Introduction to Michigan Metrology

5. WYKO NT8000 Vertical Scanning Interferometer (VSI) Instrumentation: 10 X

6. Measurement Capabilities: Measurement Area - 0.15mm x 0.1mm to 7mm x 5mm + w/Stitching Lateral Resolution - 2.5 microns - 20 microns Height Resolution – 6 nm / 0.2 nm Printing Plate Fuel Regulator Component

7. Analysis Capabilities: Surface: “The boundary that separates an object from another object, substance, or space…” Texture: “The composite of certain deviations that are typical of the real surface. It includes roughness and waviness…” X Y Z “ Surface Roughness”, Ra is the average of the absolute value of profile heights over a given length (area). L 2D 3D Surface Texture (Surface Roughness, Waviness and Lay) ANSI/ASME B46.1, 1995, American Society of Mechanical Engineers, NY, New York 10017.

8. “ Hard to reach areas” Problem : ABS component ball seat – high leak rate Solution : Quantify the texture / machining problems / coining problems. Measured Surface Failed Leak Test Passed Leak Test 0.5mm Sa = 60 (micro inch) Sa = 16 (micro inch) Applications:

10. “ Statistical Based” … Amplitude Parameters .. Rq, Rsk, Rku Calculate the “moments” of the distribution: (Sq) Rq = “RMS”, = (Ssk) Rsk = Skew , Skewness (Sku) Rku = Kurtosis = Analysis Capabilities:

11. Amplitude Parameters .. Rq, Rsk, Rku Application: Bearing issues, lubricant retention Mfg. Process, tool wear etc. Limitation No spatial information Analysis Capabilities: Rq=3, Rsk = 0, Rku=3, Gaussian Surface Rq=12, Rsk = -1, Rku=8, Negatively Skewed Rq=12, Rsk = 1, Rku=8, Positively Skewed Rq=4, Rsk = 0, Rku=1.5, Slowly Varying Rq=4, Rsk = 0, Rku=10, Extreme Peak/Valley

12. Quantify by parameters such as Rsk Problem : Plastic molded component – leak paths at sealing locations Solution : Quantify the component surfaces –refine the mold/process Non Contact – Soft Materials Leaking Sealing Surface Improved Mold/Process 1 mm Applications: Ssk < -2.00 Ssk ~ 0.00

13. Spacing Parameters Rsm, PCL Rsm = The Average of all Smi PCL= Peak Count Level...Threshold Peak = When profile intersects lower and upper PCL Pc = Peak Density....peaks/unit length Application: Coatings/appearance, sealing (with Rz) Mfg. Process (e.g. feed-rate / vibration, forming…) Limitation “ User” determined (arbitrary?) thresholds (sometimes set to Ra) Definition of a “crossing (with noise)” causes repeatability problems Analysis Capabilities: Sm4 Sm3 Sm2 Sm1 PCL Peak 3 Peak 2 Peak 1

14. Tradeoff parameters such as Ssk, Pc -- Symmetry and Spacing Problem : Optimize Clutch plate texture – shudder vs. durability Solution : Quantify the component surfaces –Define/Design the surface Sa not enough, needed parameters such as Ssk, Pc to control function. Quantify Texture – Surface Engineering Applications:

15. Hybrid Parameters...Slope, R  q,  q (Sdq) R  q = 2  Rq/R  q Slope “ Average Wavelength Weighted By Amplitude”  q=4  q=2 Application: Appearance, coating application Dynamic surface interactions Limitation Very sensitive to measured lateral resolution Analysis Capabilities: Low  q High  q

16. Sa: In spec Sdq: Low Sa: In spec Sdq: High Quantify Texture – Process Control Problem : Brake Rotor Ra “inspec” …some work ..some have NVH issues Solution : Quantify the surfaces – Spec additional texture parameters  q Solution : Identify cause of texture variation..(materials? tools? setup?) Applications:

17. “ Functional” Bearing Area Parameters .. Rpk, Rk Rvk.... (Spk) Rpk = “Peak Height” .. First Region of contact (Sk) Rk = “Core Height”... “working” Region ..”Base” (Svk) Rvk = “Valley Depth” ... “Lubricant Retention Region” Mr1 = “1st Material Ratio”... “Peak Material” Mr2 = “2nd Material Ratio” ... “Valley Material” V 0 = Rvk(100-Mr2)/200......”Retention Volume” Application: Bearing systems, machining operations, wear studies, Lubricant issues Limitation No spatial information Analysis Capabilities: D C B A t p = 100% x (A + B + C + D )/L t p Peaks “ Core ” Valleys 100% 50% 0% Min Ht Max Ht 40% Rvk Rk Rpk Mr1 Mr2

18. Bearing Area Analysis: Lube Retention - Svk Load Distribution- Spk Quantify Texture – Cylinder Bore Honing Process Control Applications:

19. Problem : Warranty….Excessive wear/field failure Solution : Quantify the component surfaces – Solution : Quantify the wear rate under test Profile Along Worn Contact Fuel level Sender Wear EGR Sensor Wear Quantify Wear Wear Depth = 12 um Applications:

20. Full Conventional Stylus Analysis, Cutoffs, etc. Plant Floor Correlation – Simulate Stylus Based Gages Applications:

21. Analysis Capabilities: The Next Generation – ISO 25178-2

25. 3D Surface MicroTexture/Wear Measurement, Analysis, Inspection Services Solving problems related to squeaks, leaks, friction, wear, appearance, adhesion… providing… Michigan Metrology, LLC