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Real Time Measurement and Feedback System for Production Ultra Precision Machining--Red Cone Research Inc., 11579 Apache Trail, Conifer, CO 80433-7200; 303-838-5376
Dr. David C. MacPherson, Principal Investigator
Dr. David C. MacPherson, Business Official
DOE Grant No. DE-FG03-98ER82654
Amount: $600,000
Building the next linear collider will require machining two million copper cells with sub-micron dimensional tolerances. A non-contact method for rapidly measuring cell dimensions is needed to insure that each cell is made to the correct size. If the cells can be measured while they are spinning on the lathe, the impact on production time would be minimized. A measurement device with this capability would also insure that cells are properly mounted on the lathe. This project will develop a high-speed interferometer to measure the dimensions of parts spinning on a diamond turning machine. The interferometer will have 0.1 micron resolution and a 1 ms measuring time. In this approach, the interferometer laser beam follows behind the cutting tool, measures cell dimensions, and provides real time quality control on each part. In Phase I, a high-speed prototype interferometer was assembled and used to demonstrate the measurement of an accelerator cell while it was spinning in a lathe chuck. Variations in the distance to the cell of +/- 0.2 microns were measured, along with the thickness of the oil films left by the cutting fluid. In Phase II, the interferometer will be perfected and packaged in a 1 cubic foot enclosure. It will then be incorporated onto a diamond turning machine to complete the real time measurement system. The interferometer will also be incorporated onto a coordinate measuring machine for general-purpose quality control measurements.
Commercial Applications and other Benefits as described by the awardee: The interferometer should be useful as a general-purpose tool whenever 100% dimensional control is needed. The coordinate measuring machine should have much higher resolution than optical systems currently available. This interferometer could also improve the consistency of laser eye surgery by providing topographical feedback during corneal ablation.