Alicona tool measurement technology supports AMRC machining research

(Video uses German subtitles, but offers a visual description) IFM is being used for very precisely measuring tool geometry and wear, important factors in the AMRC's core work of developing innovative and optimised machining processes, which falls within its Machining Research Group's scope of activities. Chris Taylor, technical lead at the AMRC, explains: "We are primarily using this system for studying the effects of cutting tool wear, checking tool geometry, and measuring the roughness of machined surfaces. We can now get 3D detail and functionality, which we couldn't achieve with a standard microscope. "With a standard microscope, it can be hard to tell whether you are looking at a worn tool or a tool with some of the cut material stuck to it," says Taylor. "With the IFM, we can perform volumetric calculations by scanning the tool before and after use, to see whether material is being lost or gained." "Quite a few of our partners have the same system or are interested in getting one," notes Mr Taylor. "For our needs, it is the best tool for the job." IFM allows sub-micron, full form measurement of a wide range of tools including, drills, end mills, diamond-tipped tools, coated tools and carbide inserts. IFM accurately measures surface features, such as flank angles, thread pitch, clearance, whilst the tool's automatic 360° rotation allows complete form measurement. The system can precisely measure complex cutting tool geometries, such as profile, rake, clearance angle, flute dimensions, concentricity and relief grinding, with measurements reaching a vertical resolution of up to 10 nm. In addition, IFM is able to measure tools' cutting edge radii, enabling the precise examination of the results of edge finishing techniques such as honing. The advanced Alicona optical system is able to measure the most complex geometries and to gauge the dimensional accuracy of even the smallest toleranced features, then compare the achieved results with CAD data to identify potential deviations from nominal conditions. The AMRC is part of the High Value Manufacturing Catapult, a new consortium of seven manufacturing and process research centres backed by the Technology Strategy Board (TSB), with the mission of stimulating UK manufacturing and reducing the risk of innovation for new and established businesses. The AMRC is based in two state-of-the-art research factories, part-funded by the European Regional Development Fund, at the Advanced Manufacturing Park in Rotherham. The facility is a world-class centre for advanced machining and materials research for aerospace and other high-value manufacturing sectors. It is a partnership between industry and academia, which has become a model for research centres worldwide. The AMRC identifies researches and resolves advanced manufacturing problems, with a focus on developing new technologies and processes for machining the high performance metal alloys used in aerospace and other industries. Researchers work is undertaken with individual companies on specific projects, whilst collaboration on generic projects is also carried out for the benefit of all members. Alicona's products are used by the world's national standards institutes, including the UK national standards laboratory - The National Physical Laboratory - which use Alicona systems for a wide range of high precision applications, while the German national metrology institute - PTB (Physikalisch-Technische Bundesanstalt) - also use the Alicona system.