Simone Carmignato

Testing of x-ray microtomography systems using a traceable geometrical standard

X-ray computed microtomography is an interesting imaging technique for many applications, and is also very promising in the field of coordinate metrology at the micro scale. The main advantage with respect to traditional tactile-probing or optical coordinate measurement systems is that x-ray tomography can acquire dimensional and geometrical data for both inner and outer surfaces, without accessibility restrictions. However, there are no accepted test procedures available so far and measurement uncertainty is unknown in many cases, due to complex and numerous error sources. The paper presents the first results of a test procedure implemented for determining the errors of indication for length measurements of x-ray microtomography systems, using a new reference standard featuring a regular array of inner and outer cylindrical shapes. The developed test method allows the determination of specific characteristics of x-ray microtomography systems and can be used for the correction of systematic errors.

Dimensional measurement of micro-moulded parts by computed tomography

Computed tomography (CT) is progressively assuming an important role in metrology applications and great efforts are being made in order to turn it into a reliable and standardized measuring technology. CT is typically used for non-destructive tests, but it is currently becoming very popular for dimensional metrology applications due to its strategic advantages such as the capability of performing measurements on both the components surface and volume, allowing inspection possibilities to otherwise non-accessible internal features. This paper focuses on the dimensional verification of two micro-injection moulded components, selected from actual industrial productions, using CT metrological tools. For this purpose, several parts have been measured with two different CT machines, and the results have been compared with the measurements obtained by other measuring systems. The experimental work carried out and the analysis of the results provide valuable conclusions about the advantages and drawbacks of using CT metrology in comparison with other measuring systems when these techniques are employed for the quality control of micro-moulded parts.

Ceramic-On-Metal for Total Hip Replacement: Mixing and Matching Can Lead to High Wear

Ceramic-on-ceramic and metal-on-metal bearing surfaces are often employed for total hip replacement because of their resistance to wear. However, they have some limits: brittleness is a major concern for ceramic, and ion release is a drawback for metal. To reduce the effect of these limitations, a hybrid coupling of ceramic-on-metal has been proposed. The theoretical advantage of this new coupling might lead orthopedic surgeons to use it indiscriminately. We asked whether the wear rate of this innovative solution was comparable with that of ceramic-on-ceramic, which is considered to be the gold standard for wear resistance. In a hip simulator study, we tested the wear pattern of a hybrid ceramic-on-metal coupling supplied by the same distributor; in particular, three different configurations were tested for 5 million cycles: 36-mm ceramic-on-ceramic, 32-mm and 36-mm ceramic-on-metal. These combinations were gravimetrically and geometrically evaluated. After 5 million cycles, the volumetric loss for the metal acetabular cups (Phi 36-mm) was 20-fold greater than that of the ceramic cups of the same size (Phi 36-mm); a volumetric loss of 4.35 mm(3) and 0.26 mm(3) was observed, respectively, for ceramic-on-metal and ceramic-on-ceramic combinations. Significant statistical differences were observed between all 36-mm different combinations (P < 0.0001). The increased diameter of the 36-mm ceramic-on-metal configuration resulted in a lower volumetric loss compared with that of the 32-mm ceramic-on-metal configuration. Our findings showed an increase in wear for the proposed hybrid specimens with respect to that of the ceramic-on-ceramic ones. This confirms that even in the case of ceramic-on-metal bearings, mixing and matching could not prove effective wear behavior, not even comparable with that of the ceramic-on-ceramic gold standard.

Unicompartmental knee prostheses: in vitro wear assessment of the menisci tibial insert after two different fixation methods

Knee osteoarthritis is a complex clinical scenario where many biological and mechanical factors influence the severity of articular degenerative changes. Minimally invasive knee prosthetic surgery, with only a compartment replacement (unicompartmental knee replacement), might be a good compromise between osteotomy and total knee prosthesis. The focus of this study was to develop and validate a protocol to assess the fixation method of the femoral components in mechanical simulation, for pre-clinical validation; the wear behaviour of two different fixation frames was quantified and compared. In particular, two different wear tests were conducted using the same knee simulator, the same load profiles and the same kinematics; two different fixation methods were applied to the femoral sleds (synthetic femur and metal block). Surface characterization on both articulating bearings was performed by a roughness measuring machine and coordinate measuring machine. The wear produced by the tibial inserts using the synthetic femur was considerably higher than the wear registered by the metal-block holder. Roughness measurements on femoral sleds showed a limited number of scratches with high R(t) values for the metal-block set-up; the damaged surface broadened in the case of femoral condyles and tibial inserts mounted on composite bone, but lower R(t) and linear penetration values were measured. The two holding frames showed different wear activities as a consequence of dissimilar dynamic performance. Further observations should be made in vivo to prove the actual importance of synthetic bone simulations and specific material behaviour.

A New Method for Thread Calibration on Coordinate Measuring Machines

Abstract This paper presents a new method for the calibration of thread gauges on coordinate measuring machines. The procedure involves scanning of thread profiles using a needle-like probe, achieving traceability by substitution of different thread portions with corresponding paths on a calibrated sphere. The feasibility of applying the method to calibrate a parallel thread gauge with respect to all the relevant thread parameters was demonstrated experimentally using a precision CMM. Application of the comparator approach as described in ISO DTS 15530-3 gave measuring uncertainties comparable to the values from usual calibration methods on dedicated equipment, e.g. a measuring uncertainty of 1.8 μm was achieved for measurement of the pitch, and 2-2.5 μm for diameter measurements.

Towards geometrical calibration of x-ray computed tomography systems - A review

Industrial x-ray computed tomography (XCT) is seen as a potentially effective tool for the industrial inspection of complex parts. In particular, XCT is an attractive solution for the measurement of internal geometries, which are inaccessible by conventional coordinate measuring systems. While the technology is available and the benefits are recognized, methods to establish the measurement assurance of XCT systems are lacking. More specifically, the assessment of measurement uncertainty and the subsequent establishment of measurement traceability is a largely unknown process. This paper is a review of research that contributes to the development of a geometrical calibration procedure for XCT systems. A brief introduction to the geometry of cone-beam tomography systems is given, after which the geometrical influence factors are outlined. Mathematical measurement models play a significant role in understanding how geometrical offsets and misalignments contribute to error in measurements; therefore, the application of mathematical models in simulating geometrical errors is discussed and the corresponding literature is presented. Then, the various methods that have been developed to measure certain geometrical errors are reviewed. The findings from this review are discussed and suggestions are provided for future work towards the development of a comprehensive and practical geometrical calibration procedure.

Coordinate metrology using scanning probe microscopes

New positioning, probing and measuring strategies in coordinate metrology are needed for the accomplishment of true three-dimensional characterization of microstructures, with uncertainties in the nanometre range. In the present work, the implementation of scanning probe microscopes (SPMs) as systems for coordinate metrology is discussed. A new non-raster measurement approach is proposed, where the probe is moved to sense points along free paths on the sample surface, with no loss of accuracy with respect to traditional raster scanning and scan time reduction. Furthermore, new probes featuring long tips with innovative geometries suitable for coordinate metrology through SPMs are examined and reported.

Error Sources in Atomic Force Microscopy for Dimensional Measurements: Taxonomy and Modeling

This paper aimed at identifying the error sources that occur in dimensional measurements performed using atomic force microscopy. In particular, a set of characterization techniques for errors quantification is presented. The discussion on error sources is organized in four main categories: scanning system, tip-surface interaction, environment, and data processing. The discussed errors include scaling effects, squareness errors, hysteresis, creep, tip convolution, and thermal drift. A mathematical model of the measurement system is eventually described, as a reference basis for errors characterization, with an applicative example on a reference silicon grating.

Metrological performance verification of coordinate measuring systems with optical distance sensors

Optical coordinate measuring systems are gaining increasing interest in production quality control, due to their rapidity and other advantages with respect to traditional measuring techniques using contact probes. This paper presents an experimental investigation on procedures and standards for testing coordinate measuring systems equipped with optical distance sensors. Particular attention is given to methods for testing two of the most important specifications of optical coordinate measuring system: the probing error and the error of indication for size measurement. The investigation is aimed at improving the performance verification methods employed at the state of the art. This will help the industrial users in the selection process of those systems, with an improvement of measurement precision in manufacturing.

Integrated friction measurements in hip wear simulations: Short-term results

Abstract Hip joint wear simulators are used extensively to simulate the dynamic behaviour of the human hip joint and, through the wear rate, gain a concrete indicator about the overall wear performance of different coupled bearings. Present knowledge of the dynamic behaviour of important concurrent indicators, such as the coefficient of friction, could prove helpful for the continuing improvement in applied biomaterials. A limited number of commercial or custom-made simulators have been designed specifically for friction studies but always separately from wear tests; thus, analysis of these two important parameters has remained unconnected. As a result, a new friction sensor has been designed, built, and integrated in a commercial biaxial rocking motion hip simulator. The aim of this study is to verify the feasibility of an experimental set-up in which the dynamic measurement of the friction factor could effectively be implemented in a standard wear test without compromising its general accuracy and repeatability. A short wear test was run with the new set-up for 1×106 cycles. In particular, three soft-bearings (metal-on-polyethylene, Φ = 28 mm) were tested; during the whole test, axial load and frictional torque about the vertical loading axis were synchronously recorded in order to calculate the friction factor. Additional analyses were performed on the specimens, before and after the test, in order to verify the accuracy of the wear test. The average friction factor was 0.110 ± 0.025. The friction sensors showed good accuracy and repeatability throughout. This innovative set-up was able to reproduce stable and reliable measurements. The results obtained encourage further investigations of this set-up for long-term assessment and using different combinations of materials.