Considerations on numerical modelling for compensation of in-process metrology in manufacturing

M. R. Sonne, A. Mohammadi, G. Dalla Costa, D. G. Madruga, L. De Chiffre, J. H. Hattel

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Abstract

The growing demands for quality and flexibility and at the same time production speed challenges conventional metrology. The future tendency is that metrology is an integrated part of the production line and thus is placed in a production environment. This is a challenge since dimensional metrology in a production environment might lead to higher uncertainties due to dynamic variations both in the conditions of the environment and in the conditions produced parts, with all the influencing factors such as temperature, vibrations, forces and humidity etc. that lies outside the requirements from todays standards referring to 20oC and 0 N (zero forces acting on the part). However, many of these effects can be treated as systematic errors if the physical phenomena leading to the deviations can be described. Today, it is very common to compensate for the variations in temperature in a classical 1D manner where a measurand is compensated via the coefficient of thermal expansion (CTE) and the difference from the reference temperature. However, when temperature gradients and very complex part geometries exist the deformation pattern might not at all follow a linear path. Instead, more advanced three-dimensional thermomechanical numerical models should be used for predicting the deformation of the parts due to the thermal effects taking the inherent build-up of residual stresses and warpage into account. The same goes for other effects that might change the dimensions over time such as hygroscopic swelling (for polymer parts), which can be taken into account by considering numerical modelling. In the present work, different academic and industrial parts will be used as cases in order to show the advantages of using numerical simulation tools for compensation of the dynamic changes and further also highlight and discuss where the classical 1D approaches might be sufficient for a desired uncertainty.
Original languageEnglish
Title of host publicationProceedings of the 18th International Conference of the european Society for Precision Engineering and Nanotechnology
EditorsD. Billington Billington , R. K. Leach, D. Phillips , O. Riemer, E. Savio
PublisherThe European Society for Precision Engineering and Nanotechnology
Publication date2018
Pages453-454
ISBN (Electronic)9780995775121
Publication statusPublished - 2018
Event18th International Conference of the european Society for Precision Engineering and Nanotechnology (euspen 18) - Venice, Italy
Duration: 4 Jun 20188 Jun 2018

Conference

Conference18th International Conference of the european Society for Precision Engineering and Nanotechnology (euspen 18)
CountryItaly
CityVenice
Period04/06/201808/06/2018

Keywords

  • Metrology
  • Production environment
  • Numerical modelling
  • Hygroscopic swelling

Cite this

Sonne, M. R., Mohammadi, A., Dalla Costa, G., Madruga, D. G., De Chiffre, L., & Hattel, J. H. (2018). Considerations on numerical modelling for compensation of in-process metrology in manufacturing. In D. B. Billington , R. K. Leach, D. Phillips , O. Riemer, & E. Savio (Eds.), Proceedings of the 18th International Conference of the european Society for Precision Engineering and Nanotechnology (pp. 453-454 ). The European Society for Precision Engineering and Nanotechnology.
Sonne, M. R. ; Mohammadi, A. ; Dalla Costa, G. ; Madruga, D. G. ; De Chiffre, L. ; Hattel, J. H. / Considerations on numerical modelling for compensation of in-process metrology in manufacturing. Proceedings of the 18th International Conference of the european Society for Precision Engineering and Nanotechnology . editor / D. Billington Billington ; R. K. Leach ; D. Phillips ; O. Riemer ; E. Savio. The European Society for Precision Engineering and Nanotechnology, 2018. pp. 453-454
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abstract = "The growing demands for quality and flexibility and at the same time production speed challenges conventional metrology. The future tendency is that metrology is an integrated part of the production line and thus is placed in a production environment. This is a challenge since dimensional metrology in a production environment might lead to higher uncertainties due to dynamic variations both in the conditions of the environment and in the conditions produced parts, with all the influencing factors such as temperature, vibrations, forces and humidity etc. that lies outside the requirements from todays standards referring to 20oC and 0 N (zero forces acting on the part). However, many of these effects can be treated as systematic errors if the physical phenomena leading to the deviations can be described. Today, it is very common to compensate for the variations in temperature in a classical 1D manner where a measurand is compensated via the coefficient of thermal expansion (CTE) and the difference from the reference temperature. However, when temperature gradients and very complex part geometries exist the deformation pattern might not at all follow a linear path. Instead, more advanced three-dimensional thermomechanical numerical models should be used for predicting the deformation of the parts due to the thermal effects taking the inherent build-up of residual stresses and warpage into account. The same goes for other effects that might change the dimensions over time such as hygroscopic swelling (for polymer parts), which can be taken into account by considering numerical modelling. In the present work, different academic and industrial parts will be used as cases in order to show the advantages of using numerical simulation tools for compensation of the dynamic changes and further also highlight and discuss where the classical 1D approaches might be sufficient for a desired uncertainty.",
keywords = "Metrology, Production environment, Numerical modelling, Hygroscopic swelling",
author = "Sonne, {M. R.} and A. Mohammadi and {Dalla Costa}, G. and Madruga, {D. G.} and {De Chiffre}, L. and Hattel, {J. H.}",
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Sonne, MR, Mohammadi, A, Dalla Costa, G, Madruga, DG, De Chiffre, L & Hattel, JH 2018, Considerations on numerical modelling for compensation of in-process metrology in manufacturing. in DB Billington , RK Leach, D Phillips , O Riemer & E Savio (eds), Proceedings of the 18th International Conference of the european Society for Precision Engineering and Nanotechnology . The European Society for Precision Engineering and Nanotechnology, pp. 453-454 , 18th International Conference of the european Society for Precision Engineering and Nanotechnology (euspen 18), Venice, Italy, 04/06/2018.

Considerations on numerical modelling for compensation of in-process metrology in manufacturing. / Sonne, M. R.; Mohammadi, A.; Dalla Costa, G.; Madruga, D. G.; De Chiffre, L.; Hattel, J. H.

Proceedings of the 18th International Conference of the european Society for Precision Engineering and Nanotechnology . ed. / D. Billington Billington ; R. K. Leach; D. Phillips ; O. Riemer; E. Savio. The European Society for Precision Engineering and Nanotechnology, 2018. p. 453-454 .

Research output: Chapter in Book/Report/Conference proceedingConference abstract in proceedingsResearchpeer-review

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T1 - Considerations on numerical modelling for compensation of in-process metrology in manufacturing

AU - Sonne, M. R.

AU - Mohammadi, A.

AU - Dalla Costa, G.

AU - Madruga, D. G.

AU - De Chiffre, L.

AU - Hattel, J. H.

PY - 2018

Y1 - 2018

N2 - The growing demands for quality and flexibility and at the same time production speed challenges conventional metrology. The future tendency is that metrology is an integrated part of the production line and thus is placed in a production environment. This is a challenge since dimensional metrology in a production environment might lead to higher uncertainties due to dynamic variations both in the conditions of the environment and in the conditions produced parts, with all the influencing factors such as temperature, vibrations, forces and humidity etc. that lies outside the requirements from todays standards referring to 20oC and 0 N (zero forces acting on the part). However, many of these effects can be treated as systematic errors if the physical phenomena leading to the deviations can be described. Today, it is very common to compensate for the variations in temperature in a classical 1D manner where a measurand is compensated via the coefficient of thermal expansion (CTE) and the difference from the reference temperature. However, when temperature gradients and very complex part geometries exist the deformation pattern might not at all follow a linear path. Instead, more advanced three-dimensional thermomechanical numerical models should be used for predicting the deformation of the parts due to the thermal effects taking the inherent build-up of residual stresses and warpage into account. The same goes for other effects that might change the dimensions over time such as hygroscopic swelling (for polymer parts), which can be taken into account by considering numerical modelling. In the present work, different academic and industrial parts will be used as cases in order to show the advantages of using numerical simulation tools for compensation of the dynamic changes and further also highlight and discuss where the classical 1D approaches might be sufficient for a desired uncertainty.

AB - The growing demands for quality and flexibility and at the same time production speed challenges conventional metrology. The future tendency is that metrology is an integrated part of the production line and thus is placed in a production environment. This is a challenge since dimensional metrology in a production environment might lead to higher uncertainties due to dynamic variations both in the conditions of the environment and in the conditions produced parts, with all the influencing factors such as temperature, vibrations, forces and humidity etc. that lies outside the requirements from todays standards referring to 20oC and 0 N (zero forces acting on the part). However, many of these effects can be treated as systematic errors if the physical phenomena leading to the deviations can be described. Today, it is very common to compensate for the variations in temperature in a classical 1D manner where a measurand is compensated via the coefficient of thermal expansion (CTE) and the difference from the reference temperature. However, when temperature gradients and very complex part geometries exist the deformation pattern might not at all follow a linear path. Instead, more advanced three-dimensional thermomechanical numerical models should be used for predicting the deformation of the parts due to the thermal effects taking the inherent build-up of residual stresses and warpage into account. The same goes for other effects that might change the dimensions over time such as hygroscopic swelling (for polymer parts), which can be taken into account by considering numerical modelling. In the present work, different academic and industrial parts will be used as cases in order to show the advantages of using numerical simulation tools for compensation of the dynamic changes and further also highlight and discuss where the classical 1D approaches might be sufficient for a desired uncertainty.

KW - Metrology

KW - Production environment

KW - Numerical modelling

KW - Hygroscopic swelling

M3 - Conference abstract in proceedings

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EP - 454

BT - Proceedings of the 18th International Conference of the european Society for Precision Engineering and Nanotechnology

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A2 - Leach, R. K.

A2 - Phillips , D.

A2 - Riemer, O.

A2 - Savio, E.

PB - The European Society for Precision Engineering and Nanotechnology

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Sonne MR, Mohammadi A, Dalla Costa G, Madruga DG, De Chiffre L, Hattel JH. Considerations on numerical modelling for compensation of in-process metrology in manufacturing. In Billington DB, Leach RK, Phillips D, Riemer O, Savio E, editors, Proceedings of the 18th International Conference of the european Society for Precision Engineering and Nanotechnology . The European Society for Precision Engineering and Nanotechnology. 2018. p. 453-454