A model- and simulation-based approach for tolerancing and verifying the functional capability of micro/nano-structured workpieces

The evaluation of functional features of manufactured workpieces is based on GO- and NO-GO-test results, which are obtained by comparing measured geometric characteristics with nominal dimensions and tolerances specified by the designer. These geometrical specifications are based on a tolerancing system, which was originally defined for the function mating capability. Against the background of upcoming lots of other new functions (like reduction of flow resistance, light absorption, reduction of friction, diffraction of light, self-cleaning or mass transmission) are to be realized with our products – particularly by micro- and nano scaled features. If the verification process will deliver the prediction of the achievable degree of functionality, the usability of a part can be assessed more accurately and in consequence quality and economics can be improved. So, a new principle for tolerancing and verifying turns out to be necessary. In this paper the fundamental deficit of the actual tolerancing and specification systems GPS and ASME Y14.5 is derived and the path for enlarging the system by preposing a functional model is shown. To verify the functional capability of the workpieces an approach based on simulations done with the parameterized mathematical–physical model of the function is suggested. Advantages of this approach will be discussed and demonstrated by examples with microstructured inking rolls, crankshafts and injection valves.     

Refractive index of soft contact lens materials measured in packaging solution and standard phosphate buffered saline and the effect on back vertex power calculation

PurposeTo measure the refractive index (RI) of commonly available soft contact lens (CL) materials, their packaging solutions and compare to the manufacturers’ nominal RI. The relationship between RI versus water content, and the effect of inaccurate RI when converting lens power measured in solution to in-air back vertex power were examined.MethodsThe RI of 18 single vision soft CL materials were measured using CLR 12–70 digital refractometer. Three lenses of each material were measured, in their packaging solution and then after soaking in standard phosphate buffered saline (PBS). The RIs of packaging solution were also measured. Accuracy requirements for correct wet to dry power conversion based on thick lens formula were projected.ResultsThe standard deviation between three samples was less than 0.005. The measured RI ranged from 1.3744 ± 0.001–1.4265 ± 0.0004 for PBS soaked and from 1.3739 ± 0.0003–1.4264 ± 0.0024 for packaging solution soaked materials. Comparing nominal with mean measured PBS and packaging solution RIs, 5 and 3 lens materials, respectively, fell outside ISO tolerance. The packaging solution RI of DailiesAquaComfortPlus had the largest difference of 0.0040, compared to RI of standard PBS. For converting lens power measured in PBS to in-air power, the difference between measured and nominal RI of 0.0104 would result in wrongly calculated in-air power 0.99 D for a -6.00 D lens.ConclusionThe CLR 12–70 is reliable and accurate refractometer for the measurement of soft CL materials. Accurate RI measurements are of relevance with increased use of wavefront sensors to measure lens power while they are immersed in solution. Even small errors in solution or material RI can lead to significant errors in converted in-air power. To obtain valid in-air lens power results, measurement conditions must match the material and solution RIs used for the conversion.     

Geometrical metrology for metal additive manufacturing

The needs, requirements, and on-going and future research issues in geometrical metrology for metal additive manufacturing are addressed. The infrastructure under development for specification standards in AM is presented, and the research on geometrical dimensioning and tolerancing for AM is reviewed. Post-process metrology is covered, including the measurement of surface form, texture and internal features. In-process requirements and developments in AM are discussed along with the materials metrology that is pertinent to geometrical measurement. Issues of traceability, including benchmarking artefacts, are presented. The information in the review sections is summarized in a synthesis of current requirements and future research topics.     

Study and characterization of porous copper oxide produced by electrochemical anodization for radiometric heat absorber

The aim of this work is to optimize the different parameters for realization of an absorbing cavity to measure the incident absolute laser energy. Electrochemical oxidation is the background process that allowed the copper blackening. A study of the blackened surface quality was undertaken using atomic force microscopy (AFM) analysis and ultraviolet-visible-infrared spectrophotometry using a Shimadzu spectrophotometer. A two-dimensional and three-dimensional visualization by AFM of the formed oxide coating showed that the copper surfaces became porous after electrochemical etching with different roughness. This aspect is becoming more and more important with decreasing current density anodization. In a 2 mol L ^-1 of NaOH solution, at a temperature of 90°C, and using a 16 mA cm² constant density current, the copper oxide formed has a reflectivity of around 3% in the spectral range between 300 and 1,800 nm. Using the ‘mirage effect’ technique, the obtained Cu₂O diffusivity and thermal conductivity are respectively equal to (11.5 ± 0.5) 10 to 7 m² s^-1 and (370 ± 20) Wm^-1 K^-1. This allows us to consider that our Cu₂O coating is a good thermal conductor. The results of the optical and thermal studies dictate the choice of the cavity design. The absorbing cavity is a hollow cylinder machined to its base at an angle of 30°. If the included angle of the plane is 30° and the interior surface gives specular reflection, an incoming ray parallel to the axis will undergo five reflections before exit. So the absorption of the surface becomes closely near 0.999999.     

Performance evaluation of a cheap,open source,digital environmental monitor based on the Raspberry Pi

We report on the design, construction and evaluation of a low-cost digital environmental monitoring system based on a popular micro-computer board and mass market digital sensors. The system is based around the use of open source software and readily available digital sensors, providing key parameters required for environmentally-controlled calibration laboratories: air temperature, pressure and humidity. Each system logs data at set intervals with front-panel display, web page graphical display and email alerting when exceeding set tolerances. The sensors have been calibrated at the National Physical Laboratory using standards traceable to the SI. Long term stability of the system is estimated and in addition to monitoring of laboratory environments for regulatory purposes, the systems can also be used to provide on-demand values for local refractive index with an expanded (k = 2) uncertainty of 1.1 × 10⁻⁷ as required for many optical-based measuring systems.     

Enhancing multisensor data fusion on light sectioning coordinate measuring systems for the in-process inspection of freeform shaped parts

A method for automatic determination of sensors positions and orientations in multisensor laser triangulation coordinate measuring systems is presented. Based on a series of measurements on a conical artifact without the use of external light sources, the approach allows for both optimized adjustment of the physical sensors alignment and improved 3D data registration by software. Simulations were conducted to quantify the sensitivity of the method. Experimental results based on measurements of steep details of complex shaped parts show a 5-times reduction of deviations between measurements of sensors with respect to an already optimized adjustment by manual methods.     

Numerical comparison of sampling strategies for BRDF data manifolds

The bidirectional reflectance distribution function (BRDF) is one of the fundamental concepts in such diverse fields as multidimensional reflectometry, computer graphics and computer vision. BRDF manifolds form an infinite-dimensional space, but typically the available measurements are very scarce. Therefore, an efficient learning strategy is crucial when performing the measurements.In this paper, we perform simulation studies within a mathematical framework that allows to establish more efficient BRDF sampling and measurement strategies in the sense of statistical design of experiments and generalized proactive learning. Our simulation studies suggest that the default BRDF measurement strategy is suboptimal for a wide class of loss functions.     

虚拟仪器在力矩工具检定装置中的应用

本文介绍了我单位研制的力矩工具自动检定系统在量值传递工作中的应用情况。提出了通过虚拟仪器在力矩工具计量检定、数据统计等方面实现信息化、自动化的设想及具体技术手段。     

当前企业计量工作的现状和发展

本本文分析企业计量工作在工作标准模式、测量设备的配备和量值管理、计控一体化模式、目前的困难和不足、计量管理的信息化、网络化等五个大的方面系统地提出了建议和思路,对当前企业计量工作应采纳的国际先进的管理标准、人员的管理要求、测量设备的配备和量值管理、企业自动化控制发展方向和阶段性目标、如何克服目前的困难、改进不足以及如何建立企业计量工作网络、开展计量管理信息化工程均进行了详细的阐述。     

基于双重逆极限空间液压系统泄漏特征提取方法

为了检测大型锻造液压机液压系统的泄漏问题,提出了一种基于双重逆极限空间的特征分析方法。将大型锻造液压机液压系统的泄漏作为原信息空间,并在此基础上建立与之拓扑同构的双重逆极限空间。在双重逆极限空间,并通过拓扑不变性来反映大型锻造液压机液压系统的泄漏情况。最后通过仿真实验验证了此理论方法的可行性。结果表明,基于双重逆极限空间的特征提取方法更适合提取泄漏的耦合特征,所提取的特征信息对泄漏具有很好的检测和定位能力。