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Curve Radii Repeatability
Curve Radii Repeatability
SPHERICAL CURVE GENERATION PROCESS CAPABILITY
© 2010 Lattice Materials LLC • 516 E Tamarack St., Bozeman, MT 59718 • (406) 586‐2122 • LatticeMaterals.com
Spherical Curve Generation Process Capability
This paper quantifies Lattice Materials’ measurement methodology and manufacturing repeatability of a small
diameter spherically generated silicon blank.
Part Configuration and Measurement Methodology
The part used to illustrate the principles discussed in this paper is 26.2mm diameter, with a convex radius of
20mm ±0.05mm on one side, plano on the other side, and center thickness of approximately 7.9mm. Figure 1 is
an illustration of the part configuration, and defines the basic terms of the geometry.
Figure 1
Basic Part Configuration
Curve radius is measured using a Mahr gauge attached to a spherometer ring. The gauge is placed on the radius
of the part then the sag is recorded and compared to the min/max values determined by the manufacturing
engineer from the customer’s radius tolerances. The system is depicted in cross‐section in Figure 2.
The process is continuously monitored: parts are sample tested using a digital Mahr‐type gauge integrated to
the CNC curve generator, and the machine adjusts as needed to ensure operation within the specification limits.
Figure 2
Mahr Gauge and Spherometer Ring
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© 2010 Lattice Materials LLC • 516 E Tamarack St., Bozeman, MT 59718 • (406) 586‐2122 • LatticeMaterals.com
Figure 3 defines the sag limits at in‐process test. The allowable sag range for this part is 4.8713 – 4.9037mm, or
32.3µm, when the sag is measured at the full diameter of the part. Since the center thickness is defined by
customer specification, the variation in radius is realized at the edge of the part.
Figure 3
Sag Detail, Exaggerated for Clarity
Typically the spherometer ring is smaller than the full diameter of the part, as illustrated in Figure 2 above.
Stocking a ring for every diameter part that comes across the factory floor is prohibitively expensive, and using a
smaller‐diameter ring allows the Mahr gauge to be translated across the spherical surface to gauge the
sphericity of the part. If the sag value is not constant, an aspheric surface is indicated and the operator knows
the machine needs adjusting.
One consequence of using a smaller ring is that the total allowable sag range is reduced, and so is measurement
resolution. Figure 4 illustrates the practical implications of measuring the sag of the same part, but using a
16mm diameter spherometer ring: the overall sag tolerance range is reduced from 32µm to 8µm, effectively
tightening the manufacturing specification. The spherometer ring must be sized to provide the maximum
measurement resolution, while still allowing for the gauge to be moved across the part in order to gauge the
sphericity of the surface.
Figure 4
Sag Value Range of a 16mm Spherometer Ring on a 20mm Radius Part
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© 2010 Lattice Materials LLC • 516 E Tamarack St., Bozeman, MT 59718 • (406) 586‐2122 • LatticeMaterals.com
Statistical Process Results
Figures 5 and 6 illustrate the curve radius distribution as measured on two high‐volume generated curves at the
in‐line inspection station. Both parts are 26mm diameter, and the data has been normalized to indicate percent
deviation of radius from the target value. For reference, a typical radius tolerance is ±0.25%.
Figure 5 Figure 6
Process Capability on a 14mm Convex Radius Part Process Capability on a 25mm Concave Radius Part
The process typically runs well within ±0.25% of the target radius due to the inherent stability of the equipment,
and also due to continuous monitoring to quickly correct process deviations. Parts are also subject to final
inspection before shipping, where they are inspected for chips and cosmetic defects, and a final dimensional
inspection.
Maintaining such tight control over the process is necessary to minimize manufacturing costs, which allows
Lattice to supply high quality components at competitive prices.
The Price and Cost of Quality
Ordering more raw material than you really need, and then inspecting and sorting parts once they’ve arrived at
your dock is expensive and a waste of valuable human resources. Add to that the cost of in‐process fall out
because of inferior raw materials, and the risk of shipping late to your customer. Paying a little more for high
quality materials is ultimately more economical for you.
Lattice Materials firmly believes that quality must be built in to the parts, it can’t be “inspected in.” Our high in‐
process yields, low scrap rate, and even lower return rate* validate our manufacturing and test methods and
prove our commitment to making the parts right the first time.
* 0.156% return rate in 2010 for machining errors or part dimensions out‐of‐spec.
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© 2010 Lattice Materials LLC • 516 E Tamarack St., Bozeman, MT 59718 • (406) 586‐2122 • LatticeMaterals.com