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Toward Production Inspection of the LH 2 Absorber Window

Toward Production Inspection of the LH 2 Absorber Window. John Greenwood, Fermilab Alignment & Metrology Group. Premise . Some day all of the testing will be completed and a cooling channel will be built. Premise .

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Toward Production Inspection of the LH 2 Absorber Window

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  1. Toward Production Inspection of the LH2 Absorber Window John Greenwood, Fermilab Alignment & Metrology Group MuCool October 22, 2002

  2. Premise • Some day all of the testing will be completed and a cooling channel will be built. MuCool October 22, 2002

  3. Premise • Some day all of the testing will be completed and a cooling channel will be built. • Among other devices, the LH2 Absorber Windows will require pre-installation inspection. MuCool October 22, 2002

  4. Premise • Some day all of the testing will be completed and a cooling channel will be built. • Among other things, the LH2 Absorber Windows will require pre-installation inspection. • You are invited to consider some of the issues associated with production inspection and certification of these parts. MuCool October 22, 2002

  5. Among the issues to be determined… • How many Windows will be built? • 20 • 100 • >200 MuCool October 22, 2002

  6. Among the issues to be determined… • How many Windows will be built? • 20 • 100 • >200 • Will all units be inspected or just a sampling? • If just a sampling, what selection criteria? MuCool October 22, 2002

  7. Among the issues to be determined… • How many will be built? • 20 • 100 • >200 • Will all units be inspected or just a sampling? • If just a sampling, what selection criteria? • Expected production rate? • Units/month • Size of batch MuCool October 22, 2002

  8. More issues… • Will the inspection be – • Static? • Conformance to design • Both convex and concave surfaces MuCool October 22, 2002

  9. More issues… • Will the inspection be – • Static? • Conformance to design • Both convex and concave surfaces • Dynamic? • Pressurized to ??? psi • Number of epochs MuCool October 22, 2002

  10. More issues… • Will the inspection be – • Both Static and Dynamic • Conformance to design for both convex and concave surfaces • Pressurized for several epochs to ??? psi MuCool October 22, 2002

  11. Still more issues… • Special facilities will be needed • Must be clean, stable, dedicated • For how long? MuCool October 22, 2002

  12. Still more issues… • Special facilities will be needed • Location? • Fermilab • NIU • Other MuCool October 22, 2002

  13. Still more issues… • Special facilities will be needed • Location? • Who will do inspection? • Fermilab Alignment & Metrology Group • NICADD • 3rd party MuCool October 22, 2002

  14. Inspection • Surface preparation • < 20 units, Met-L-Chek • > 20 units, or measuring thickness/eccentricity, use a production coating such as TiO2 MuCool October 22, 2002

  15. Inspection • Surface preparation • Go, No Go criteria • What constitutes an “in” tolerance part? • What constitutes an “out” of tolerance part? • Can these be salvaged? • Remediation issues • Are “in” and “out” the same? MuCool October 22, 2002

  16. GD&T!!! • Geometric Dimensioning & Tolerancing – ASME Y14.5M 1994Standard • Datum Reference Frame (DRF) simulation– an abstraction of part features MuCool October 22, 2002

  17. DRF features • Position of 6 precision 0.125” (+0.0005, -0.0000) holes, plus one indicator hole, on convex-side flange surface • Describes • Flange plane • Window center • Window orientation MuCool October 22, 2002

  18. Window DRF – Button targets Targets MuCool October 22, 2002

  19. Window DRF – Plane Plane constructed from projected dots on flange face MuCool October 22, 2002

  20. Window DRF – Circle Best-fit circle constructed from button targets projected on flange plane MuCool October 22, 2002

  21. Window DRF - Clocking XY plane = flange plane, +Y toward button near clocking mark MuCool October 22, 2002

  22. DRF features… • If thickness is to be measured, a second set of holes will be required on concave-side flange surface MuCool October 22, 2002

  23. Photogrammetry Non-contact Fast Many data points Slightly less accurate than best CMM CMM Contacting Slow Sparse coverage Higher accuracy Current inspection tools MuCool October 22, 2002

  24. Best current practice • Combination of CMM + V*STARS • Using CMM to coordinate 6 target holes on flange face • Produces a stable, accurate DRF – plane, point, orientation • V*STARS “attaches” to DRF features for scale and orientation • Simplifies photogrammetry setup • Enhances accuracy • Provides cross-check • Considered as mandatory if thickness and/or eccentricity is to be measured MuCool October 22, 2002

  25. Surface modeling • SPSF (Small Patch Sphere Fit) • Is it useful for new Window shape? • Other options • Kotem Technologies’ SmartFit • MayaMetrix MuCool October 22, 2002

  26. New window shape MuCool October 22, 2002

  27. Inspection tools of the future • Laser CMM in 3-5 years • < 100 nm @ << 1ms/point on small parts (5-10 cm) • Full surface mapping in < 60 seconds • Current development under DOE SBIR MuCool October 22, 2002

  28. NLC Copper Structure Copper discs MuCool October 22, 2002

  29. Summary of objectives • Process must… • Efficiently manage production inspection and documentation • Simplify the process to the extent possible • Insure confidence MuCool October 22, 2002

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