Diamant Tool Measurement

High precision manufacturing requires high precision production equipment and high precision tools.
Diamont Tool To create a highly accurate surface, diamond tools are the best cutting tools for this task.
There are a lot of different types diamond cutting tools but the most common is the cutting tool with a predefined radius.
Not only the tolerances on the cutting radius are important but even more important is the Waviness of the tool.
By definition, waviness is defined by the amount of deviation from a true circle. For true accuracy, the peak to the valley is probably more important.

New version Diamond Tool Measurement DTM112

June 2016: J.A.I.M.S. introduced an upgraded version: Diamond Tool Measurement DTM112 and supersede DTM110 introduced at October 2015. This new upgraded version is used at international companies producing high accurate and very low waviness tools, and contains a lot of new possibilities.

The new version DTM112 measures the radius and waviness of a diamond tip with a higher resolution and therefore more accurate. This DTM112 includes a more extensively manual measurement area selection. Half radius tools or small arc tools, radius and waviness can be measured accurately.
After radius measurement is performed relevant data selection and noise filter adjustment gives the best and most reliable result. Tool_radius segment

The DTM112 measures the waviness and width of a facet tip, including the facet angle and included angle.
Multi facet angles up to 3 facets are measurable by manual selection including the waviness of the tip.
Results are presented on a pdf measure report or certificate and saved on a netwerk server or local disk. Customers sebsequently can download the certificate of their tool.
Tools can be measured by a bottom illumination as well as a top illumination. (Bright field or back light respectivily Dark field or front light).

Multifacet Result Multi facet report

Camera settings as gain, exposure time and frame rate can be changed to optimize for best light intensities.
Measurement settings can be changed to optimize the edge detection of the tool tip and eliminate measurement noise.
Changing the measurement, camera and directory settings is only possible by authorized personnal.
The authorization is protected by a password up to 8 levels and up to 10 program levels can separately autorized.
Calibration software calibrates the system using a chessboard or a line pattern and can be performed by own qualified personnel.

No calibration or service contract necessary!
Microscope objectives can freely added, removed or changed by authorized personnal. New optics and microscopes are configurable by qualified personnel.

Special shaped tool results in image Medical thread cutter results in image The DTM112 is also used as a platform for measuring special shaped tools.
Measuring shape, diameter, pitch, radii and waviness of thread cutters for medical purposes are performed and extensively showed in the downloadable DTM112 folder.

For more detailed information about DTM112 download the pdf:
Diamond Tool Measurement DTM112.pdf

Measure Sequence

Measuring the cutting tool radius and waviness has to be performed in the following, by software guided, steps:
Diamont Tool

Rough positioning the tool and select the magnification, microscope objective.
A live image is generated so the diamont tool can be postioned roughly at the centre position in the image. Also rough focussing can be performed manually by the operator.
The operator can also select between a convex shaped tool or a concave shaped tool.
If necesarry the operator can select an other microscope objective so the diamont tool tip fits in the image.
Next the operator has to select the appropriate magnification which matches the microscope objective magnification.
Focussing the tool tip

Focusing the microscope, accurate positioning the cutting tool and adjusting the back light
The software measures the current sharpness of the tool edge in the image.
Meanwhile the software saves the sharpness maximum so the operator can adjust to the most sharp setting of the microscope.
Simultaneously the software measures the backlight intensity and the position of the diamont tool tip in the image.
The intensity has to be adjusted to a predefined value.
Because most microscopes are equiped with a halogene lamp, which is not temperature stable, this adjustent is necesarry for the best result.
The cutting tool tip has also be adjusted to a predefined position in the image to perform as less distortion as possible. These measurement are performed in almost real time. Select Arc

Positioning the cutting tool. to the centre of the image so less distortion is achieved. The operator has an almost real time image and tools to position the cutting tool accurately.

Select the measurement area or Arc. The operator selects the measurement area or arc, the software measures and calculates instantaneously the top angle. After the measurement is performd a post processtep is available, and a more accurate selection on pixel level is possible.

Measurement of the radius and waviness. The software detects the edge of the diamont tool tip and calculates the radius and the waviness in the defined area or arc.

Accurate selection measure area or Arc. In this post processtep the operator selects more accurate the valid measure data or arc if required. The new measure data is instanteneously calculated and shown to the operator. Tool info data INput

Preparing Measuring Report.
The following input is requested and given in by the operator:
Artical Type Number, Customer name, Order Number, Tool number, Top Angle, Clearance Angle.
If necessary the operator can give some remarks.
The Date, Arc, Radius and Total Waviness are generated automatically.
The operator selects if the raw measure data has to be saved.

Report Generation. The report will be generated by the software. The report output is a .pdf file and will be saved at a predefined directory on the hard disk and/or on the disk of a local network server.
The directories is selectable.
_JAIMS Waviness Measure Report_02 _JAIMS Waviness Measure Report_03 _JAIMS Waviness Measure Report_04 Three Waviness Measuring Reports are shown, left measure range: -2.50 to 2.50 micrometer, centre and right measure range: -0.25 to 0.25 micrometer.
The Waviness Measuring Report on the right shows a deviation of 0,05 micron or better. Measuring a low waviness tool is no problem for this measurement equipment.

Though this Low Waviness Diamant Measurement equipment is developed for diamond cutting tools with a low waviness radius, other shaped tools can be measured. When the edge points of the cutting tool contour are found, every mathematical shape or polynomial, e.g. parabolic, ellipsoidal, high order polynomial shape can be calculated.

So this measurement equipment and software is not only limited to diamond cutting tools but can also used for all kind of accurate shaped products, e.g. needle tip quality and hyperbolic curve for medical purposes, accurate knife cutting edges e.g. scalpel, balls for high precision ball-bearings.

Diamont Tool Measurement History

In 1996 the first waviness measurement system based on a microscope and a vision system is developed for Technodiamant and Philips Research. This first measurement system was based on an analog camera and a Single Board Image Processor (SBIP,Philips Industrial Vision).
For the customer, available microscope for cutting tools inspection is used. The software was developed with LabVIEW from National Instruments and the vision library of Philips Industrial Vision Promise. This library contains a very accurate and stable edge detection algorithm, called the ruler.
This ruler is also very accurate for measuring the radius of circle shaped forms like the diamond cutting tool.
Calibration pattern

To get the best result out of the measurement a few problems on instabilities and inaccuracies are solved.
At that time it was difficult to create square pixel so first square pixels has to be created by changing the pixel sample clock.
This was all done using a chessboard calibration pattern.
Eight years later an upgrade to digital camera is performed. These cameras are equipt with a square pixel sensor. So no complex calibration was necesarry.

2013: Diamont Tool Measurement Upgrade

In 2013 a major upgrade of the measurement equipment and software is performed.
Following improvements are performed:

  • A 2Mpixel (1600x1200 pixels) camera is used. The pixelsize is comparable with the previous camera so no new microscope objectives are required.
    Remark: A higher resolution camera e.g. 5Mpixel is equiped with a smaller pixelsized sensor, so high quality microscope objectives are required.
    High quality microscope objectives are expensive and therefore not acceptable.
  • Calibration software is made more user friendly.
  • Radius and waviness measurement software is made more user friendly.
  • Adjustment of the measurement angle is improved and made more user friendly.
  • A very accurate adjustment of the valid measurement angle and data is added, the radius and the wavines is calculated instantly.
  • The measured edges data (measured points) on pixel level can be saved in a data file for further analyses.
    This data file includes:
       Customer name, Customer order, Order Number, Tool number, Date and Time of measurement and Calculated radius. So all the necesarry information and raw data are available.
  • The Waviness Measuring Report is improved and foreseen with all necesarry data for the customer.
    This measuring report includes also:
       Customer name, Customer order, Order Number, Tool number, Date and Time of measurement, Radius, Total Waviness, Arc and Top Angle.
    Major change is made on visualising the contour and waviness of the tool.
      The deviation of the tooltip is generated in a polar diagram and in a linear diagram. So the customer get detailed information of the contour.
      The scaling is automatically selected, scale is 0.25; 0.5 and 2.5 micrometer.
      Date of measuring is automatically generated
  • The Waviness Measuring Report is automatically generated in .pdf format and saved on the hard disk or on a local network drive.
    When the network drive is not available a backup of the report is saved on the local harddisk. So no data is lost.
    This .pdf report file is saved in a pre-defined format:
        Customer; Order Number; Tool Number; 'Measure Report'; Date and Time of measurement. 'Measure Report' is a fixed name.
    Of course it is possible to make a print out of these reports but customers can also login on the suppliers network and ask for the .pdf report. So no loss of a on paper printed report.
  • 2015: Diamont Tool Measurement Upgrade to DTM110

    In 2015 an upgrade of the Diamond Tool Measurement equipment and software is performed which results in the Diamond Tool Measurement: DTM110.
    A few improvements for DTM110:

  • After the radius measurement is performed, measure data selection and adjusting the noise filter by the operator results in a better and more reliable result.
  • Single Facet tools are very accurate measurable. The waviness of the tip and the included angle is calculated and presented in a measure report or certificate.
  • Adjustable scaling settings for measure report or certificate.

    2016: Diamont Tool Measurement Upgrade to DTM112

    For more informations see on top of this site or download
    Diamond Tool Measurement DTM112.pdf