Date of Award

2020

Degree Type

Capstone Project

First Advisor

Dr. Hamouda Ghonem

Abstract

For the project “Hexagon Surface Finish Probe” the team assigned, team 4, was required to design a bracket, mounted on a 5mm diameter rod, to be converted from an optical z-sensor into a stylus profilometer. Hexagon approached the team to convert their existing surface roughness measurement machines which only used lasers, into an apparatus that combined both the accuracy of the lasers, and a stylus probe which would contact the surface. The newly designed system would correct for the shortcomings of the laser and allow for a more complete measurement of the surface. The team began the project by conducting literature searches to find what information was needed to create a sufficient design. This includes researching topics such as beam bending, flexures, and noise reduction. The patent search was mainly focused on the assurance that the project would not infringe on another idea, and to find previous work done in this area to stimulate creative thinking. The group then came up with 120 preliminary designs, and conducted a design review to select the best design. After receiving feedback from sponsor at Hexagon, a final design was decided upon.

The design the group ultimately used for testing consisted of a 3-D printed bracket, a hole for a nut and bolt in the bracket that allowed for tightening around the rod, stainless steel flexures glued onto the bracket, a connector rod between the flexures, and a stylus glued to the bottom of the bottom flexure. Additional weight was added to correct for required downward force of the system at rest.

After the design was finished, the team created a computer aided design of the proposed apparatus. Once the 3-D drawing was generated, simulations were able to be run. From the simulations, the group was able to finalize all of the dimensions and begin ordering parts for the prototype. Moreover, a 3-D printed prototype was made to conceptualize the size of the system.

Comments

Sponsor: Gurpreet Singh - Hexagon Metrology

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