Inspecting form & finish in Ultra Precision Machining

Ultra-precision machining as manufacturing process produces components with extremely tight tolerances, achieving a super high surface finish, with form accuracy typically in the sub-µm and roughness in the (sub)nanometer range. Ultra-precision machining involves dedicated machining technology and tools, including control systems for reaching the super fine texture/ finish. For face milling, grinding, lapping or polishing surfaces and ultraprecise roughness - inspect your results as machining feedback with Polytec whiltelight interferometers.

The smaller the geometrical characteristics, the more challenging the inspection and processing. Surface properties are key for high-precision motion, automatic assembly or service life. Optical surface metrologyis steadily gaining importance for precision machining, diamond turning or single point diamond turning (SPDT). TopMap white-light interferometers capture larger areas, bigger samples or multiple samples even without need for stitching with over 2M data points in a single measurement in just a matter of seconds. At production level, one-click software solutions manage and load predefined measurement recipes for a significant increase of testing efficiency.

Highlights

  • Reliable inspection of tolerances based on repeatable measurements
  • Fast and efficient areal measurements in production or inline
  • Capture large UP machined surfaces with FOV up to 230x220 mm
  • Large 70mm scan range reaches deep holes and recessed areas
  • Multi-sample measurements and pattern recognition avoids mechanical fixture
  • Smart Scanning Technology measures on all surfaces & materials (smooth & rough) 
Inspecting surface flatness, steps, angle and parallelism on the cuvette of a NIR spectroscope for ultra-precise alighnment and positioning
Inspecting surface flatness, steps, angle and parallelism on the cuvette of a NIR spectroscope for ultra-precise alighnment and positioning
Resolve ultra-precision machined surfaces with sub-nm precision, evaluate finish and areal roughness Sa, Sq, Sz
Resolve ultra-precision machined surfaces with sub-nm precision, evaluate finish and areal roughness Sa, Sq, Sz
Surface flatness evaluation of precision mechanics for optical instruments
Surface flatness evaluation of precision mechanics for optical instruments
Quality control of machined parts on production-level
Quality control of machined parts on production-level
Telecentric lens with 70mm large Z range reaches the insides of holes and deep steps
Telecentric lens with 70mm large Z range reaches the insides of holes and deep steps
2Million measurement points scanned areally within just seconds capture entire precision mechanic surfaces
2Million measurement points scanned areally within just seconds capture entire precision mechanic surfaces
Inspecting surface flatness, steps, angle and parallelism on the cuvette of a NIR spectroscope for ultra-precise alighnment and positioning
Inspecting surface flatness, steps, angle and parallelism on the cuvette of a NIR spectroscope for ultra-precise alighnment and positioning
Resolve ultra-precision machined surfaces with sub-nm precision, evaluate finish and areal roughness Sa, Sq, Sz
Resolve ultra-precision machined surfaces with sub-nm precision, evaluate finish and areal roughness Sa, Sq, Sz
Surface flatness evaluation of precision mechanics for optical instruments
Surface flatness evaluation of precision mechanics for optical instruments
Quality control of machined parts on production-level
Quality control of machined parts on production-level
Telecentric lens with 70mm large Z range reaches the insides of holes and deep steps
Telecentric lens with 70mm large Z range reaches the insides of holes and deep steps
2Million measurement points scanned areally within just seconds capture entire precision mechanic surfaces
2Million measurement points scanned areally within just seconds capture entire precision mechanic surfaces

Fast and efficient surface inspection with large field of view (FOV)

Large field of view profilers from Polytec show their advantages in big samples, capturing entire workpiece areas 44x33 mm without stitching in a single shot. Expanded field-of-view based on image stitching reaches 230x220 mm areas. This configuration is great for measuring flatness, investigating parallelism of two workpiece sections and, with the telecentric optical beam path plus the 70mm high vertical range of the white-light interferometer, it can safely measure the bottom of deeper lying areas, drill holes etc. Large field-of-view scanning gathers over 2M data points within just seconds and in a single shot, perfectly visualizing the true shape, waviness or even producing material histograms. Using the integrated pattern recognition algorithms the large field-of-view allows for multi-sample measurements in a single shot, leading to significant time saving in testing especially on production level.

Capture areas with 230x220 mm extended field-of-view?

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Multi-sample pass-fail analysis in manufacturing
Multi-sample pass-fail analysis in manufacturing

Reliable pass-fail analysis inline or online

Early defect detection and pass-fail analysis integrated in the production line of precision engineered parts allow a live feedback for the manufacturing process. Data based insights from TopMap 3D surface profilers enable manufacturers to take precautions in an early stage. Often, the entire workpiece topography needs to be checked prior to certification. Polytec TopMap surface metrology increases testing efficiency with large areal measurements and enables fast and easy 100% testing. With integrated pattern recogniton for multi-sample inspections in a single shot to speed up production testing, by automatically detecting lay and orientation.
 

Material ratio curve enabling the analysis of a flat lapped surfaces and a face milled surface
Material ratio curve: here split view into Peak, Core and Scoring sections by geometrical considerations
Material ratio curve: here split view into Peak, Core and Scoring sections by geometrical considerations
Ra, Rz roughness values as quality parameter? Differently machined surfaces might not always reveal different Ra, Rz parameters
Ra, Rz roughness values as quality parameter? Differently machined surfaces might not always reveal different Ra, Rz parameters
Quality control on grinding patterns, analyzing ground, lapped or polished surfaces
Quality control on grinding patterns, analyzing ground, lapped or polished surfaces
Material ratio curve enabling the analysis of a flat lapped surfaces and a face milled surface
Material ratio curve: here split view into Peak, Core and Scoring sections by geometrical considerations
Material ratio curve: here split view into Peak, Core and Scoring sections by geometrical considerations
Ra, Rz roughness values as quality parameter? Differently machined surfaces might not always reveal different Ra, Rz parameters
Ra, Rz roughness values as quality parameter? Differently machined surfaces might not always reveal different Ra, Rz parameters
Quality control on grinding patterns, analyzing ground, lapped or polished surfaces
Quality control on grinding patterns, analyzing ground, lapped or polished surfaces

Material distribution & material ratio curve

The performance of ultra-precision machined product surfaces can be modified and requirements can be optimized accordingly by characterizing the detailed material distribution. TopMap optical profilers capture surfaces quickly and precisely in lab and production. In some applications, increased friction brought about by distributing diamond particles on one surface can help to prevent the undesirable relative movement of touching surfaces. The desired level of friction is achieved by modifying the particle size, shape and quantity. TopMap 3D profilers help evaluate the detailed material distribution reliably.

Inspecting tribological systems, analyzing e.g. the wear or volume as potential load capacity
Inspecting tribological systems, analyzing e.g. the wear or volume as potential load capacity

Tribology: Anticipating wear & tear

Optimize the mechanical loading capacity supported by precise surface characterization. Tribological system design requires very small surface parameter tolerances, while throughput must remain at a consistent and high level. To this end, TopMap white-light interferometers by Polytec offer non-contact tribology measurements with a high repetition rate to record the entire surface’s topography in a matter of seconds. Wear and tear studies are typical applications for TopMap surface metrology systems.

Resolve (sub) nanometer steps?

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Classic applications

Contact your PolyXpert

+49 7243 604-2302
dms-info@polytec.de