Machining accuracy is vital
"Key to minimising the risk of defects is ensuring optimal machining machine tool accuracy. Previously we assessed this based in tool displacement using an eye glass with a scale. However, this method has limitations, even for the highly experienced tool setters within our team" says Anthony Woodhouse.
Because of these challenges, the management team at Vision Labs sought another solution, and it came in the form of a KEYENCE VHX-7000 digital microscope.
The system's high magnification and 4,000 pixel count – the world's first microscope to offer this – combined with two-dimensional edge detection software which snaps to the lines of contrast meaning the risk of differences between users is eliminated, allows calibration tolerances as low as 0.1 microns.
Meanwhile, the glare removal feature and rapid 3D depth composition, combined with the VHX's easy-to-use of software, meant that wear on diamond cutting tools can be rapidly assessed to ensure they are replaced only when needed, creating cost savings for Vision Labs.
Perhaps the greatest benefit has come in the area of analysing coatings, where the VHX's world first optical shadow effect mode (OPT-SEM) allows these transparent features to be viewed more readily and so defects identified more rapidly. The multi-lighting feature, allowing immediate change between ring, coaxial, polarised and transmitted lighting, also assists the clarity of view.
Anthony Woodhouse continues: "The KEYENCE microscope is easy to use and gives us incredibly accurate and detailed information. removes the issues associated with the previous visual testing, as it enables us to calibrate our machines extremely accurately and counter any issues in our processes. It has enabled us to view defects in a way that was not possible before, equipping us with a better understanding of how they occur – and how we can minimise the risk of defects."
"We had used other KEYENCE equipment with great success for a number of years and so we were already aware not just of the quality of their products, but the depth of support and training that would be provided. The feedback from colleagues has been fantastic. Overall, we have great confidence in both the equipment and the KEYENCE team."
"This latest investment in KEYENCE equipment has resulted in higher-quality products, fewer interruptions to production and enhanced cutting tool lifetimes – meaning a significant impact on our productivity, service and the bottom line."