High-precision CT measurement technology optimizes workflow

Computer X-ray layering technology is already in use in the industrial sector. It offers a wide range of technical solutions for applications in the consumer goods, automotive and pharmaceutical sectors. It shortens technology development cycles, allows for rapid prototype inspection reports and shortens reaction times for damage analysis.

Carl Zeiss has developed universal technology solutions specifically for the manufacture of complex parts in the injection molding industry – from complete measurement of parts, tool calibration to standard measurement of plastic gears. The ability to generate a 3D model of the actual part without destroying the actual part makes computer X-ray layering technology extremely important in part inspection. The 3D image of the part shows the entire part including internal and external geometry. In addition, X-ray layering systems allow high-precision dimensional measurements of complex parts. This eliminates the need to cast the part in synthetic resin and then gradually destroy the resin for 2D layering measurements. Another advantage of this computer X-ray layering technology is that the measurement results are easy to interpret. Compared with traditional measurement records, manufacturers can quickly and clearly identify where the part deviates from the nominal state with the color image.

Color deviation display of a plug [page]

Products made of all materials can be measured with the aid of X-ray layering. Depending on the material's ability to be seen, a computer X-ray layering system can see through the component over a length of 1 mm to 0.5 m. Plastics and silicone are particularly easy to see through. This measurement method is particularly suitable for composite components, as the X-rays can make the fibers inside the material visible. The measurement process takes different times, depending on the resolution required. The instrument can provide the first data results after 5 minutes of measurement. However, the longer the measurement time, the more accurate the results. For example, in the pharmaceutical industry, every detail is required. It is important that the measuring instrument can detect deviations of a few microns. In this case, the measurement process often takes 1 hour or more. In this case, the system can detect all the details inside the product.

Injection molding and die casting parts usually do not correspond very well to the mold negative due to different materials and process parameters (such as shrinkage). Therefore, mold manufacturing often requires a repetitive process of one or even up to ten steps. X-ray layering technology can reduce these cycle times and significantly shorten development time: Carl Zeiss's Calypso measurement software provides a "tool calibration" function for this purpose. In this way, manufacturers can not only measure the actual shape deviations, but also "mirror" the actual surface. This allows the shrinkage dimensions of the mold to be predefined and the measured values ​​to be incorporated into the tool calibration program. The measured data can be used directly as setpoints for the tool secondary processing. Since the tool calibration workload is significantly reduced, the components can be put on the market faster. User surveys have found savings potentials of up to 50% to 70% in this regard.

X-ray layering technology is also a powerful tool in the manufacture of plastic gears. In general, when measuring plastic gears, the same parameters must be measured as for steel gears. The main difference is that each tooth of the plastic gear must be inspected. Carl Zeiss's Gear Pro software helps to describe the tooth flank surface. This is necessary so that the toothing can be measured based on the CAD data. The calculation process used is certified.

A key point of advanced software is the issue of easy operation. Only four data: number of teeth, base diameter, thread inclination and tooth thickness, are used to describe the basic shape of a component. In addition, more data is required so that the user can better define the measurement and evaluation according to the drawing requirements. Depending on the evaluation requirements, up to 1,000 values ​​can be provided. Such a large number of values ​​can only be managed by software, such as Gear Pro, which provides users with these methods.

It is impossible to list all the applications of X-ray layering technology here. Among them, X-ray layering technology can automate measurement and inspection processes, visualize measurement results, and centralize various processes on one device. For the inspection of lightweight materials, this method also has completely new prospects. With the Metrotom 1500 and Metrotom 800 computer X-ray layering systems, users can not only obtain the functions of coordinate measuring machines, but also various non-destructive inspection functions.

In particular, the Metrotom 800 instrument has entered the ranks of X-ray measurement systems due to its excellent price-performance ratio. It is particularly suitable for quality assurance and structural inspection of complex plastic and composite workpieces. (end)