Evaluation of the IWF-Wunder Reproduction Method for Generating Positive Replica
Marcel Henerichs, Michael Egeter, Thomas Liebrich,
Robert Voß, and Konrad Wegener
Institute of Machine Tools and Manufacturing (IWF), Swiss Federal Institute of Technology Zurich (ETH), Tannenstrasse 3, 8092 Zürich, Switzerland
Research into manufacturing technology requires regular measurement and documentation of workpiece and tool quality. The instant or direct measurement of tool or workpiece surfaces is often difficult or impossible. Remounting of workpieces or tools leads to undesired remounting errors, a direct integration of adapted measurement systems is not suitable for research and development. Additionally, abrasive or transparent surfaces can be unsuitable for use with some measurement systems. This study evaluates an imprinting method for the production of positive replicas of tool or workpiece surfaces. The resulting errors between original sample and replica are evaluated. The analyses include common test methods, such as tactile surface profiling, focus variation microscopy, and white light interferometry. The study shows that for the evaluated reproduction method, the difference between original and replica is less than 10%of the surface roughness, Ra, for original surface roughnesses greater than Ra = 0.1µm. Mostly better results are achieved (difference < 2%). In addition, contour dimensions greater 1 mm can be copied with deviations less than 0.5%.
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