1. Challenges in Ultra Precision Manufacture
Paul Shore, FREng

2. Some things have got bigger!
Some things have got bigger!
Ultra Precision Engineering Conference
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3. Some things have got faster!
Some things have got faster!
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4. Some things have got “smarter”!
Some things have got “smarter”!
Ultra Precision Engineering Conference
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5. One critical thing has got smaller!
One critical thing has got smaller!
0.01mm mm mm mm
0.01mm mm mm mm
0.0001mm mm mm mm
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6. So we might wonder………………………………
1) How do product development pathwaths influence manufacturing, manufacturing research and measurement research?
2) What key technical developments will help secure and establish future successful manufacturing capability?
3) What future manufacturing developments will be critical to human-kind’s long term prosperity?
Ultra Precision Engineering Conference
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7. Presentation structure
Presentation structure
Some observations and questions
Enabling our future?
Drivers of accuracy improvement
Power of metrology innovations
Precision manufacturing
examples
6 Summary
Ultra Precision Engineering Conference
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8. Presentation structure
Presentation structure
Some observations and questions
Enabling our future?
Drivers of accuracy improvement
Power of metrology innovations
Precision manufacturing
examples
6 Summary
Ultra Precision Engineering Conference
IfM, Cambridge, England,

9. Energy = enabling our future
Wind turbine market will increase and mature
Solar energy generation will increase and mature (government drive/environmental pressure)
People in rapidly growing countries need more energy, and soon 9

10. Energy = enabling our future
Fission energy will continue to be used, despite
German government announced
the country's nuclear power plants
phased out by 2022 10

11. Environment = enabling our future
Flooding seems to be a growing problem
Drought continues to plague many despite huge technical advancements
Fires rage in locations near wealthy human dwellings
Consumption of earths natural resources is not slowing
Lots of bright / credible scientists say the earth is warming up 11

12. Differential Absorption LIDAR “DIAL”
Mobile airborne pollution measurement
Remote sensing system providing rapid, accurate measurements of airborne atmospheric pollutants
Completely self-contained laboratory carrying a suite of measurement devices to monitor meteorological parameters and ambient gas concentrations
Used across the World to offer service
Achieved using absorption in UV-VIS-NIR spectral regions including: SO2, NO2, NO, ozone, benzene, toluene, xylene and higher aromatics, alkanes, alkenes, petroleum and diesel vapours, HCl, N2O, HF and H2S

13. Medical /aging population = enabling our future
People live longer
People want to be active longer & will spend money on doing so
People are more conscious of their appearance
Younger people are familiar (trust) computer based technologies
Lots of bright / credible scientists say the protective layers of the earth are waning 13

14. Consumer devices = enabling our future
Display based products will increase & they will become 2.5D / 3D capable
Plastic WiFi enabled “newspapers” will emerge
Hand held communications devices present major opportunities Computing speeds will need to continue to increase 14

15. Presentation structure
Presentation structure
Some observations and questions
Enabling our future?
Drivers of accuracy improvement
Power of metrology innovations
Precision manufacturing
examples
6 Summary
Ultra Precision Engineering Conference
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16. Drivers of manufacturing accuracy capability Year 1600 1800 1900 1930
Drivers of manufacturing accuracy capability
astronomy…………….particle physics…………..…..gravity/space…………environment…………………….
…….………………………….defence…………………..…
trains…… automotive, aerospace……………………
…………micro-electronics…….
…………………wind & water mills……
renewable energy
1600
1800
1900
1930
1960
1980
2000
2010
2020
Year
Ref, Shore, Morantz, Phil. Trans. Royal Society 2011

17. Enabling technology that swept away 2000 years
consideration given to an “earth-centred” universe
The enabling technology that swept away 2000 years of an earth centred universe looks simple.
Yet the emerging manufacturing technology of the 1600’s : grinding and polishing of glass lens, together with an optical development of “stopping down the aperture” enabled clearer images
Are subjects that remain key to advanced manufacturing as can be seen through a number of CIRP activities.
Emerging manufacturing technology of the 1600’s
1, Grinding and polishing of glass lenses
2, Optical imaging “stopping down” the aperture

18. ”measure what is measurable make measurable what is not” Maxim ascribed to Galileo Galilei

19. Presentation structure
Presentation structure
Some observations and questions
Enabling our future?
Drivers of accuracy improvement
Power of metrology innovations
Precision manufacturing
Current examples
Future developments
6 Summary
3rd International Conference on Advanced Manufacturing Engineering and Technologies
Stockholm, Sverige, /30

20. CE Johansson
Carl Edvard Johansson 1864–1943
inventor and metrologist

21. Combination gauge block set
CE Johansson worked for the Swedish Carl Gustaf arms factory.
Johansson was concerned that components of their rifles were not “interchangeable”.
His combination gauge block set, which he patented, enabled effective calibration of inspection gauges and testers.

22. Cadillac Model T Henry Martyn Leland 1843 – 1932
Cadillac Model T
Henry Martyn Leland 1843 – 1932
a machinist, inventor, engineer and automotive entrepreneur
Founded Cadillac and Lincoln

23. Henry Ford Henry Ford employed CE Johansson
Ford realised the concept of “inter- changeability” proposed by Leland at Cadillac to produce high quality cars would allow others to employ a new production concept to make affordable automobiles.
Production-line assembly
Mass production assembly is enabled through effective inspection of components prior to assembly.
Johansson Slip gauges were in practice the mechanism by which inspection could be achieved in factories.

24. Soichiro Honda
Honda transformed the motorcycle industry by a combination of innovation and detail attention to quality.
Attention to tolerance band reduction
Honda had concern for not only dimensional tolerances but also geometric tolerances.
Honda motorcycles reliability on the race track rapidly turned into huge sales of their commercial motorcycles .
Honda out sold both Triumph in England and Harley Davidson in the US in just 5 years.

25. Power of metrology innovation
From top left counter clockwise
Circa 1920 Slip Gauge Set, 1959 co-ordinate measuring machine, 1970’s laser interferometer,
modern touch-trigger probe. (Courtesy of CE Johansson, Hewlett Package, Ferranti, Renishaw)

26. Power of metrology innovation
Circa 1955, Louis Essen assisted by Jack Parry
at the National Physical Laboratory

27. Power of metrology innovation
kilometres above the earth
GPS provides 3D positioning uncertainty of < 10 metre
5 parts in 107
In the near future,
23 million metres above the earth
Galileo targeting a positioning uncertainty to 0.01 m (1 cm)
5 parts in 1010

28. BOLTZMANN Primary Thermometer
Most accurate thermometer in human history
Combined microwave and acoustic resonator
with quasi-spherical inner surface enabling:
Thermodynamic temperature within ±0.2 mK
From 118 K to 303 K - extendable
Mode-to-Mode agreement:
Acoustic resonances uR < 0.5 ppm (~0.1 mK)
Microwave resonances uR < 0.1 ppm (~6 nm)
Fractional Excess Acoustic half-width < 10-6
Achieved by:
Internal surface is trixial-ellipsoid within 1.5 µm performed at Cranfield University
Calculation of probe and shape perturbations
Lower Pictures illustrate
Manufacture of hemispheres
On lathe assessment of shape
Traceable CMM assessment of resonator shape
Precision Assembly
Acoustic and Microwave Transducers
World Class Thermometry
Main Picture
Close up of resonator showing the loudspeaker (base) and microphone (right) Also shown (left ) is the microwave waveguide
Main Graph
Error in T- T90 determined with this resonator
Images here
during testing

29. On the Basic Concept of 'Nano-Technology’
N. Taniguchi, Proc. Conf. Prod. Eng. Tokyo, Part II, JSPE, 1974
(0.1mm)
Turning and milling machines
Grinding machines
CNC machines
Lapping and honing machines
Jig boring & grinding machines
Step and repeat cameras
Optical lens grinding machines
Precision grinding machines
Super-finishing machines
Diamond grinding machines
High precision mask aligners
Ultra precision diamond
turning machines
Diffraction grating ruling engines
Free abrasive machining
Electron beam lithography
Soft X ray lithography
Ion beam machining
STM/AFM molecular manipulation
Normal Machining
Machining accuracy capability (µm) 10
1 (1µm)
Precision Machining
0.1
0.01
Ultra Precision Machining
(1nm)
0.3 nm Atomic Lattice Separation
(1Å)
Ref: McKeown after Taniguchi

30. Nanotechnology “first concepts”
“There’s plenty of room at the bottom” - an invitation to enter a new field of physics by Richard P Feynman
Talk given on the 20th December 1959 at annual meeting of the
American Physical Society. Published in the February 1960 issue of
Caltech’s Engineering and Science Journal. Discussed:
Nanometre scale information storage by electron writing
Integrated circuits for computing
Machines for manipulation of atoms and molecules

31. Each letter is made of holes approximately 4nm diameter
Electron beam writing
Encyclopaedia Britannica on the head of a pin
100 nm
Each letter is made of holes approximately 4nm diameter
C. Humpheys, 1992, University of Cambridge

32. SEM image of the cold virus
100 nm

33. Presentation structure
Presentation structure
Some observations and questions
Enabling our future?
Drivers of accuracy improvement
Power of metrology innovations
Precision manufacturing
examples
6 Summary

34. One critical thing has got smaller!
One critical thing has got smaller!
0.01mm mm mm mm
0.01mm mm mm mm
0.0001mm mm mm mm

35. Minimum feature size/areal density
Development of transistors

36. Silicon wafer development trend

37. Adherence to Moore’s law
2 parts in 109 relative precision of accuracy to size
2010: NXE EUV systems, Resolution: 32 < 20 nm, overlay: 2 nm

38. Laser produced plasma light source
30 micrometre
Tin droplets

39. Large ultra precision optic demands
Astronomy mirror fabrication and
space mirror coating technologies
are now to be found in the next
generation of EUV microlithography
systems
Helping to hold “Moores law”
density packing of transistors
on integrated circuits.
2010: NXE EUV systems
Resolution: 32 < 20 nm, overlay: 2 nm

40. Enabling technology that swept away 2000 years
consideration given to an “earth-centred” universe
The enabling technology that swept away 2000 years of an earth centred universe looks simple.
Yet the emerging manufacturing technology of the 1600’s : grinding and polishing of glass lens, together with an optical development of “stopping down the aperture” enabled clearer images
Are subjects that remain key to advanced manufacturing as can be seen through a number of CIRP activities.
Emerging manufacturing technology of the 1600’s
1, Grinding and polishing of glass lenses
2, Optical imaging “stopping down” the aperture

41. Astronomy: driver of Precision Manufacture
E-ELT 40 30
TMT
Diameter of telescope (metres) 20
LBT
KECK 10
Subaru
This graph shows that ground based telescopes are presently going through a period of intense size scale up.
This is after a 50 year period where sensor sensitivity had been the most cost effective means to improve performance.
A key science driver today is the detection of earth like planets, meanings planets to size of earth being located a similar distance from its star as earth is from our sun.
Astronomers considered m scale ground based telescopes will be needed.
Hale
AAT
HET
Hooker
WHT
VLT
Galileo
1609
1900
1920
1940
1960
1980
2000
2020
Year

42. Next generation ground-based telescope

43. Reqd. Production rate: 1 per day
Astronomy: driver of production & precision
Here we can compared the 10.2m Keck telescope mirror with that being proposed for the 42m E ELT.
The Keck telescope has 36 mirror segments.
EELT has nearly 1000 segments.
Here the tennis court again.
E ELT
~1000 segments
Reqd. Production rate: 1 per day

44. ESO ELT mirror segment SKF International Conference Amsterdam
June 2010

45. BoX® Ultra Precision Machine 1600
SKF International Conference
Amsterdam
June 2010
BoX® Ultra Precision Machine 1600
Rapid grinding and measuring system
for free-form optics
BoX ® performance
Work-piece quality
Form accuracy: < 1 um RMS
Sub-surface damage: < 5 um
Roughness: nm
(Zerodur data)
Processing rate
Grind time: 20 hours
(10 hours per m2)
Measurement time: ~ 4 hours
Load time: 1 hour

46. Workpiece metrology has full system accuracy ~ 0.25 μm
In machine metrology
Optical Straightedge
Workpiece metrology has full system accuracy ~ 0.25 μm
Z axis
Mini-laser
interferometer
X axis
LVDT probes
Workpiece

47. BoX® Ultra Precision Machine 1600
In-situ post grinding measurement
using laser based metrology frame

48. Growth in size of commercial wind turbines (height in metres)
IPCC (2011), “Special report on renewable energy”

49. KMT Lidköping Vertícal Hard turning/Grinding machine
Grinding and hard turning in the same setup.
Machine designed for bearing rings.
Dedicated Man-Machine-Interface.
Linear motors – ultra precision.
Hydrostatic slides and workhead.
In machine metrology
X-Z slide circular accuracy diagram
Machine weight kg
Working range, OD – mm
Max workpiece weigth kg

50. Wind turbine bearing fabrication

51. Complex shape component processing
Technology Strand to Develop
Effective Manufacturing.
Ref, Rolls Royce

54. Emerging production Shifting from processing
stable silicon substrates to films
Shifting from
“step and repeat” operations to
“reel to reel”
continuous processing 54

55. Indoor “GPS” Technology
High accuracy measurement complement to GPS / Galileo
Frameless that makes buildings the
measuring machine frames
Able to identify element and perform measurements on them

56. Presentation structure
Presentation structure
Some observations and questions
Enabling our future?
Drivers of accuracy improvement
Power of metrology innovations
Precision manufacturing
examples
6 Summary

57. Summary
1) How do product development paths influence manufacturing? generally they demand higher levels of measurement accuracy to be performed ……….and often closer to production processing itself
2) What key developments secure successful manufacturing capability?
those which are demonstrably deterministic (repeatable) in their application
Looking forward,
3) What future manufacturing developments are critical to human-kind’s long term prosperity?
those that enable sustainable energy generation…..whatever form that may take

58. Summary
1) How do product development pathwaths influence manufacturing, manufacturing research and measurement research? Tend to demand higher relative levels of accuracy, on components of shape complexity with greater scale
Noting: energy is enemy of precision but the driver of production
2) What key technical developments will help secure and establish future successful manufacturing capability? Processes that can be performed in more “hostile” environments on materials having lower stability levels and more complexity
3) What future manufacturing developments will be critical to human-kind’s long term prosperity?
Those that enable effective energy production technologies

59. Acknowledgements EPSRC UPS2 IKC Programme EPSRC Ultra Precision Centre
EPSRC UPS Basic Technologies
EPSRC UPS2 IKC Programme
EPSRC Ultra Precision Centre
UK National Measurement System
Companies and organisations
Microsharp, RAPT, Surrey Satellites, Qioptiq, Loxham, Gooch and Housego, RAL, LLNL, LMJ, CP, UK ATC, ESO, ESA, NASA, NPL , Rolls Royce, Lidkoping Machine Tools, SKF, SBC, CERN

60. Closing remark To save the earth we need to concentrate
on environmentally safe energy generation
methods.
We need to focus on these engineering
challenges with the same level of engineering
concentration seen in the space race of the 1960’s