measurements that can be achieved by Focus-

Variation open new possibilities for research,

and, consequently, new insights into cutting

edge characterization which was not possible

in such a form until now. One of the most si-

gnificant benefits for us is the fact that we are

now able to perform traceable measurements

of both geometry and roughness of various

edge types.

"One of the greatest advantages,besides the high vertical resolu-tion, is the fact that with Focus-Variation we are able to performtraceable measurements of geo-metry and roughness of differentedge forms."

The main subject of our current studies is

dealing with possible effects that the cutting

edge form might produce on the processing

result in addition to the edge radius. There-

fore every common edge form, ranging from

simple edge roundness to a more complex,

elliptic form has to be completely measured.

At GFE we perform these measurements pri-

marily by means of InfiniteFocus optical mea-

suring system. Due to a lateral resolution in

the submicrometer range and a vertical reso-

lution in nanometer range, the device is ideal

for defining necessary roughness parame-

ters. With the 3D measurement device by Ali-

cona we also measure additional parameters

such as the roughness on the clearance and

chip surface. These parameters analyze the

impact of roughness on the machining pro-

cess, workpiece quality, durability and chip

flow.

Heinz-Wolfgang Lahmann from the Society for Production Engineering and Development(GFE e.V.) Schmalkalden/Germany is an expert in the application of optical measurementprocedures for the evaluation of precision tools. Among other subjects, he specializes inthe metrological characterization of a tool's micro geometry and is familiar with the de-velopments in measurement and test engineering. For basic research on cutting edge cha-racterization he also uses Focus-Variation. From the traceable edge measurement withInfiniteFocus he expects significant progress, which he describes as follows.

FOCUS-VARIATION FROM THE PERSPECTIVE OF A TOOL RESEARCH ASSOCIATION

A GUEST EDITORIAL BY HEINZ-WOLFGANG LAHMANN

Another subject of research is the correlation

between a tool and a workpiece. The study

examines effects of the material, a tool has

been made of, on the machined workpiece or

vice versa, how the material of a workpiece

affects the tools as for its wear and the like.

Here, we benefit from the flexibility of Infinite-

Focus as we use the system for the measure-

ment of a tool and a workpiece.

For a research association, visualization plays

an important role as well. It delivers an additio-

nal evaluation possibility for a better analysis of

a tool. The visualization in true color information

with InfiniteFocus also allows us to detect

coated areas quickly and without much effort.

Technology I alicona 61

Heinz-Wolfgang Lahmann Society for Production Engineering and Development (GFE e.V.), Schmalkalden/Germany

62 alicona I Accessoires

1

7

6

3

4

5

2

ACCESSORIES 1 INSERT-GRIP

A tool for placing small components in an exact 45° position.

This minimizes sources of error and increases repeatability.

Usable for:

IF-EdgeMaster, InfiniteFocus, InfiniteFocusSL

2 ADVANCED-INSERT-GRIPGrip for the measurement of small objects in variable oblique positions. This grip

can be adjusted to most specimens and also locked in the desired position.

Measurement comfort and repeatability are increased.

Usable for:


3 ROTATION-GRIPClamping device, for horizontal mounting of components such as drills or mil-

ling cutters enabling it to be rotated into the desired position. Also cutting

edges are measured easily.

Usable for:


4 CLAMPING-SETA set of different clamping bars for mounting and securing specimens in

a certain position: A flexible solution for flat, steep and round components.

Usable for:


5 ROUGHNESS-STANDARDRoughness standard for optical and tactile measurements traceable to the PTB.

With this tool the accuracy of optical roughness measurements is verified. All

ISO optical measurement techniques are validated.

Usable for:

All Alicona 3D measurement systems

6 CALIBRATION TOOL Standard, traceable to the PTB, for verifying the vertical and lateral accuracy of

InfiniteFocus. It provides a height step (1000µm) for the vertical check and

various chess patterns for the verification of lateral results.

Usable for:


7 VERIFICATION-TOOLStandard, traceable to the PTB, with miscellaneous form artifacts such as

steep slopes, angles and cylinder sizes. Used for verifying the accuracy of

form measurements.

Usable for:


Alicona offers a range of accessoires which increase usability and minimize

user influence. A selection of standards ensures traceability of the

measurements performed.

Selected customers I alicona 63

Bass Ceratizit EDM ETH

Fraunhofer IPAFraunhofer VisionFZGFette

Heidelberg Inspire NFI NPL

PTSPTBoerlikon SIMTEK

VollmerTU Hamburg Harburg

VargusKomatsuSeiki IFAS

VW University of Wisconsin

Makino

AtomicProfin LMT Fette Rohde & Schwarz

GFEGF AgieCharmilles Cassidian Sutton Tools

SELECTED CUSTOMERS

Selected customers who have contributed to the magazine series FOCUSvariation.

IF-IF-20102011-3.1Technical data, images, descriptions without obligations. We reserve the right to modify content. ®alicona and

®InfiniteFocus are registered trademarks, ©copyright by alicona

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phone +49 8652 6553901fax +49 8652 6553902

[email protected]

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phone +49 175 [email protected]

Alicona headquarters Alicona Imaging GmbHDr.-Auner-Straße 21a8074 Raaba/Grambach

Austriaphone +43 316 403010 700fax +43 316 403010 711

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phone +49 151 1214 [email protected]

Germany South/East Matthias Strößnerphone +49 151 23530254

[email protected]

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