1. Center for Precision Metrology University of North Carolina at Charlotte Dr. Robert Hocken, Director (hocken@uncc.edu) Center Facts  Designated an NSF IUCRC with a nine member industrial affiliates program  25 faculty & staff from 5 academic departments  50+ Masters and PHD students  Center occupies more than 30,000 sq ft of laboratory and office space  Capital equipment in excess of $20M Research/Educational Focus  Dimensional, Coordinate Machine Tool, and Computational Metrology  Nanotechnology Instrumentation Design  Manufacturing Process Modeling  Machine Dynamics and High-Speed Machining  Computer –Aided Tolerancing  Electro-Optics

2. Center Mission  To further applied research and technological progress in the field of precision metrology as applied to manufacturing by:  Education of highly skilled technologists  Performance of original research, and  Involvement with industry

3. Center History & Growth  Late 1980’s, Early 1990’s – Development of graduate program in precision engineering  Early-Mid 1990’s – Industrial Consortium in Precision Metrology  Mid 1990’s – State recognition as a Center  Late 1990’s - Funded as a NSF I/UCRC  2003 – Refunded as an NSF I/UCRC  2008 – Graduated as an I/UCRC  Future – Collaborative research with industrial R&D divisions located on UNCC CRI campus

4. Center Facts - 1  CC Cameron building with 1000 sq ft temperature controlled metrology lab.  Clean room access.  Duke building with Center on the first floor. Approximately 30,000 sq ft with new metrology labs  main metrology  diamond turning  precision CMMs  instrument development

5. Center Facts -2-  Capital equipment ranging from scanned probe microscopes to high speed machining centers.  7 CMMs and fully equipped metrology and surface finish labs.  Diamond turning machines, jig bore, jig grinder, and precision wire EDM.

6. Center Facts -3-  Center core projects fund approximately 20 graduate students annually. Funding includes a stipend, tuition and books.  Core funding comes from the Federal government and industrial affiliates.  Industrial affiliates pay $30,000 per year.  Other projects (about 30 more students) are funded by industry and government (NSF, NIST, DOE, DOD…)

7. Current Affiliates  Cummins Engine Co., Inc.  BWXT -Y12  Intel Corporation  Lawrence Livermore National Lab  GE Energy  Mitutoyo America Corporation, Micro Encoder  United Technologies  Corning Cable Systems  General Dynamics

8. Initiation of Projects  Affiliates meet twice a year to propose new projects. Professors and students also propose projects.  Projects are voted on and selected projects are started.  This November a project using MEMs accelerometers for machine positioning and a project using MT connect were started.

9. Some past projects  Laser tracker for API NIST  Spindle error analysis (Lion Precision)  Standing wave probe (Insitu Tech)  Chip breaking  Tool setting  Hole standard  5 axis machine accuracy  B5.54 and B5.57standards (machining centers and lathes)

13. Input Excitation X i,  i Output Response Y(t) Probe-Surface Interaction Resonator generates sufficient energy to transfer pronounced standing wave along a high aspect ratio Virtual tip Mode shapes Inertial forces 7 um diameter > 3.5 mm lengths Standing wave probe principle of operation InsituTech

14. Example aerospace projects  Critical components for helicopters  Pioneered thin walled aircraft parts  F/A-18 avionics tray  Monolithic technology has spread to other parts  Thin walled parts for radar systems(challenge part from Milacron)

15.  Rotor yoke for Bell 412 Helicopter  Machining time reduced by more than 60%

16.  Bell Helicopter V-22 Blade Fold Support  Advancement Recognized in 2003 with Pinckney Award from American Helicopter Society

17. Raw stock 2,449 kg Completed part 113 kg 3 m x 1.7 m x 14 cm 9.8’ x 5.6’ x 5.5” Part of the raised cargo floor for the flight deck of the Boeing 777-300ER UNCC was instrumental in creating the technology to manufacture components with thin walls and thin floors.

18. Inner center spar for the A380

19. Thin parts outside aerospace Radar challenge part: 4 inches high.0.040" wall thickness

20. The Cobra Judy phased-array radar system on the missile range instrumentation ship USNS OBSERVATION ISLAND (T-AGM 23) Location: PEARL HARBOR, HAWAII

21. Grid-Lock tolerance requirements

22. Fiducials measured on CMM Fiducials measured in machining environment Part Program NC Code Automated coordinate transformation program NEW Part Program NC Code Features measured on CMM are correct The fiducial calibration system references the machine positioning metrology directly to the current state of a workpiece through the measurement of fiducials.

23. Fiducial Calibration System  Approaches error avoidance and error correction from a different point of view  Uses fiducials to generate information about the existing errors, and their corrections  Allows part to be more accurate than the long-range accuracy of the machine  Allows small machines to make large parts

24. Deformation Machining - Many aerospace parts are mostly 3-axis, but have a few sections which require 5-axis machining There is a weight issue: -Machining the obtuse angle is easy -Machining the acute angle leaves much material behind

25. Lighter weight –

26. Other projects - nanotech  Nanoimprinting machine with UCLA, Berkeley, Stanford et al.  Nanometer positioning  10 nanometer feature size  Subatomic Measuring Machine  10 picometer resolution  Sub nanometer accuracy over 25 mm  With MIT

27. UCLA IMPRINTING METHOD Lower stamp into contact with substrate Pull vacuum to remove air Apply 50 psi to both stamp and substrate to flatten Flood area with UV light to cure resist Separate stamp and substrate

31. Summary  The Center for Precision Metrology has research covering a wide range.  Emphasis is on technologies needed for precision manufacturing.  We are ready to work with industry on both short and long term projects ranging from high speed machining to nanotechnology.  Now building instrument for plasmonic lithography for Berkeley  Current proposals being developed for large scale metrology.