Machining systems company may be the only one able to combine into a single measuring cycle touch-trigger probing with laser scanning and non-contact video measurement.

With the installation of the latest OGP SmartScope 650 Vantage 3D measuring centre with a full five-axis positioning capability, Mikron Machining Technology is able to combine into a single measuring cycle touch-trigger probing with Renishaw SP-25, laser scanning and non-contact video measurement. Mikron Machining Technology is believed to be the only company with such a modern laboratory providing a wide range of measuring equipment at the disposal of customers. Working closely with the Mikron service department it also provides qualified support when process checks are required by customers on their production machines.

In addition to the OGP SmartScope 650, equipment available in the laboratory includes three Mitutoyo CNC driven co-ordinate measuring machines, a SmartScope ZIP non-contact 3D measuring machine, Formtester surface measurement, a Profiletracer and Formtracer machines.

Following the latest installation, fully integrated measurement processes can now be incorporated using five-axis positioning of customer components in order to automatically carry out precise process capability evaluation of sample and machining trial components at the Agno, Switzerland machine tool build facility.

Explained Alan Franzoni, responsible for the measurement and quality laboratory at Agno, Switzerland: 'The quality laboratory is a key part of the whole machine tool operation.

We can check and verify in a single automated cycle, independent of the machine tool, all size and geometrical relationships of widely varying component features that tend to be combined into the typical parts that customers have purchased our machines to produce.' The SmartScope 650 measuring machine, with linear drives and a 500mm by 660mm by 300mm working envelope, has a resolution of 0.1 microns and is able to magnify, display and record elements of a component being inspected at up to 400 times magnification.

The ability of the SmartScope 650 to independently replicate five-axis positioning, remote from the machine tool, is very important as many components produced on the Mikron range of machines involve compound angle holes or features.

These are machined to meet key target areas for start and breakthrough positions to provide oil and fuel feeds, such as in fuel injection, hydraulic and pneumatic valves and pumps.

Indeed, in line with the type of components being produced, extremely close tolerances tend to be applied to size, geometry and surface finish specifications produced by the Mikron range of rotary and in-line transfer machine tools.

So, included in the measuring machine installation is a specialist 0.1mm diameter Apollo probe and Renishaw probe autochange that is able to accommodate automatic measuring cycles to check batches of machined samples.

One important advantage for Mikron's inspection team is that with the programmable integration of video, laser scanning and contact measurement, precise data of chamfers, forms and radii plus monitoring and visual display of edge definition and burrs on the intersection of internal hole breakthroughs, can be made.

In addition, full and detailed process control analysis of collated measurement data can be performed in 'real-time' using the Mitutoyo StatPAK statistical process control software and QC-CALC software that is fully networked with other CNC controlled measuring equipment in the laboratory.

The capability of Mikron machines spans small batchwork to high volume production.

The highly flexible Mikron Multistep and latest development, the 140-axis Mikron NRG-50 rotary transfer machine, cover small to medium batch production while MultifactorTM and MultistarTM, the fastest transfer machine in the world, is capable of producing up to 480 parts/min.

With such demanding component complexity and production requirements, the measurement and quality laboratory is very closely involved with the original application engineering and machine quotation team at the initial project appraisal.

As a result, parameters can be set for measurement and process control to ensure the production solution will fully accommodate the often complex design requirements of the customer.

When the project turns into an order, the department creates an initial measurement protocol for the various features of the component.

This is agreed with the customer and as key structural and moving elements of the machine tool are manufactured such as the rotary table, Hirth indexing ring, fixture locations and datums, these are inspected by the quality laboratory and appropriate data recorded in the project file.

Once the machine is built, alignment checks are performed on the machine and initial 'first chip' parts are measured to establish that the precise geometric, size and surface finish achieved matches the customer specification and order requirements.

When 'first chip' processed parts are accepted by the project team, the next stage is to take a minimum number of five parts from each fixture of the machine to ensure the process is repeatable.

Said Franzoni: 'Bearing in mind a Mikron transfer machine can have up to 24 stations it is here the Mikron measurement and quality laboratory will play an important part.

Only when the machining criteria is established is a four hour production run initiated during which time further parts per fixture of the machine are collected and catalogued every five minutes to determine internal acceptance of the process.

This is performed prior to the customer being called for its own acceptance trials when the Mikron laboratory is put at the service of the customer.'