Manufacturing and Metrology Systems

Head of Unit

Amir Rashid

Manufacturing & Metrology Systems is two fields combined into one unit, these fields are Machine and Process technology and Metrology and Optics.

Manufacturing & Metrology Systems

Description of the field

The subject area of ​​machine and process technology includes the use of engineering production equipment specifically related to metal cutting. The professorship has been existing (with some modifications during the years) since the Technological Institute, later Royal Institute of Technology, was founded in 1827. Today, the activities of the department is highly future-oriented with a pronounced use of Applied Information Technology (IT).

The department is engaged today in :
 

  • Metal cutting theory and various aspects of manufacturing processes practical possibilities and limitations in the processing of materials from raw material to finished product.
  • Modeling of cutting process for predictive simulation.
  • Real-time Analysis of processing data's, fixture and machine elements impact on the stability and machining performance.
  • Automation and control technology in real time for cutting.
  • Production Preparation and processing.
  • Choice of economic or optimal processing data.
  • Development of resource conservative production

Research

The topic of machining is the core of the department's research activities. Research on the cutting processes and tools used in combination with various work materials and tools is essential. In the future processing technology, it will be very important in the early stages of product development process to predict problems in the physical production. Therefore the group works constantly with the modeling of cutting processes.

In recent years the research group has been concentrating on interference problems associated with the manufacturing process. Such disturbances may be a lack of rigidity in the machine system, clamping or workpiece. Since several years back, the group has been looking into the field of process control. The department is developing an advanced prototype systems for processing control connected to a CNC lathe.

Sustainable production technologies have also become an important area of ​​research and the research team is working to develop models that describe the entire product life cycle, from raw material to en of use. These models can be used as a tool for decision-making activities. The vision is to strive towards a resource-conservative production. "System dynamics" is the philosophy that the group uses to work in this activity.

All these activities require professional use of computers and information technology.

The long term goal is to completely master the simulation and modeling of all manufacturing processes, and to strive towards a resource-conservative production.

  • Metal cutting theory and various aspects of manufacturing processes practical possibilities and limitations in the processing of materials from raw material to finished product.

  • Modeling of cutting process for predictive simulation.

  • Real-time Analysis of processing data's, fixture and machine elements impact on the stability and machining performance.

  • Automation and control technology in real time for cutting.

  • Production Preparation and processing.

  • Choice of economic or optimal processing data.

  • Development of resource conservative production

Metrology and Optics

Description of the field

The insight of metrology as a precondition for maintaining high quality standards in production has grown strong over the past years. Many have realized that shortages in quality are the real cost driver, and not the costs for metrology systems and processes in themselves. A prerequisíte for the production and control of precision products are thus well developed metrology techniques. The increased interest for metrology was also reflected when we initiated SIMET - the Swedish Industrial Metrology Forum - a forum for all interested in metrology, from instrument suppliers, consultants, educators, academic researchers to users who have a chance to have an effect on status, research and education.

Metrology has been going through rapid development in the past years and new technology in the form of optical scanners and production adapted CMMs incorporates now directly in the production lines. This creates entirely new preconditions for effective quality management but requires good collaboration between construction, production and verification.

Metrology planning has therefore become one of the most important areas to investigate and systematize, resulting in a forward-looking research work concerning generic metrology planning strategies for the Swedish engineering industry.

Miniature products with demands on nanometer resolution in the metrology systems is an area that has received proper resources at EU level. At the same time a lot of metrology research remains on three-dimensional structures in the micrometer range with big depth/width relations. Mechanical measuring devices cannot access surfaces, the light cone from optical microscopes is cropped so heavily that the measurment accuracy is lost and scanning electron microscopes has too great uncertainty.

Surprisingly, many commercial instruments are subject to having large measurement errors on so-called "high aspect ratio microstructures," but appealing by collaboration with the instrument companies resulted in improved performance and world record in the measurement of extreme height / width ratios of 8 microns wide and 400 microns deep structures. The group's own surfaceprofile measurment instruments for micro topography measurements over areas up to 2 mm, with a height resolution at the atomic level, is otherwise one of the keys to successful international research collaboration. New initiatives are underway in optical tomography in the micrometer level.

Interferometric measurement techniques, holographic presentation and visualization is another research field in which the group has been very active since the laser group was started in 1966 by Nils Abramson and an extra professorship in Technical Production Metrology was set up for him in 1981. One of the few remaining holographic laboratories that can produce high-quality holograms are within the group. This research has led to the development of a unique 3D display that does not require either glasses or other accessories to experience virtual objects in full 3D of high optical quality which floats freely in space. The scope of this display is multidisciplinary and covers everything from interactive product design to the modeling of 3D environments and simulation of surgical procedures in the medical education. Research in this field is now oriented towards full-color presentation and corrections of image errors, with the intention of eventually commercializing the display.

Metrology and Optics also includes conventional engineering metrology and optical metrology and we run demands for the restoration of the metrology technique as a compulsory element in civil engineering and Bachelor of Science program. There is a major skill shortage in today's engineering industry of educated metrology technicians, a fact that prompted debates about that the quality of production is in serious danger in Sweden.
The group performs research with funds mainly from Vinnova and the EU, but has carried out extensive research projects for industry, swedish military and SKB. Expert assistance and metrology tasks are a natural part of our business and we are hired also for the evaluation of EU projects with metrological approach.

190 um high Siemensstar produced with X-ray LIGA technique.
The record - 400 um deep and 8 um wide structure measured with an optimized optical profilometer

Siemensstar with 190 um depth. With a similar star we have together with a leading instrument supplier set the world record in measurments ”High aspect ratio microstructures” – with depth/width ratios of 400 : 8 on samples produced by Forchungscentrum Karlsruhe with x-ray lithographical technology.

www.engineeringtalk.com/news/mnw/mnw100.html

micromanufacturing.com/showthread.php?p=241 www.minamwebportal.eu/index.php?m1=Public-Area&l1=News&idnews=79

newsweaver.co.uk/mntnetwork/e_article001046619.cfm?x=bckhPgW,b58dPr8C

Jonny by the 3D-display

The 3D-display based on holographic technique is unique with its high optical quality and luminosity. There is no need for any shieldning aid in form of glasses or helmet. Therefore the symptoms of carsickness is eliminated, these are otherwise common when using 3D-displays.

Page responsible:infomaster@itm.kth.se
Belongs to: Department of Production Engineering
Last changed: Feb 08, 2019