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Advanced image analysis verifies geometry performance of micro-milling systems.

Bita Daemi, Peter Ekberg, Lars Mattsson

    Applied Optics
    |April 5, 2017
    PubMed
    Summary

    This study introduces an optical technique for precise dimensional measurement of micro-milled parts. The method achieves submicron uncertainty, aiding in equipment assessment and adjustment for micro-milling machines.

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    Area of Science:

    • Metrology
    • Precision Engineering
    • Optical Measurement Techniques

    Background:

    • Accurate dimensional measurement of micro-milled components is critical but challenging.
    • Machine specifications often lack operational parameters for workshop verification.
    • A need exists for tests assessing geometrical performance across a machine's working area.

    Purpose of the Study:

    • To present an optical technique for submicron uncertainty dimensional measurement of micro-milled features.
    • To enable assessment and adjustment of micro-milling equipment.
    • To verify geometrical performance over large working areas (>10 cm²).

    Main Methods:

    • Utilizing an ultra-precision measurement microscope.
    • Employing advanced image analysis to determine the center of gravity of milled cross-shaped features at subpixel levels.

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  • Developing specialized algorithms to mitigate interference from burrs and milling marks.

    • Main Results:

    • Demonstrated submicron uncertainty in dimensional measurements over areas greater than 10 cm².
    • Achieved high repeatability and reproducibility in measurements across three micro-milling facilities.
    • Identified an uncharacterized 2 μm amplitude undulation in one facility's performance.

    Conclusions:

    • The developed optical technique provides a reliable method for verifying micro-milling machine geometrical performance.
    • The technique effectively handles common challenges like burrs and milling marks.
    • This approach aids users in assessing, adjusting, and ensuring the precision of their micro-milling equipment.