Tutorials 

Monday 7th June 2021, Copenhagen, DK

euspen’s 2021 extensive tutorial programme will cover a range of key topics for the precision engineer

Whilst covering a clear technical curriculum, tutorials are less formal than a lecture; providing more personalised learning in a social atmosphere.
They incorporate existing challenges in the workplace which cover conceptual theories through to best practice applications.
These tutorials will take place on Monday 7th June 2021.

T1 ECP2 Online Taster Course
T2 Analysis and Design Concepts for Ultrastable Mechanical Systems: Thermal Effects
T3: Metrology Process Chain: The Toolbox to Support Manufacturing
T4 Optical Metrology for Precision Engineers
T5 Passive Damping in Mechatronics Systems by means of Polymers
T6 Uncertainty evaluation for precision engineers
T7 X-ray computed tomography metrology

Tutorial 1: ECP2 Online Taster Course

Exclusive tutorial will be online only
 7th June 2021
Time: Half Day (AM)

The tutor is Prof. Liam Blunt, University of Huddersfield

Tutorial 2: Analysis and Design Concepts for Ultrastable Mechanical Systems: Thermal Effects

DTU, Copenhagen, DK
 7th June 2021
Time: Half Day (AM)

The tutor is Nicolas Jobert, Alma Consulting

This tutorial will provide the framework required when designing mechanical systems with high immunity against thermal effects, i.e. temperature drifts and/or thermally induced elastic distortions. It will span basic and advanced concepts, practical evaluation tools and methods, as well as control strategies. A particular emphasis will be placed on the usage of an integrated approach, allowing to develop compact thermal elastic models sufficient to provide an understanding of the key parameters governing each problem. Such models can not only be used to decide on the severity of individual sources of disturbance but are also mandatory when designing practical mitigation solutions, either passive or active.

The approach will be illustrated with applications ranging from simple academic test cases and widespread components such as flexure-based translation stages, up to more advanced  opto-mechanical systems.

From these examples, it will be demonstrated that the design of high-performance systems relies on a  small set of concepts and rules, which can be effective for fulfilling ordinary or less conventional customers’ requests.

Intended audience: This is a beginning to intermediate level course, with material ranging from basic to complex, to provide both an overview and references for further study. The intended audience is graduates, postgraduate engineers/physicists, plus industry technical staff having a first experience in systems for which thermal stability aspects are relevant, and aiming at strengthening their insight so as to reduce guesswork for future projects.

Nicolas Jobert studied Mechanical Engineering at the Ecole Centrale Marseille, where he specialized in Noise and Vibrations. After graduating in 1996 he has been active in a range of consulting companies providing services for industry,  civil engineering companies and academic research centers. During these periods, he carried out problem characterization via in the field or in the shop measurement campaigns, as well as the design and numerical simulation/validation of corrective procedures.   Nicolas has also worked in a large international group  on the safety of nuclear power systems, and recently at the French National Synchrotron Radiation Light Source (SOLEIL), where he contributed to the design, validation and commissioning of accelerators and  beamline systems.

In 2018, he founded Alma Consulting in order to offer his services in the field of Precision Engineering.

He also teaches Master 2 classes (Université Paris-Saclay) together with specialized sessions for professionals, with an emphasis on high-precision optomechanical systems.

Tutorial 3: Metrology Process Chain: The Toolbox to Support Manufacturing

DTU, Copenhagen, DK
 7th June 2021
Time: Half Day (AM)

The tutors are Dr Kim da Costa Carneiro & Klaus Liltorp, Danish Technical University (DTU)

Figure 1: The Metrology Process Chain aligns the metrology, which is needed in mechanical manufacturing, with the generalised Manufacturing Process Chain, shown above.

Whereas metrology is generally is considered a necessary ingredient in engineering manufacturing, it is equally often considered a necessary evil, which in turn leads to slobby measurements and poor quality. In order to make the threshold to proper measurements we have development a new approach to metrology in mechanical manufacturing that both increases motivation for and quality of the conformity assessment that leads to customer satisfaction and market success.

We take our starting point in the canonical manufacturing process chain, sketched in Figure 1 with coarsely separated process elements DESIGN, PRODUCTION and CHARACTERIZATION. We build a “metrology toolbox” that assemble in metrology work packages (MWP) within the proper element, so that it is clear when the individual Metrology Tasks should be put into play – and deliver traceable results!

As Figure 2 shows, the total toolbox consists of 6 work packages and 13 metrology tasks, each of which will appear several places in the real production process chains.

We have been building our Metrology Process Chain toolbox over last three years and it is now in use in the majority of the manufacturing related courses at the Department. This has made metrology more transparent which both students and professors appreciate, and it has decreased significantly the overlap of metrology teaching.

The Metrology Process Chain is documented in seven power point files, from which the teachers can pick the metrology tasks individually. Practical measurements have increased.

Figure 2: The MPC is organized in six Metrology Work Packages, MWP (Three in DESIGN, one in PRODUCTION and two in CHARACTERIZATION). The MWPs consist of 13 Metrology Tasks, MT.

Learning outcomes: The tutorial will present the overall process chain and give detailed insight in selected metrology tasks.

Intended audience: The curriculum presented covers bachelor to Ph.D. level.

Dr Kim da Costa Carneiro was first introduced to euspen in the late 1980s when he was asked by Prof. Pat McKeown to join the founding Board of Directors on the planned European counterpart of the American and Japanese Societies of Precision Engineering. This led to a long-term friendship between the two as well as the sustainable, successful euspen, which many have contributed to and are profiting from.

As the first Chairman of euspen Pat led the organization through the initial, exciting times. Kim followed as the third Chairman; his task was to establish a professional and sustainable organization with ups and downs, and a never empty moneybox, while keeping up the enthusiasm. Many people have also contributed to the wellbeing of euspen.

Kim studied engineering at the Technical University of Denmark, DTU, covering mechanics and electro physics, including a postdoc in USA. Over the next ten years Kim held the positions of Associate Professor in condensed matter physics at the University of Copenhagen and the founding director at the Danish Institute of Fundamental Metrology. At the end of this term Kim became senior advisor at the Mechanical Department at DTU; where he adopted a new approach to teach metrology within manufacturing engineering.

Klaus Liltorp

In 1985, Klaus Liltorp graduated as a technical metrologist, focusing on how to extract knowledge from specimens in order to be able to make correct technical decisions.

Since then Klaus has worked in a wide range of Danish and international companies with his work focused on metrology, inspection, quality control, quality assurance and quality management. Klaus has represented production, procurement, inspection, technical audit, logistics, research and development in both hands-on and hands-off positions.

In 2017, Klaus joined the Institute of Mechanical Engineering at the Danish Technical University (DTU) focusing on the various aspects of geometrical metrology. This includes using a wide range of measuring strategies and equipment from simple hand held equipment, small and large tactile CMM-s, Optical CMM-s, laser interferometers over confocal microscopes to more classical profilometers and roughness testers as well as reference equipment.

At DTU the instruction and training in the use of the equipment is accompanied through teaching, guiding and supervising on metrology topics as an integrated part of any production or research chain. Klaus’ work has focused on the need for a common understanding of metrology. The ability to create a connection between hypothesis and experimental result, specification and work piece, part ordered and manufactured part received.

Klaus’ practical and hands-on knowledge has been paired with a more academic approach through his work with Dr Kim da Costa Carneiro and this has proved to be very fruitful combination.

Tutorial 4: Optical Metrology for Precision Engineers 

DTU, Copenhagen, DK
 7th June 2021
Time: Full Day

The tutor is Dr Peter de Groot, Zygo Corporation

This is a fast-paced, comprehensive optics course for precision engineers, with an emphasis on the principles and applications of non-contact instruments for dimensional metrology. We begin with basic geometrical optics of lenses and mirrors, moving up to common optical tools such as telescopes, autocollimators, fringe projection systems, alignment scopes, conventional and confocal microscopes, machine vision, and systems based on focus and triangulation. We then tackle dimensional metrology applications that make use of the wave nature of light, including diffraction, interference, and holography.  This provides the foundation for distance-measuring interferometers and optical encoders, laser Fizeau interferometers for optical surfaces such as lenses and mirrors, and interference microscopes for surface structure analysis. Hot topics include the latest performance enhancements, new instrument designs, vibration robustness, accommodation of highly sloped surfaces, metrology for additive manufacturing, and the analysis of transparent surface films.

Learning outcomes: By the end of the course, you will have greater confidence in the selection, invention and evaluation of optical metrology solutions for practical applications in precision engineering and manufacturing.

Intended audience: This is a beginning to intermediate level course, with material ranging from basic to complex, to provide both an overview and reference for further study.  The intended audience is engineers, scientists and measurement specialists interested in gaining a greater understanding of the operating principles and best practice use of advanced optical instrumentation.

Peter de Groot is a Physics PhD specializing in applied optics, with experience in both industrial and academic environments. As a scientist in optical metrology, Peter has published 180 technical papers and book chapters in the fields of physics, optical testing, surface structure analysis, semiconductor wafer process metrology, stage motion measurement, international standards for metrology, and large-scale coordinate measurement. His research has led to 140 US patents and several commercial products. He is a Fellow of the SPIE, the Optical Society of America, the Institute of Physics, and the International Academy of Engineering Technology. Dr. de Groot is an Honorary Professor at the University of Nottingham, and an experience teacher and presenter of professional short courses.

Tutorial 5: Passive Damping in Mechatronics Systems by Means of Polymers

DTU, Copenhagen, DK
 7th June 2021
Time: Full Day

The tutors are Dr Ir. Ing. Theo Ruijl & Ir. Ing. Pieter Wullms,  Mi-Partners

Specifications on the dynamic position stability of systems become increasingly tighter. Damping is a very effective and robust way to improve the dynamic behaviour. This can either be done in an active (e.g. feedback control) or in a passive manner. In several applications, passive damping can be considered as an excellent alternative to active damping, or can even be an addition to active systems to suppress resonances which limit the controller bandwidth and to increase the robustness of the system.

The focus of the course is on viscoelastic material damping, on the reason of simplicity, cost and robustness compared to other passive damping principles.

Viscoelastic materials are applied in the past in various applications to achieve damping, however in many of these applications the precise performance is less critical and often by ‘trial and error’ the design is realized. In our high-end performance applications, the complexity, requirements and conditions are such that extensive modelling is necessary and predictability of the final performance is crucial for a successful design of the entire system. The tutorial  focusses on visco-elastic material properties, modelling and designing with viscoelastic materials in a predictable manner.

Tutorial subjects:

  • Understanding the dynamic behaviour of viscoelastic material (frequency and temperature dependence)
  • Material characterization and modelling of viscoelastic materials dynamically
  • Dynamic system modelling with viscoelastic materials
  • Modelling damping by means of the energy method
  • The design and application of damped tuned mass dampers
  • Examples by means of several cases: high and low frequency applications
  • During the course the participant will be actively involved by means of example cases (hand calculations need to be done)
  • Several example materials and designs will be shown.

Learning outcomes:

The course covers the basics on visco-elastic material properties, relevant for damping applications in mechatronic systems. It  offers the participant a methodology for designing with visco-elastic materials, in a predictable manner on system- and on component-level.

Intended audience:

The tutorial is aimed at engineers and physicists, dealing with vibrations and resonances in precision machine design and seeking passive damping solutions by means of polymers. The emphasis of the tutorial is to apply passive damping with visco-elastic materials in a predictable manner, to significantly improve dynamic system performance.

Dr Ir. Ing. Theo Ruijl (born 1967)

Theo Ruijl studied Mechanical Engineering in Eindhoven (The Netherlands) receiving his MSc in Tribology in 1994. Within the Mechatronics Department at Philips Research he made his Ph.D. on the design of an Ultra Precision CMM.

For more than 20 years he is active in de development of high-end mechatronic systems for all kind of precision application e.g. in the semi-conductor, scientific and medical industry.

Theo is a member of the Euspen Council, where he co-initiated in 2006 the Special Interest Group of Thermal Effects in Mechatronics Systems, and a member of the ASPE College of Fellows.

After working at FEI Electron Optics, the joined in 2010 Mi-Partners, a Dutch engineering company in Eindhoven, focusing on mechatronic development, where he holds the role of CTO. Since the beginning of joining Mi-Partners, he initiated the competence of passive damping with polymers. Several projects has be done successfully since then, showing that this technology can be used in high-end mechatronic applications in a systematic and predictable approach..

Theo teaches over 20 years several classes in the field of Mechatronics Systems Design: tutorials and technical courses at universities related to Dynamics & Control, Thermal, Metrology, and Damping with Polymers.

Ir. Ing. Pieter Wullms (born 1985)

Pieter Wullms studied Mechanical Engineering in Eindhoven (The Netherlands) receiving his MSc in Mechanical Engineering in 2011.

After finishing his Master thesis at MI-Partners, he joined the company in 2011, where he holds the position of mechatronic system designer. Since a 2016 Pieter also leads the Passive Damping Competence at MI- Partners.

He has been involved in various training activities related to damping with polymers.

Tutorial 6: Uncertainty Evaluation for Precision Engineers

DTU, Copenhagen, DK
 7th June 2021
Time: Half Day (AM)

The tutor is Prof. Richard Leach, University of Nottingham

The course will arm precision engineers with a basic understanding of the key elements of uncertainty evaluation for measurement applications. It will require a basic knowledge of mathematics (up to the level of differentiation) and will cover the following elements:

Basics of metrology

  • Why measurement is essential
  • A short history of measurement
  • Measurement traceability – fundamental principal, global and legal infrastructure
  • Terminology
  • Error types and calibration
  • The SI infrastructure

The GUM uncertainty framework I

  • Systematic and random errors
  • Single value uncertainty evaluation
    • Mean, standard deviation and standard deviation of the mean
    • Uncertainty distributions and confidence intervals
    • The standard uncertainty concept
  • Propagation of uncertainties
    • Direct calculation
    • Calculation using derivatives
    • Calculation using a Monte-Carlo method

The GUM uncertainty framework II

  • Measurements with multiple variables
  • Propagation of standard uncertainties
  • Uncertainty budgets
  • Confidence intervals
  • Propagation of probability distributions

Richard Leach is currently a Professor in Metrology at the University of Nottingham and prior to this spent 25 years at the National Physical Laboratory. He has been researching and lecturing on surface metrology for over 30 years. He is on the Council of the European Society of Precision Engineering and Nanotechnology, the Board of the American Society of Precision Engineering and several international standards committees. He is the European Editor-in-Chief for Precision Engineering and has over 500 publications including eight textbooks. He is a Fellow of the Institute of Physics, the Institution of Engineering & Technology, Higher Education Authority, the Institute of Measurement & Control, the International Society of Nanomanufacturing and the International Academy of Production Engineering (CIRP). He is a visiting professor at Loughborough University and the Harbin Institute of Technology.

Tutorial 7: X-ray Computed Tomography Metrology

DTU, Copenhagen, DK
 7th June 2021
Time: Half Day (AM)

The tutor is Dr Adam Thompson, University of Nottingham

In this course, we discuss the basics of measurement using X-ray computed tomography (XCT). We will cover the history of and principles behind XCT metrology, including discussion of reconstruction methods and artefacts for calibration. We will examine specific case studies of relevance to dimensional measurement using XCT and review the state of the art in XCT measurement. We will also address some of the issues faced when making XCT measurements and the limitations of the technology, and, finally, cover the specific use of XCT for surface measurement.

Learning outcomes: To gain a basic understand of measurement using X-ray computed tomography, containing an overview of the theory behind how measurement data is acquired and the factors that affect measurements.

Intended audience: Graduates, postgraduate engineers/physicists, post-doctoral researchers, plus industry technical staff working in measurement using X-ray computed tomography. Aimed at novice to intermediate users.

Dr Adam Thompson has been a post-doctoral researcher in UoN’s Manufacturing Metrology Team (MMT) since October 2018. Prior to this position, Adam completed his PhD in at the University of Nottingham, entitled “Surface texture measurement of metal additively manufactured parts by X-ray computed tomography”, for which he was awarded the Gertrude Cropper Scholarship. Adam has published 12 papers and a book chapter, and presented his work at 22 conferences. Adam’s research background is in surface topography measurement of additively manufactured parts, authoring papers on the measurement of metal and polymer parts. Adam also has expertise across metrology, having undertaken postdoctoral projects in performance verification of fringe projection and X-ray computed tomography measurement. Adam also has a deep understanding of co-ordinate and in-process measurement principles, having taught numerous undergraduate and postgraduate courses in basic advanced metrology and performed research activities in the area. Prior to his PhD, Adam taught Physics at secondary school level.

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