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CTMA 2005. Tools for Improving Machine Tool Volumetric Accuracy. Robert (Buz) Callaghan Chief Engineer. Why Improve Machine Tool Volumetric Accuracy?. Measuring machine performance. Allows process improvements before parts are made. Allows predictive repairs of machines. - PowerPoint PPT Presentation
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Independent Quality Labs, Inc.Independent Quality Labs, Inc. 11© 2005© 2005
CTMA 2005CTMA 2005
Tools for Improving Tools for Improving Machine Tool Volumetric AccuracyMachine Tool Volumetric Accuracy
Robert (Buz) Callaghan
Chief Engineer
22Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Why ImproveWhy ImproveMachine Tool Volumetric Accuracy?Machine Tool Volumetric Accuracy?
Measuring machine performance
Allows process improvements before parts are made.
Allows predictive repairs of machines.
33Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Why ImproveWhy ImproveMachine Tool Volumetric Accuracy?Machine Tool Volumetric Accuracy?
Measuring finished part dimensions Can only be done after the part is
completed.
Causes reject parts to be repaired or thrown way.
44Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
What are the Tools?What are the Tools?
Machine Error Budgets
Machine Parametric Measurement
55Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
HowHow did these tools evolve?did these tools evolve?
For over 90 years, the builders determined machine performance standards.
Dr. Georg Schlesinger recognized the need to do measurements on machine tools.
66Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
squareness level
HowHow did these tools evolve?did these tools evolve?
Schlesinger’s book, Testing Machine Tools, contains parametric tests, such as
limited to the characterization of machine spindles and moving components
roundness straightness
77Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How did these tools evolve?How did these tools evolve?
Engineers at Lawrence Livermore National Labs found these methods inadequate for specifying their machines.
88Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How did these tools evolve?How did these tools evolve?
The ISO 230 Specifications were for the assembly of machine tool components not the capability of machines to make parts.
© 2005© 2005 99Independent Quality Labs, Inc.Independent Quality Labs, Inc.
“parametric error budgeting”
“parametric error measurement”
What were their solutions?What were their solutions?
They developed techniques to aid in specification, design & production of the world’s most accurate machine tools.
1010Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Identify machine axis relation parameters
Identify machine thermal error parameters
Identify machine environmental error parameters
Sum error parameters
Parametric Error BudgetingParametric Error Budgeting
Identify machine motion error parameters
1111Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Motion Error ParametersMotion Error Parameters
1212Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Motion Error ParametersMotion Error Parameters
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Relation ParametersRelation Parameters
1414Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Machine Error BudgetMachine Error BudgetFULL VOLUME ERROR MODEL
X Y ZStart -289.0000 0.0000 -55.6700End 0.0000 161.0000 0.0000
Travel 289.0000 161.0000 55.6700
Error Description Error Comments Ang Error Offset Full ErrorDir (AS) (in/ft) (in) (in)
1 eXx Lin Acc x Systematic Deviation (E) 0.0016002 erXx Repeat x Unidirectional Repeatability (R) 0.0002003 eYx Str Y y 0.0023004 eZx Str Z z 0.0021005 eAx Roll z Offset Y Travel 8.0 0.00047 90 0.0034926 eBx Pitch x Offset Z Travel+ W Travel - Tool Length 4.8 0.00028 90 0.0020957 eCx Yaw x Offset Y Travel 4.1 0.00024 31 0.0006168 eoCxy Sq x Offset Y Travel 6.0 0.00035 90 0.0026259 eYy Lin Acc y Systematic Deviation (E) 0.003200
10 erYy Repeat y Unidirectional Repeatability (R) 0.00010011 eXy Str X x 0.00030012 eZy Str Z z 0.00040013 eBy Roll x Offset Z Travel+ W Travel - Tool Length 12.4 0.00072 31 0.00186414 eAy Pitch y Offset Z Travel+ W Travel - Tool Length 8.1 0.00047 10 0.00039315 eCy Yaw y Offset Scale Distance from S C/L 10.6 0.00062 10 0.00051416 eoAyz Sq y Offset Z Travel - Tool Length -55.0 -0.00320 90 -0.02400017 eZz Lin Acc z Systematic Deviation (E) 0.00060018 eZz Repeat z Unidirectional Repeatability (R) 0.00010019 eYz Str Y y 0.00010020 eXz Str X x 0.00040021 eCz Roll x No Offset 2.3 0.00013 90 0.00100422 eBz Pitch x Offset Z Travel - Tool Length 2.5 0.00015 31 0.00037623 eAz Yaw y Offset Z Travel - Tool Length 1.6 0.00009 31 0.00024124 eoBxz Sq x Offset Z Travel - Tool Length 4.6 0.00027 31 0.00069825 eXs Rad Err X x 0.00010026 eYs Rad Err Y y 0.00009327 eZs Axial Err Z z 0.00011028 eoAxs Sq SX x or z Offset Tool Length 4.3 0.00025 8 0.00016729 eoBys Sq SY y or z Offset Tool Length 5.3 0.00031 8 0.000207
Sum = 0.005514
1515Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Extending Budgeting MethodsExtending Budgeting Methods
Part Feature Assessment
Process Error Budget
1616Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Part Feature AssessmentPart Feature Assessment
Part features and tolerances are well defined by ASME Y14.5M-1994 Dimensioning and Tolerancing.
The definitions of size, form, profile, location, orientation, and run-out are used to relate features with processes.
1717Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Part Feature AssessmentPart Feature Assessment
Length
Width
HeightSize
Diameter
Straightness
Flatness
Circularity
For Individual Features
Form
Cylindricity
Of a LineFor Individual or Related Features Profile
Of a Surface
Position
ConcentricityLocation
Symmetry
Angularity
PerpendicularityOrientation
Parallelism
Circular
For Related Features
RunoutTotal
1818Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Part Feature AssessmentPart Feature Assessment
Feature Tolerance Ratio (FTR)
determined by dividing the feature tolerance bandwidth by the distance over which it is applied
1919Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Part Feature AssessmentPart Feature Assessment
2020Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Process Error BudgetProcess Error Budget
The development of a Process Model from the Full Volume Model involves four steps.
2121Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Process Error BudgetProcess Error Budget
2. determine which of the machine axes are moved and how far
1. use the FTR to identify the features and tolerances, which will govern capability
2222Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Process Error BudgetProcess Error Budget
3. determine the effect of squareness and angular errors
4. compare the sum of all errors to feature tolerance bandwidth = Part Tolerance Ratio (PTR)
2323Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Process Error BudgetProcess Error Budget
Part Tolerance Ratio (PTR) should be greater than 4
2424Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Process Error BudgetProcess Error Budget
2525Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Parametric Error MeasurementParametric Error Measurement
Methods specified by ANSI Standards
Methods require full documentation to assure repeatability
Errors exceeding budgeted values must be corrected
2626Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Parametric Error MeasurementParametric Error Measurement
Roll with Electronic Level
2727Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Parametric Error MeasurementParametric Error Measurement
Accuracy with Laser
2828Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Parametric Error CorrectionParametric Error Correction
Proper measurement and presentation of errors
Leads to rapid error correction
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Yaw ErrorsYaw Errors
Loose Saddle
3030Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Yaw ErrorsYaw Errors
Before Gib Adjustment
3131Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Yaw ErrorsYaw Errors
After Gib Adjustment
3232Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Tools Under DevelopmentTools Under Development
Computer Aided Process Specification (CAPS)
LOCUSw Machine Measurement and Correction Software
3333Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
CAPSCAPS
Objective:
To integrate the existing budgeting methods with CAD/CAM to produce Machine Performance Specifications
3434Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
Current CAPSCurrent CAPS
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New CAPSNew CAPS
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CAPS How will it work?CAPS How will it work?
2. Select or build Machine Error Budget.
3. Scan CAM files to establish axis paths and tool selection.
4. Create Process Error Budget.
5. Print Parameter Specification
1. Scan CAD files and establish FTRs.
3737Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
LOCUSwLOCUSw
Objectives;
1. Create data for CAPS.
2. Incorporate error correction.
3. Facilitate training
3838Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
LOCUSw Define MachineLOCUSw Define Machine
3939Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
LOCUSw Select SequenceLOCUSw Select Sequence
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LOCUSw Setup TestLOCUSw Setup Test
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LOCUSw Run TestLOCUSw Run Test
4242Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
LOCUSw Review ResultsLOCUSw Review Results
4343Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How do these tools affect Weapon How do these tools affect Weapon System Sustainment? System Sustainment?
Many parts are produced on Computer Numerically Controlled (CNC) Machines.
Using digitally transferred programs to produce a single part.
One reject means 100% scrap.
Worn parts from existing Weapon Systems must be replaced by the Depots.
4444Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How do these tools affect Weapon How do these tools affect Weapon System Sustainment? System Sustainment?
Parts for new Weapon Systems are often made at the lowest cost.
This has caused the large Defense Contractors to out-source.
Resulting in smaller companies attempting to produce increasingly complex parts.
4545Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How do these tools affect Weapon How do these tools affect Weapon System Sustainment?System Sustainment?
Parts for new Weapon Systems are also produced on CNC Machines.
Smaller companies do not always have the resources to solve complex problems.
Resulting in scrap, delays and cost over-runs.
4646Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How can these tools improve CNC How can these tools improve CNC Machines? Machines?
CAPS matches capability with part requirements.
For selecting new machine vendors. For selecting out-source vendors. For selecting existing machines for new parts. For determining the repair schedule. For selecting machines to be retired or rebuilt.
Each CNC machine has it’s own unique capability.
4747Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How does LOCUSw Software help Weapon How does LOCUSw Software help Weapon System Sustainment?System Sustainment?
To reduce the time of machine performance measurement and correction.
To capture, analyze and diagnose CNC machine errors.
4848Independent Quality Labs, Inc.Independent Quality Labs, Inc.© 2005© 2005
How does LOCUSw Software help Weapon How does LOCUSw Software help Weapon System Sustainment?System Sustainment?
Adding knowledge based software for diagnostics.
Improving hands-on training at Weapons Depots.