Full-scale plug-plate drilling tests II
Sloan Digital Sky Survey Telescope Technical Note
19950130_01
Walter
Siegmund and Russell
Owen
Contents
Introduction
The plug-plates of SDSS project are responsible for locating the
optical-fiber plugs spatially and for defining the plug tilts normal
to the fiber axis. The plates are 787 mm (31") in diameter and 3.2 mm
(0.125") thick. Approximately 700 holes will be drilled in each
plate. For drilling, the plate is held by a drilling fixture that
deforms it elastically so that its upper surface is convex. The
center of the drilling region is about 10 mm higher than the edge.
The hole axes are drilled vertical. In the telescope, the plate is
deformed to match the surface of best focus. When this is done, the
hole axes are aligned with the principal rays from the optics.
Drilling comments
Two plates were drilled at Karsten Engineering Corporation,
Phoenix, AZ on December 14-15, 1994. A horizontal milling machine, a
Mitsui Seiki HR-6A (#18), was used. The machine has a travel of 1600
mm (63") in x and 1000 mm (39.4") in y. This was more than adequate
to reach the entire drilling region.
The machine was calibrated in x and y prior to drilling the plates
on December 5-6, 1994. The calibration was performed using a laser
interferometer to measure the nonlinearity and scale of the x and y
axes. In x, one standard deviation was 1.5 µm. In y, one
standard deviation was 3.0 µm, although it was similar to the x
axis away from one extreme of its travel.
Fig. 1. Histogram of the x
location error for ke100. The histograms for the y error and for
ke102 are similar. The errors are dominated by systematic effects,
especially a difference in scale in x and y.
Karsten Engineering plate 100 (ke100) took 84 minutes and Karsten
Engineering plate 100 (ke102), 86 minutes. (There was no ke101.) This
did not include the time required to set up the plate for drilling.
It did include the time to measure the room and coolant temperatures
(5 measurements) and to check hole size (four checks) using a plug
gauge. Also included was the measurement of the runout of the spade
bit after the last hole was drilled (5 minutes).
The hole drilling order for ke102 was not well optimized whereas
the order for ke100 was optimized using the simulated annealing
travelling salesman algorithm (from Numerical Recipes,
William H Press, Saul A. Teukolsky, William T. Vetterling and Brian
P. Flannery, Cambridge, New York, 1994). This may account for the 2%
difference in drilling time. However, possible variations in the time
spent making manual measurements make it difficult to conclude
anything other than that the drilling order does not have a large
effect on drilling time. This is not surprising since the machine
moves quickly between holes.
The drilling time is almost twice that estimated in SDSS Technical
Note 19941206, i.e., 44 minutes. The more extensive monitoring and
record keeping contributed to the increase. Ke100 took 33 minutes to
set up and 12 minutes to unload. Ke102 took 22 minutes to set up and
8 minutes to unload. The load/unload operations were considerably
more difficult on the horizontal milling machine at Karsten than on
the vertical milling machine at the University of Washington. Three
people were necessary. However, the drilling fixture could be
modified for perhaps $5000 to make this an efficient one-person
operation.
The corrected C program described in SDSS Technical Note 19941206
was used to generate the CNC program from the table of hole locations
and depths. No problems with the CNC program were reported. Minor
modifications were made by Karsten Engineering to make it consistent
with local conventions.
Fig. 2. Histogram of the hole
diameter for ke100.
Fig. 3. Histogram of the hole
diameter for ke102. The standard deviation of the distribution is
similar to that for ke100.
The plates were drilled at 3500 rpm. A different 9.5 mm long spade
drill bit was used to drill each plate. The diameter of each bit was
specified to be 0.0867+0/-0.000,50" (2.202 +0/-0.001 mm). The bits
were made of carbide steel by Johnson Carbide Produces, Inc.,
Saginaw, Mich. A custom drill bit holder (described in SDSS Technical
Note 19940412-01) was made by Karsten Engineering to minimize bit
runout.
The temperature of the coolant was measured at 15 minute intervals
during the drilling. For ke100, the temperature was 21.6 +/- 0.15 deg
C. For ke102, the temperature was 21.2 +/- 0.05 deg C. A new bit was
used for each plate. After drilling, the bit was inspected. In both
cases, minor chip build-up was reported.
Plate measurements
Before shipping the plates to Fermi National Accelerator
Laboratory (FNAL), the plates were cleaned by Karsten Engineering
using a sequence of pressure washing, rinsing in isopropynol, and
vapor degreasing.
The plug-plates were measured on January 11, 1995 at FNAL. A
Giddings & Lewis-Sheffield Measurement, Inc., Apollo RS-50
coordinate measuring machine (CMM) with an accuracy specified at
+/-2.5 mm (0.0001") was used for the measurements. The CMM was
checked by Giddings & Lewis technicians on January 25 and 26 and
found to be within calibration.
The plates were measured flat on the CMM. The two 4.76 mm
(0.1875") locating pin holes that are at a radius of 349.3 mm
(13.750") and define the x-axis were used to center and orient the
plate. Twenty-one points were measured on the top of the plate and
the average of these became z = 0.
The CMM extracts hole location, diameter and non-circularity from
measurements at eight points equally spaced in angle at the same
value of z. Non-circularity is defined as the difference in radius
between the points closest to and farthest from the center of the
hole. Consequently, non-circularity is quite sensitive to
contamination of the hole. These parameters were recorded at three
different heights; -2.5375, -1.5875 and -0.3810 mm (-0.1000",
-0.0622" and -0.0148").
The hole locations at the three heights were averaged to obtain a
mean hole location, x and y. The desired hole locations (the drilling
machine coordinates) were subtracted from these values to get hole
location errors. The functions f(x) = dx + b1*y + (a1 + a3*r^2 +
a5*r^4)*x and g(x) = dy - b1*x + (a1 + a3*r^2 + a5*r^4)*y were fit to
the x and y errors respectively. The coefficient a1 includes the
effect of thermal expansion between drilling and measurement and the
lowest order effect of bending the plate for drilling. The
coefficients a3 and a5 account for higher order effects due to the
drilling fixture. The coefficients dx and dy are the offset of the
plate center between drilling and measurement. The coefficient b1 is
the rotation of the plate between drilling and measurement.
During operation, guide stars on 5 arc-second diameter coherent
fiber-optic bundles will be used to determine the actual value of a1,
dx and b1 and the telescope scale, pointing and rotator angle will be
adjusted accordingly. The telescope scale is adjusted by moving the
primary axially and refocusing. Consequently, errors in these
coefficients may affect the initial acquisition of the guide stars,
but will not affect the ability of the telescope to center the
targets in the spectrograph fibers.
The holes for the coherent fiber-optic guide bundles are the same
diameter as the holes for the spectrograph fibers and will be drilled
intermingled with the spectrograph fiber holes. Consequently, we
expect that the coherent fiber-optic guide bundles will share the
same mean location and orientation statistics as the spectrograph
fibers.
The fit coefficients are given in Table 1. The
a3 and a5 coefficients cannot be determined separately for each plate
during operations without measuring each plate. Since this is not
envisioned, these coefficient were set using finite element model
results. As for the UW plates, the plate center and rotation offsets
would correspond to 1 to 2 arc seconds (the scale is 60 µm/arc
second).
Table 1: Hole location fit
coefficients for each plate
Plate a1 a3 a5 b1 dx dy
(mm/mm) (mm/mm^3) (mm/mm^5) (mrad) (mm) (mm)
100 -0.224 9.26E-06 -4.65E-11 -0.026 51.1 32.0
102 -0.194 9.26E-06 -4.65E-11 -0.042 13.1 39.5
Table 2 summarizes the results of the hole
measurements. The histogram of Figure 1 showing
the distribution of residual hole location error in x for ke100 is
typical of the results in both axes and plates. The distribution is
dominated by systematic errors, i.e., primarily a difference in scale
in the x and y axes. Histograms of the hole diameters are shown in
Figure 2 and Figure 3. The
standard deviation of hole diameter for ke102 is similar to that for
ke100. Figure 4 shows that small hole diameters
are correlated with large noncircularity. A similar but larger effect
was reported in SDSS Technical Note 19941206 and was attributed to
contamination in the holes. Robert Riley, who performed the
measurements, reports as follows regarding ke100 and ke102. "The
coating on the plates appears to be ground into the sides of the
holes. The particles adhere well to the holes. We use adhesive tape
to clean many of our parts before we measure them. Using tape on
these holes pulls out a lot of particles, but will not get all of
them. These particles probably account for the circularity deviations
you're seeing." 
Fig. 4. Non-circularity is
plotted vs. diameter for the mid-level data for ke100. A uniform
random number with an amplitude of half the data quantization level
(2.5 µm) has been added to each value so that individual points
are distinct. These data are typical of those for other levels and
for ke102.
The radial components of the hole location at the top and bottom
of the each hole in combination with the separation of the two
measurements were used to calculate the tilt of each hole. The hole
tilt as a function of radius is compared to the ideal tilt from the
optical design (kent005) and to the finite element model of the
plug-plate in its drilling fixture (drl42) is shown in Figure
5 and Figure 6.
Table 2: Results for each
Plate
Plate Pos Error Diameter Error Non-Circ Tilt
RMS mean std dev RMS RMS std dev RMS
(mm) (mm) (mm) (mm) (mm) (mrad) (mrad)
100 24.1 -7.0 7.8 10.5 17.0 2.5 3.3
102 24.0 -4.9 8.7 10.0 13.3 2.2 2.6
Fig. 5. Hole tilt is plotted as
a function of radius for ke100 (open circles). The filled squares are
the optimal tilts from the optical design. The filled diamonds are
the tilts calculated from the finite element model.
Fig. 6. Hole tilt is plotted as
a function of radius for ke102 (open circles). The other symbols have
the same meaning as in Figure 5. One outlier was removed at x =
-153.40 mm and y = 124.01 mm. The measurements at z = -0.381 mm
indicated a non-circularity of 137 µm, the largest value on the
plate, and suggesting that contamination may have been present.
The temperature of each plate was monitored during measurement by
taping a thermocouple probe to the plate. No thermally conductive
grease was used. Each plate took 3 hours to measure and the
temperature was recorded every half hour. During measurement of
ke100, the temperature was in the range of 18.7 to 20.1°C. For
ke102, the temperature was in the range of 18.7 to 19.4°C. In
Figure 7, the residual error in radius is plotted
against the hole drilling/measurement order. Also, the quantity
-(T-22°C)*24.3 µm/m °C*0.327 m was plotted for the
drilling temperature data and the quantity (T-19°C)*24.3
µm/m °C*0.327 m was plotted for the measurement temperature
data. These curves give the predicted effect of temperature changes
on radial position error at the edge of the drilling region due to
the thermal expansion of the aluminum. The center of the plate is
assumed not to move. A correlation is apparent between the sum of the
measuring and drilling expansion curves and the residual errors in
radius. The variation of temperature during measurement was much
larger than the variation during drilling.
Fig. 7. The residual hole
location error in radius is plotted against drilling/measurement
order. Also plotted is the predicted effect of measured temperature
variations during drilling and measurements at the edge of the
drilling region assuming the center of the plate was fixed. The
coefficient of thermal expansion used was 24.3 µm/m °C
(aluminum 6061 T6).
The large residual errors in the measured locations of the holes
drilled by Karsten Engineering are due to large-scale effects, not
random errors. The most important is a difference in the scale in the
x and y axes. To explore this in more detail, we fit an eight
parameter model to the data. For comparison purposes, we fit the same
model to the data for University of Washington (UW) plate 100 (uw100)
and UW plate 102 (uw102). The functions f(x) = dx + rx*y + (sx +
a3*r^2 + a5*r^4)*x and g(x) = dy - ry*x + (sy + a3*r^2 + a5*r^4)*y
were fit to the x and y errors respectively. The parameters dx and dy
are the mean offsets of the holes in x and y. The mean of rx and ry
is the mean rotation of the holes about the plate center (positive
counterclockwise). The difference of rx and ry is the
non-perpendicularity of the x and y axes. The parameters sx and sy
are the scale factors errors in x and y. Finally, a3 and a5 are the
high order distortion coefficients due to the bending of the plate
for drilling. The residual 2-d errors indicate that the random error
of the measurements is very comparable for the UW and Karsten plates
(Table 3). The Table indicates that the main
systematic error in the Karsten measurements is that sx and sy are
different by 160 and 210 µm/m for ke100 and 102 respectively.
The non-perpendicularity indicated by the rx and ry coefficients is
comparable for the UW and Karsten measurements. This
non-perpendicularity in the UW data was noted but not removed in SDSS
Technical Note 19941206. The uncertainties in a3 and a5 are such that
the differences in these coefficients between plates are not very
significant.
Table 3: Results of an eight
parameter fit to each plate.
Plate dx dy rx ry sx sy a3 a5 error
µm µm µrad µrad µm/m µm/m µm/m^3 µm/m^5 µm RMS
uw100 19.9 16.6 54 0 -253 -257 8557 -46900 6.1
uw102 20.1 36.8 170 115 -225 -232 8859 -50800 5.7
ke100 51.2 30.1 -57 10 -142 18 6205 -36200 7.2
ke102 12.9 40.6 -60 -35 -164 46 6463 -36100 5.1
It will be necessary to control the light scattering off the
sky-facing side of the plug-plates to avoid contamination of target
spectra by unwanted light. Consequently, the sky-facing side of ke100
and ke102 was blackened using Aluminum Black (Small Parts, Inc.,
(305)557-8222, part number Q-YCL-AB). This material proved
unsatisfactory because it was not robust and proved to be a source of
contamination. Inspection of the holes under a microscope indicated
that most were contaminated by approximately 20 micron black
particles. Also, personnel at Karsten Engineering reported that it
was difficult to apply. We plan to investigate other possible
solutions to this problem.
Conclusions
The error budget that we proposed in SDSS Technical Note 19930430
allows 9 mm root-mean-square (RMS) for hole location and 8 mm RMS for
plug/hole concentricity. The position error measured for the Karsten
plates is not consistent with our error budget. It is not clear
whether the scale error difference reported above occurred during
measurement or drilling.
One possibility is that the scale difference is due to an
anisotropic strain that was imposed on the plate during drilling or
measurement. The scale difference is 160 µm/m and 210 µm/m
for ke100 and ke102 respectively. The elastic modulus of the aluminum
alloy is 73.1 GPa and its thickness is 3.2 mm, so a stress of 13.5
MPa and a force of 43 kN/m (247 lb/in) would be required. The
clamping force needed to deform the plate in the drilling fixture is
only 3 kN/m (17 lb/in). It seems unlikely that friction between the
plate and the bending fixture during the clamping operation could
cause a stress of the required magnitude. Turning the argument around
and assuming a friction coefficient of 0.5 between the plate and the
bending fixture, the maximum expected strain would be 6 µm/m,
much too small to be a concern.
In the absence of deformation of the plate during drilling or
measurement, it would appear that either measurement or drilling
machine error is the source of the scale difference. However, this is
surprising given the care with which both machines are calibrated and
maintained. We plan further tests to determine the source of the
scale difference.
The RMS diameter error continues to be a concern, but would be
alleviated if bit to bit variations were better controlled. For
example, the mean diameter for ke100 was -7 µm (as compared with
the nominal drill diameter). The most positive mean diameter observed
so far was +8.9 mm (SDSS Technical Note 19940412-01). With such a
large range, it will be very difficult to achieve a good fit of plugs
in the holes. The standard deviations of the hole diameters for both
plates were significantly larger than those reported for uw100 and
uw102 (5.7 µm and 3.7 µm, see SDSS Technical Note
19941206).
The tilt results are more than adequate, although not quite as
good as those measured for the UW plates.
Acknowledgments
We are grateful to our colleagues at FNAL, Paul Mantsch, Robert
Riley and Charles Mathews for their help with the measurement of the
plates and their interest in and assistance with various aspects of
plug-plate drilling. We thank Meredith Gower and John Russell of the
Karsten Engineering for their interest and expertise.