Asia Paci�c Metalworking

@APMetalworking

RFID IN TOOLMANAGEMENT

BIG TRENDSIN MACHINE TOOLS@ CUTTING TOOLS

VOL.12 NO. 66 MARCH - APRIL 2014 www.ttim.co.th

1212

COOLANTHANDLING HEATS INCUTTING HRSA

2

Contents MARCH - APRIL 2014

8-10 Global MoveMents•GlobalManufacturing2014Movingupward

•Asia’sManufacturingOutputisPromising•GlobalDimensionalMetrologyMarketintheAerospaceIndustry

•GE’sNewEngineTestedbeforeServicing•GM’sFirstFemaleCEOinGlobalAutomotiveIndustry

•GlobalAerospaceandDefenseOutlookfor2014

12-15 asia Pacific affairs•Malaysia’sAutomotiveIndustryGrowingamidstChallenges

•Myanmar’sOil&GasIndustrytoBeaBoomin2014

•Asia’sExportStillGrowingAlongsideIncreasingChallenges

•GMHoldentoStopCarManufacturinginAustraliain2017

•VietnamStillEnjoyStrongEconomy•BoschtoOpentheFirstPlantinIndonesia•FordEcoSportUrbanSUVBeginsProductioninRayong

•HonHai’sInvestmentPlaninIndonesia

16-17 business news •HitachiSunwayProvidesPLMSolutionstoPreciseElectricManufacturing

•TungaloyHosts1stTungGolfTournament•JSRGroupRelocatedtheNewHeadOffice•ABCEnsuresQualityandQuantity

18-20 ancillaries & autoMation•RFIDinToolManagement

21 cover story•Siemens’SINUMERIK:CompleteCNCSystemPlatform

22-25 Machine tool technoloGy •EDMElectrodeMaterials

26-31 cuttinG strateGies•CoolantHandlingHeatsinCuttingHRSA•ExTRA-Seco’sSuccessSolutionforAerospacePartMachining

32-34 sheet Metal•FiberLaservsCO

2LaserCutting

I

8

26

32

Global MoveMents

cuttinG strateGies

sheet Metal

4

Contents MARCH - APRIL 2014 II36-37 InnovatIon•DirectDrivePumpInnovation:MaximizingEnergyEfficiencyinaWaterjetMachine

38-40 WIre & tube•WireHarnessAssembly;ManualvsAutomation

42-44 InspectIon•SurfaceRoughnessMeasuringby3DOpticalProfilometry

46-47 neW Launch•SandvikLaunchesNewGradesFeaturingInveio-NewStandardforSteelTurningandCastIronMilling

48-49 shoW prevIeW•ManufacturingExpo2014ShapingtheFutureoftheAuto-partsManufacturingIndustry

50-51 specIaL Feature•BigTrendsinMachineToolsandCuttingToolsMarket

52-55 Industry update•Trans-AseanGasPipelineProjectforSustainableFutureofEnergyintheRegion

56-58 MachIne shop ManageMent•WhyManufacturersShouldTurntheLightsOff

60 event caLendar

62-64 product Focus•BystronicBySun:AnEntranceintotheChampionLeagueofSheetProcessing

•Siemens’SINUMERIK828D-APerfectControlforStandardMachining

•NEWCTXecolineLathesfromDMGMORI•JSRGroupIntroducesIMADAFSASeriesForceDisplacementMeasurement

•MS2050Grade:IncreaseYourProductivityinTitaniumAlloy

•DevelopmentofNewGrades:AC405K/AC415K/AC420KforCastIronTurning

•NS9539/GT9530:NewCermetGradesforTurningCarbonandAlloySteels

•Tiger·tec®SilverHU6:InsertswithDimples•4GMills:theLatestCarbideEndMillsbyYG-156

52

48 shoW prevIeW

Industry update

MachIne shop ManageMent

6

Editor’s Note

However, as we are all very well aware of the on going anti-corruption protests in Thailand, it is inevitable that the manufacturing sectors will be impacted. As has happened under previous crises in Thailand, we can ant icipate a decrease in local consumer spending, as well as a lull in local and overseas investment.

Based on BOT Governor P rasarn Trairatvorakul’s speech at a recent seminar, the Thai economy may grow less than 3% this year, a number close to last year’s growth, as the political unrest affects consumption and investment. M o r e o v e r , t h e c o u n t r y ’ s c u r r e n t predicament coincides with the rise of frontier nations, such as Myanmar, and the resurgence of neighbors, inc luding the Phi l ippines, both of which are enjoying a period of political stability and quickening growth.

However, amidst these negative scenarios, there is a silver lining: Thailand’s exports are likely to perform better this year

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Consultant

Dr. Chienchuang Kalayanamitr

ManageMent

Publisher: Wannee SananwatananontManaging editor: Daorach Preechatham

editorial teaM

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Send us an email (daorach@ttim.co.th).Submission of a letter constitutes permission to publish it in any form or medium. Letters may be edited for reasons of space and clarity.

ISSUE 66 / MARCH - APRIL 2014

Positive thoughts KeeP You Moving on

Ms. Daorach PreechathamManaging Editor

following global economic recovery. Asign of improvement was seen in December as Srirat Rastapana, the permanent secretary of the Commerce Ministry, told reporters that exports rose 1.87% in December from the year before. This was the first increase in three months and its expected to improve in 2014 with an export growth of 5%.

Whatever may happen, let’s pray for a better and brighter future for Thailand. As it stands now there are two potential outcomes - we either havean illusive economic boom or real transparency and good governance. I think most Thai people, especially those in business, prefer the latter. We have to be patient, keep positive, and support each other as we always have. Thailand is known for bouncing back and, while times aren’t the brightest they’ve ever been, I do believe that the darkest hour is always just before the dawn.

Global manufacturing growth was boosted by some relatively robust figures at the end of 2013, and a lot of signs show this industry will continue to grow in Asia.

12

Asia Pacific affairs

Malaysia’s Automotive Industry Growing amidst Challenges

Myanmar’s Oil & Gas Industry to Be a Boom in 2014

Malaysia’s automotive sector is set to see another good year in 2014, despite challenging times, after achieving stable growth in 2013.

MIDF Research auto analyst Kelly Tan said the research firm forecasts a lower total industry volume (TIV) growth of 2.4% in 2014 to 668,000 units from an estimated 656,500 units to be sold by the end of 2013. However, industry experts and auto analysts caution that 2014 is likely to register smaller growth following the government subsidy rationalisation mea-sures. “Our forecast for 2014 is smaller because it may be rather quiet giv-en our expectations that the year will see launches being mostly refreshed models, rather than growth-propelling brand new ones. Hence, our 3.9% TIV growth forecast in respect of 2013 remains intact,” stated Tan. According to the Malaysian Automotive Association (MAA), the total industry volume (TIV) will increase to 640,000 units in 2014 (+2.1%) based on estimation of 640,000 units in 2013 (not yet officially announced exact numbers at the time of reporting) and 667,800 units in 2015 (+2.2%),

683,000 units in 2016 (+2,3%) and 699,300 units in 2017 (+2.4%).

Myanmar will be the focus of attention for the international oil and gas industry in

2014 as a batch of major offshore exploration licenses are awarded and more

blocks are expected to be put up for foreign bidding.

The winners of pending bids for 30 offshore blocks are expected to be announced

in early 2014, while the much-awaited auction of 30 offshore oil and gas sites is the

latest test of Myanmar’s economic reforms and its emerging, yet still vague, energy

policy. Industry players are watching with interest an impending tender award by

the Ministry of Energy for 30 offshore oil and gas exploration blocks, which has

attracted bidding by several major international oil companies that were absent

in previous tenders. The outcome of the tender will highlight the progress, or lack

อตุสาหกรรมยานยนต์ของมาเลเซียมองเห็นลูท่างแจ่มใสอกีครัง้ในปี 2557 นี ้แม้ว่ายงั

คงมีความท้าทายอยู่รายรอบหลังจากผ่านความส�าเร็จของปี 2556

บริษัทวิจัย MIDF โดย Kelly Tan นักวิจัยแผนกยานยนต์กล่าวว่า ประมาณการของ

ยอดรวมทัง้หมดของอตุสาหกรรมทีเ่รยีกว่าค่า Total Industry Volume หรอื TIV นัน้

จะมีการเติบโตในปีนี้เพียง 2.4% หรือประมาณ 668,000 คัน เมื่อเทียบกับยอดขาย

เมียนม่าร์ก�าลังจะเป็นศูนย์กลางของอุตสาหกรรมน�้ามันและก๊าซธรรมชาติระดับสากล

ในปี 2557 นี ้เนือ่งจากได้มกีารอนมุตัสิิทธ์ิการขดุเจาะกลางทะเลแล้วบางส่วน และอกีส่วน

อยู่ระหว่างการให้สิทธิ์ในการยื่นประมูลจากบรรดาผู้ประกอบการต่างชาติ

โดยคาดว่าจะมกีารประกาศรายชือ่ผูช้นะการประมลูสถานทีท่ีอ่ยูใ่นระหว่างการด�าเนนิการ

ได้ในประมาณช่วงต้นปี 2557 นี้ ในขณะที่ยังมีอีก 30 จุดที่รอการประมูลอยู่อีก ซึ่งจะ

เป็นบททดสอบส�าหรับการปฏิรูปเศรษฐกิจของเมียนม่าร์ ที่ก�าลังเปิดตัวและยังคงมีความ

คลุมเครือในด้านนโยบายพลังงาน ผู้ประกอบการในอุตสาหกรรมต่างก็ก�าลังจับตาดู

การยื่นประมูลของบรรดาบริษัทน�้ามันต่างชาติรายใหญ่ที่พลาดไปจากการยื่นประมูล

ครั้งที่แล้ว ผลจากการยื่นประมูลในรอบใหม่นี้ จะเป็นการตอกย�้าถึงความก้าวหน้าหรือ

ถดถอย ที่จะชี้ให้เห็นถึงความพยายามในการพัฒนาบรรยากาศการลงทุนด้านพลังงาน

ของประเทศ มีรายงานจากส่ือต่างประเทศว่าผลของการให้สิทธ์ิในการขุดเจาะพลังงาน

ของเมียนม่าร์ที่จะมีการประกาศในปีนี้ จะครอบคลุมถึงการขุดเจาะอีกกว่า 12 แห่ง ทั้ง

ในทะเลและบนฝั่ง รวมถึงอ่าวเบงกอล อ่าวมะตะบัน เป็นต้น ผู้ยื่นประมูลส�าหรับ 30 จุด

ดังกล่าวข้างต้น ขณะนี้ก�าลังอยู่ในระหว่างด�าเนินการ ซึ่งมีผู้ประกอบการด้านพัฒนา

พลังงานระดับโลกจากชาติตะวันตกเข้าร่วมการประมูลด้วย การพัฒนาอย่างรวดเร็วใน

อตุสาหกรรมน�า้มนัและก๊าซธรรมชาตใินเมยีนม่าร์นี ้เป็นตวัชีว้ดัทีส่�าคญัต่อการเตบิโตของ

อุตสาหกรรมผลิตท่อส�าหรับอุตสาหกรรมน�้ามันและก๊าซธรรมชาติด้วยเช่นกัน

Please turn to page 65 Enquiry No. 65 307

Please turn to page 65 Enquiry No. 65 308

ประมาณ 656,500 คันเมื่อปีที่แล้ว อย่างไรก็ตามผู้เชี่ยวชาญในอุตสาหกรรมและ

นักวิเคราะห์ด้านยานยนต์ต่างออกมาเตอืนว่าในปี 2557 นี ้ ยอดการจดทะเบยีนรถอาจ

ลดลง เนือ่งจากมาตรการใหม่ในการพิจารณาให้ความสนบัสนนุ โดย Kelly Tan กล่าวว่า

“เราคาดว่า ยอดขายน่าจะลดลง เนื่องจากการเปิดตัวต่างๆ ของปีนี้ น่าจะเป็นการเอา

รถรุน่เดิมมาเปลีย่นแปลงเลก็น้อย ไม่ใช่การเปิดตวัรุน่ใหม่เอ่ียมอ่อง ดังนัน้ ยอดรวมทัง้

อุตสาหกรรมน่าจะเตบิโตอยูใ่นราว 3.9% จากทีย่อดในปีทีผ่่านมาไม่มกีารเปลีย่นแปลง”

และจากการประเมินของสมาคมยานยนต์ของมาเลเซีย (MAA) ก็ได้รายงานออกมา

ในทิศทางคล้ายกันคือ คาดว่าจะมีการเติบโตประมาณ 2.1% หรือที่ยอดประมาณ

640,000 คัน ในปี 2557 โดยค�านวณจากยอดรวม 640,000 คันในปีที่แล้ว (ยังไม่ได้

ประกาศตัวเลขอย่างเป็นทางการ ณ ขณะที่รายงานข่าว) และจะเพิ่มเป็น 667,800 ใน

ปี 2558 และ 683,000 ในปี 2559 และ 699,300 ในปี 2560 ซึ่งมีอัตราการเติบโตเป็น

2.2% และ 2.3% และ 2.4% ตามล�าดับ

of one, as the country attempts to improve the climate for energy investments.

International industry reports say the award of offshore licenses is likely to lead to

the offer sometime during 2014 of more than a dozen other onshore and offshore

exploration blocks, including in the Bay of Bengal and Gulf of Martaban. Bidders

for the 30 offshore blocks currently in the pipeline include major Western global

energy development firms.

18

Ancillaries & AutomAtion

RFIDin Tool Management

RFID is a technology that uses radio waves to automatically identify objects. The most common principle is that it stores a serial number which identifies an object and other information on a microchip that is attached to an antenna (the chip and the antenna together are called an RFID transponder or an RFID tag.) The antenna enables the chip to transmit the identification information to a reader. The reader converts the radio waves reflected back from the RFID tag into digital information that can is passed on to computers to make use of it.

RFID for Tool IdentificationTool identification using industrial RFID

increases efficiency as it makes incorrect tool allocation or missing tools a thing of the past. All the tool-relevant data are stored without contact on a data carrier embedded in the tool holder. Automatic loading into the system memory means all the data are always correct and up-to-date, as the data are continuously updated when the tool is loaded and unloaded. In modern production facilities this ensures maximum tool utilization and high machine uptime.

An RFID-based identification solution is created to ensure reliable data transfer, even in the area surrounding metallic materials. As part of tool management systems, i t enables the automat ic transfer of the tool parameters, which substantially reduces non-productive time at themachine. This does not include the time and labor savings for the provision of tools and equipment and optimal utilization of the tool life. Scrap and rework due to excessive use of tools are also virtually eliminated. Additional effects include easier organization of tools and equipment and greater production assurance and avoidance of errors, such as incorrect inputs or mixed-up tools.

The core components of identification systems are robust data carriers in miniature design, a read/write head and a processor unit. In complex tool management solutions, they are also

Radio frequency identification

(RFID) technology offers the

possibility of significantly

enhancing tool management.

Its capabilities include being

able to track and automatically

identify tools being loaded in a

machine tool. RFID is a reliable

and cost effective way to

prevent manual data entry

errors and accelerate

the operational time of

machining processes.

Ancillaries & AutomAtion

MARCH - APRIL 2014 19

used in configuration and measurement devices, where, according to current practice, the first programming of the data carrier with identification and geometric data takes place. RFID systems are suitable for industrial use and designed for extreme loads from shock and vibrations and electromagnetic, thermal, or chemical effects.

RFID Tool ID Tag Further to the RFID tool identification system, RFID based tool ID  tags have been created and are compatible with the existing data control and tracking systems of general machine tools.

These new RFID tags are designed to be mounted on the end of a tool holder retention knob. This retention knob is then screwed into the top of the tool holder to provide not only a handling point for automatic tool changing, but also a reliable and repeatable place for reading a tool ID tag in existing machine tools. These tags include a center hole compatible with the cooling and sealing apparatus that allows cooling fluid to pass through the center of the tag and retention knob usedby the machines. These tags are designed to

withstand the elevated pressures and centrifugal forces present in this mounting position.

These new RFID tool tags are also designed to be 100% compatible with most existing machine tool tags reading protocols and database systems and require no change in programming. These new tags can even be interchanged with the existing CAT 40 and CAT 50 tool holder retention knobs and tags. Newly available processors and reader heads can also be used with either the machine tool’s protocol or provided with the standard RFID solution provider’s protocol for greater f lex ib i l i ty and re l iabi l i ty in interfacing.

Besides RFID, there are manytool identification systems available in a wide variety of versions in the marketplace. Many manufacturers believe that the investment pays for itself within a year or two. This demonstrates that tools that always carry their individual data with them can be optimally used and managed, an essential

part of machining achievement.

These new RFID tool tags

are also designed to be 100%

compatible with most

existing machine tool tags

reading protocols and database

systems and require no change

in programming.

เทคโนโลยี RFID ได้ช ่วยสร้างความเป็นไปได้และเป็นตัวเสริมการท�างานของการบริหารจัดการเครื่องมือให้มีประสิทธิภาพสูงยิ่งขึ้น ขีดความสามารถของระบบนี้เป็นระบบอัตโนมัติ ครอบคลุมการตรวจสอบและยืนยันเคร่ืองมือท่ีโหลดขึ้นบนเครื่องมือกล เทคโนโลยี RFID เป็นระบบที่คุ้มค่าและเชื่อถือได้ในการป้องกันความผิดพลาดที่เกิดจากการป้อนข้อมูลด้วยมือ และยังช่วยร่นระยะเวลาในการท�างานและกระบวนการกัดขึ้นรูปอีกด้วย

RFID เป็นเทคโนโลยีที่ใช้คลื่นวิทยุในการจดจ�าบ่งบอกวัตถุต่างๆ อย่างอัตโนมัติ หลักการพื้นฐานของระบบนี้คือ ระบบจะท�าการบันทึกชุดตัวเลขซ่ึงเป็นตัวที่ระบุสิ่งของและข้อมูลต่างๆ บนตัวไมโครชิปซึ่งติดอยู่กับสาย

26

Cutting StrategIeS

The Nature of HRSAsThe primary applications for HRSAs are in the aerospace, oil and gas, and pe t rochemica l i ndus t r i es , as the components in these industries need highly stable mechanical strengths at 1,000°C and above. HRSAs have high tensile, creep-rupture, and fatigue strength, good ducti l i ty and toughness, and enhanced resistance to oxidation and heat corrosion. These superb qualities are essential in the hottest parts of gas turbines both for power generation and aircraft.

When each of the three base groups of superalloy materials are machined, approximately 75% of the generated heat is removed by the chip. HRSAs require lighter cuts due to their high level of hardness, and a cutting fluid with high lubricity is recommended. It is important to be aware that in many cases, HRSAs cannot be cut using sulfur-based fluids.

Heat ChallengesHRSAs create more heat during the machining process than steel generates when being cut because of its poor conductivity. Combined with a high level of hardness, the temperature in the cutting zone will increase drastically, especially at the tool and workpiece interface. To maintain dimensional stability and prolong tool life, the coolant volume needs to be greater for cutting operations than that used to machine more common steels.

Coolant Handling Heats in Cutting HRSA

Heat-resistant superalloys

(HRSA), which are classified

into nickel-, iron- and

cobalt-based groups,

can withstand extremely

high temperatures, high stress,

and very tough conditions,

but are probably the

most demanding to machine.

This article will discuss

coolant strategies when

cutting these tricky HRSAs.

Cutting StrategIeS

MARCH - APRIL 2014 27 27

The more metal-to-metal contact between the part and the tool, the more lubrication is needed. This means that applications such as single point turning or grinding will require a coolant with a very high cooling capacity, like that of synthetics, and applications such as drilling and reaming require a lot of lubrication.

Handling the Super HeatWhen cutting these materials, the best place for coolant to be used is just before the cut, on the tool cutting edge, and on the tool’s wear surface. In other words, coolant should be placed everywhere a part/tool interface occurs. Good results can be achieved with ester-based coolants, which can lengthen tool life much like chlorinated fluid does. However, if it’s a case in which chlorine and sulfur are restricted, a high-oil-content coolant is highly recommended. If that’s not practical, then the concentration of the cool-ant should be increased to the highest recommended concentration level for the specific product.

As most HRSA materials work-harden quickly, the dwell time of the cutting tool

must be minimized; although, no coolant strategy will correct what is actually a programming error. Higher-pressure coolant delivery to the work zone helps to break chips, but it is coolant volume that moves them.

Pressure helps to break the chip and therefore is very dependent on tool choice and material. In a drilling application, high-pressure, through-the-tool coolant delivery is recommended. It’s also preferred to have the volume of the hole in coolant delivery per every revolution.

A machine shop will typically choose the coolant that solves its most difficult problems and while compromising on the others. Ordering a metalworking fluid specifically made for these applications is recommended over picking up a few pails while ordering other supplies. There is no one-size-fits-all theory for coolant, but remember, the better the coolant and coolant management system, the longer the coolant will last in the sump, thus reducing overall costs.

When cutting these

materials, the best place

for coolant to be is just

before the cut, on the tool

cutting edge, and on the

tool’s wear surface.

32

Sheet Metal

CO2 Laser Cutting Fiber Laser VS

A fiber laser is a special type of solid state laser whose basic setup consists of an undoped cladding and a doped core of higher refraction (active medium). Guided within the fiber core, the laser light passes through the fiber, and, because of its great length of interaction, it experiences a very high amplification.

Generally, f iber lasers are optically pumped. This is done by coupling the radiation of diode lasers or other fiber lasers into the cladding or the core itself in a direction parallel to the fiber core. In many cases, double clad fibers are used in order to achieve higher output power. 

Technical and Cost Benefits Speed and versati l i ty are vital in a manufacturing environment, because work-in-process adds cost to the final

product. However, there are other costs that factor into the profitability equation. For example, total operating costs for a fiber laser cutter can be about 56 cents an hour compared to $3.19 an hour for a typical CO

2 laser. What’s more, with no mirrors to

keep in alignment, no blowers to replace, no resonators to tune, and no laser gas to replace, maintenance costs are negligible or non-existent. Additionally, with a laser source that is predicted to last 100,000 hours - five times longer than a CO

2 resonator -

both replacement costs and the cost of downtime are eliminated. All things considered, a fiber laser can cut twice as fast at one-sixth the cost, with a typical payback period that is only 70% of that of a CO

2 laser.

In terms of versatility, fiber lasers are very efficient machine tools which shops of all sizes and levels of sophistication are finding to be one of their most valuable assets. For those cutting a variety of materials and thicknesses, many fiber laser cutting machines are currently capable of cutting steel up to 0.70 inches thick, stainless up to 0.394 inches, aluminum to 0.315 inches, and copper and brass to 0.197 inches with no lens change.

Parts quality benefits from a very stable beam platform that remains constant and maintains cut quality, even if there is variation in the distance between the nozzle and the sheet being cut owing

In the early 2000s, many

sheet metal companies were

heavily invested in the

manufacture and marketing

of CO2 laser cutting

machines. It seemed CO2

lasers were approaching

a mature product stage,

while very few advances

in laser cutting technology

were introduced. Then in 2008,

fiber laser technology

for cutting sheet metal

was launched for

the first time at Euroblech

in Hanover, Germany.

Article by Daorach Preechatham

Sheet Metal

MARCH - APRIL 2014 33

to any unevenness in the surface of the metal. Due to the fiber laser’s small spot size and narrow kerf width, high speed cutting is achieved without sacrificing high cut quality. That means reduced scrap and superior quality finished parts.

Key Consideration Factors Comparing to CO

2The advantages and disadvantages of fiber laser in comparison with CO

2 laser

vary greatly, depending on the products to be cut. Generally, the main reason for purchasing a fiber machine is the speed of cutting thin (up to 3 mm) materials. This is, however, a disadvantage of fiber laser when compared to CO

2, as the cutting

speed when processing thicker materials,

typically above 5 mm, is faster in a straight line and in piercing times at the start of the cut with a CO

2 machine. There is also

the advantage of a smoother surface finish with the CO

2 machine when cutting

thicker.

However, when it comes to the lower running cost and lower power consumption, using fiber technology is particularly important for companies at the top end of the electrical supply limit in their workshops. Unlike a conventional CO

2

resonator or disk laser, f iber laser machines have no moving parts or mirrors in the light-generating source. This has a distinct advantage in terms of reducing maintenance requirements and operating costs. Moreover, fiber lasers have much higher electrical efficiency, resulting in considerably lower running costs. A 3 kW fiber machine uses one third of the power of a 4 kW CO

2 machine on average

across-the-board performance.

When cutting thin material, fiber lasers can perform at higher speeds. Compared with the same 4 kW CO

2 machine, the fiber laser

is around three times faster in the straight line cutting of 1 mm mild, galvanized, or stainless steel and twice as fast when cutting 2 mm. In addition, fiber lasers cut reflective materials without back reflections damaging the machine. This allows copper, brass, and aluminum to be cut

without problems.

Fiber lasers have become the best choice when cutting thin materials, but for very thick materials, CO

2  lasers seem to be

best suited. No one can guarantee what is the next job, therefore many shops invest in both types of machines. This allows fabricators to be more flexible and operate at their best in terms of performance,

productivity, and payback time.

Due to the fiber laser’s

small spot size and narrow

kerf width, high speed cutting

is achieved without sacrificing

high cut quality.

Fiber Side ViewLow-index Cladding

Doped Core

End View

Index Profile

PumLight

LaserBeam

Pump Light inUndoped Outer Core

42

Inspection

Surface roughness is broadly understood as a measurement of how much amplitude the surface departs from a mean, and at what frequency those departures are prone to occur. Surface roughness measurement is needed for two principle reasons: to try to predict the performance of the machined parts, and to try to control the manufacturing process. The ability to perform surface roughness measurements is critical to maintaining component quality within predefined limits.

3D Optical Profilometry Optical profilometry uses light rather than a physical probe in measuring. This can be done in a number of ways, but the key component to this technique is directing the light in a way that it can detect the surface in

3D. Generally, 3D Optical Surface Profilers are whi te l ight based interference microscopes which offer fast, non- contact, high-precision 3D surface measurement  and surface roughness metrology and can be used to measure surface finish, roughness, and shape  on many surfaces, so long as enough light is reflected back into the object from the surface.

In practice, an optical profiler  scans the material vertically. As the material in the field of view passes through the focal plane, it creates interference. Each level of height in the test material reaches optimal focus, and therefore greatest interference and contrast, at a different time. With well-calibrated optical profilers, accuracy well below a Nanometer, or angstrom level, is possible (A nanometer is ten angstroms).

In 3D optical profilometry, roughness is usually expressed as surface area roughness (Sa). Profile roughness (Ra) can be extracted as a line through an area. Interestingly, Sa is also able to report average Ra through a surface by averaging several profiles.

ADVANTAGESThe advantages of optical profiling are that it is capable of areal measurement at high speed. The non-contact and areal measurement make it possible to quickly measure the full area of the workpieces, whether they are soft, thin, or wide, without damaging

As machining precision

continues to improve with

recent advances in machining

technology, there is demand

for high precision roughness

measurements. Options

for surface roughness

measurement are plentiful,

and in this article we focus

on non-contact 3D

optical profiling.

Surface RoughnessMeasuring by3D Optical Profilometry