Bruce R. Borchardt

Error compensation for CMM touch trigger probes

Abstract We present the analysis of a simple mechanical model of a common type of kinematic seat touch trigger probe widely used on modern coordinate measuring machines (CMMs). The model provides a quantitative description of the pretravel variation or “probe-lobing” characteristics that limit the use of such probes for high-accuracy dimensional measurements. We include the effects of stylus bending and the frictional interaction between the stylus ball and the part surface. The model is restricted to probes with simple straight styli, and we demonstrate significant error reduction both for vertically and horizontally oriented styli. In the latter case, gravitational forces are shown to play an important role in probe triggering and pretravel variation. Extensions to arbitrary orientations are discussed.

The estimation of measurement uncertainty of small circular features measured by coordinate measuring machines

Abstract This paper examines the measurement uncertainty of small circular features as a function of the sampling strategy; i.e., the number and distribution of measurement points. Specifically, we examine measuring a circular feature using a three-point sampling strategy in which the angular distance between the points varies from widely spaced, 120°, to closely grouped, a few degrees. Both theoretical and experimental results show that the measurement uncertainty is a strong function of the sampling strategy. The uncertainty is shown to vary by four orders of magnitude as a function of the angular distribution of the measurement points. A conceptual framework for theoretically estimating the measuring uncertainty is described, and good agreement with experiments is obtained when the measurements are consistent with the assumptions of the theoretical model. This paper is an expansion of a previous internal report 1 with additional material on analog probes and probe lobing models.

ASME B89.4.19 Performance Evaluation Tests and Geometric Misalignments in Laser Trackers.

Small and unintended offsets, tilts, and eccentricity of the mechanical and optical components in laser trackers introduce systematic errors in the measured spherical coordinates (angles and range readings) and possibly in the calculated lengths of reference artifacts. It is desirable that the tests described in the ASME B89.4.19 Standard [1] be sensitive to these geometric misalignments so that any resulting systematic errors are identified during performance evaluation. In this paper, we present some analysis, using error models and numerical simulation, of the sensitivity of the length measurement system tests and two-face system tests in the B89.4.19 Standard to misalignments in laser trackers. We highlight key attributes of the testing strategy adopted in the Standard and propose new length measurement system tests that demonstrate improved sensitivity to some misalignments. Experimental results with a tracker that is not properly error corrected for the effects of the misalignments validate claims regarding the proposed new length tests.

RECIST versus volume measurement in medical CT using ellipsoids of known size.

Two hundred eighty three uniaxial ellipsoids with sizes from 4 mm to 11 mm were measured with a coordinate measuring matching (CMM) and also scanned using a medical computed tomography (CT) machine. Their volumes were determined by counting voxels over a threshold, as well as using equivalent volumes from the length given by the RECIST 1.1 criterion (Response Evaluation Criteria in Solid Tumors). The volumetric measurements yield an order of magnitude reduction in residuals compared to the CMM measurements than the residuals of the RECIST measurements also compared to the CMM measurements.

A novel artifact for testing large coordinate measuring machines

We present a high-accuracy artifact useful for the evaluation of large CMMs. This artifact can be physically probed by the CMM in contrast to conventional techniques that use such purely optical methods as laser interferometers. The system can be used over large distances; for example, over 4 meters, with an uncertainty of less than one part per million. The artifact is relatively inexpensive, robust for use in reasonable industrial environments, and significantly reduces testing time over traditional step gauge measurements.

Properties of free-standing ball bar systems

Abstract This article offers recommendations to coordinate-measuring machine (CMM) buyers, sellers, and users on the design of free-standing ball bar systems used to evaluate the volumetric performance of CMMs according to the ANSI/ASME B89.1.12M standard. These systems are more widely used today than earlier methods such as magnetic ball bars. In this article we study the general design requirements, mechanical deformations under gravity and probing forces, vibrational considerations, and thermal effects on free-standing ball bar systems. We conclude with a summary of the issues in ball bar design, which must be considered in order to maintain an artifact error budget of ∼1 μm.

Performance evaluation of laser trackers

The American Society for Mechanical Engineers (ASME) recently released the ASME B89.4.19 Standard [1] on performance evaluation of spherical coordinate instruments such as laser trackers. At the National Institute of Standards and Technology (NIST), we can perform the complete set of tests described in the Standard, and have done so for a variety of laser trackers. We outline the tests described in the Standard, discuss our capabilities at the large-scale coordinate metrology group, and present results from B89.4.19 tests conducted on a few trackers. We also outline an analysis approach that may be used to evaluate the sensitivity of any measurement, including the tests described in the B89.4.19 Standard, to different geometric misalignments in trackers. We discuss how this approach may be useful in determining optimal placement of reference lengths to be most sensitive to different geometric misalignments.

RESULTS OF THE NIST NATIONAL BALL PLATE ROUND ROBIN

This report examines the results of the ball plate round robin administered by NIST. The round robin was part of an effort to assess the current state of industry practices for measurements made using coordinate measuring machines. Measurements of a two-dimensional ball plate (240 mm by 240 mm) on 41 coordinate measuring machines were collected and analyzed. Typically, the deviations of the reported X and Y coordinates from the calibrated values were within ± 5 μm, with some coordinate deviations exceeding 20.0 μm. One of the most significant observations from these data was that over 75 % of the participants failed to correctly estimate their measurement error on one or more of the ball plate spheres.

Estimating Volumes of Near-Spherical Molded Artifacts.

The Food and Drug Administration (FDA) is conducting research on developing reference lung cancer lesions, called phantoms, to test computed tomography (CT) scanners and their software. FDA loaned two semi-spherical phantoms to the National Institute of Standards and Technology (NIST), called Green and Pink, and asked to have the phantoms’ volumes estimated. This report describes in detail both the metrology and computational methods used to estimate the phantoms’ volumes. Three sets of coordinate measuring machine (CMM) measured data were produced. One set of data involved reference surface data measurements of a known calibrated metal sphere. The other two sets were measurements of the two FDA phantoms at two densities, called the coarse set and the dense set. Two computational approaches were applied to the data. In the first approach spherical models were fit to the calibrated sphere data and to the phantom data. The second approach was to model the data points on the boundaries of the spheres with surface B-splines and then use the Divergence Theorem to estimate the volumes. Fitting a B-spline model to the calibrated sphere data was done as a reference check on the algorithm performance. It gave assurance that the volumes estimated for the phantoms would be meaningful. The results for the coarse and dense data sets tended to predict the volumes as expected and the results did show that the Green phantom was very near spherical. This was confirmed by both computational methods. The spherical model did not fit the Pink phantom as well and the B-spline approach provided a better estimate of the volume in that case.

Pitch Diameter Measurement of Threaded Gages Using a Coordinate Measuring Machine

The reference datum for a screw thread is the pitch diameter cylinder. Although a defined method within the United States for pitch diameter measurement exists, it does not follow worldwide procedures, and the complexity and uncertainties associated with this measurement often go unappreciated. Some of the problems associated with using a coordinate measuring machine (CMM) for measurements on both external and internal threads will be discussed.