Calypso advanced techniques

Filters, Outliers and the Scanning CMM

Introduction

This document will describe the use of Filters,

Outliers and Evaluation Methods for the Scan-
ning CMM. Although Calypso has been used for
all instructions, plots and output, the techniques
described here apply to UMESS as well. Also, it
must be understood, the following techniques
apply to the Scanning CMM. Actually not only is
it “advisable” to use scanned features but
actually impossible to apply filters to features
with low data density.

In addition to data density, other areas of

discussion will be:

• Application of Filters and outliers

within the Calypso measurement
plan.
• Why and when to apply filters
and outliers.
• What’s the Standard?
• Error messages.
• Evaluation Methods.
• Centers for Out-of-Roundness.
• Instrument Response. Cutoff,
UPR and Lambda c.
• Filter types, Gauss and 2-RC.
• Low and High pass filters.
• Connect Segments.
• Elimination of Outliers.
• Range of Data Reduction.

The information in this document is from a

variety of resources including the Calypso
manual and on-line help.
Defining Filters and Outlier Elimination
There are several different points in Calypso at which
you can parameterize and activate filtration and outlier
elimination:
– For an individual characteristic
– For an individual feature
– As defaults for the characteristic groups and the
references and alignment elements of the coordinate
systems. The setting for the characteristic always takes
priority. Iffiltration/outlier elimination is not activated for
the characteristic, the setting for the feature applies. If
filtration/outlier elimination is not activated for the feature,
Calypso refers to the default settings for the characteris-
tic groups.

A feature obtained by recall from a feature filtered

beforehand is automatically not filtered subsequently,
even if filtration is activated.

Default Settings

To set the Default Filter and Outlier settings, select Re-

sources > Filter/Outlier Elimination.

Settings at this level are not applied to existing characteris-

tics, only those subsequently created. Features containing
filter and/or outliers settings will override these defaults.
Feature Settings

The next level at which Filters and Outliers can be

set is within the Feature. Open the feature window
and select Evaluation.

These settings will be automatically applied for

each characteristic in which the feature is used.
This overrides the default settings.

Characteristic Settings

From within the characteristic select the

feature button.

From this widow you can override settings

from either the feature or default. Also it is
possible to unselect settings applied by the
feature or default.
Why Use Filters

From the Calypso on-line help:

Filters can segregate the waviness profile of a
geometric feature from the effects of surface
roughness. Filters, therefore, are of assistance in
maximizing measuring accuracy. The filter methods
supported are Gaussian (ISO 11562) and 2 RC
(ISO 4291), while the filter types are lowpass and
highpass. The new statistical data of the
geometric feature are obtained from the
filtered measuring data after compensa-
tion.

What’s the Standard?

Often filters are specified on the print or

inspection plan. In some cases, roundness
for instance, a filter might be implied by the
standard:

From ANSI B89.3.1 – 1972 Measurement of

Out-Of-Roundness:

section 3.2
...If complete measurement conditions
have not been specified the:

Method of Assessment—Minimal Radial

Separation

Instrument Response—50 Cycles per

Revolution

.02
In other words:
Implies:

.02 MZC 50
That is: this surface shall be round within .02mm as
assessed by the MZC method with 50 cycles per revolu-
tion response.

If the print is specific regarding the filter it might be shown

as thus:

.02 LSC 150

That is: this surface shall be round within .02mm as
assessed by the LSC (Gauss) method with 150 cycles
per revolution response. Standards are available on the internet at: global.ihs.com
Using Filters in Calypso:

.02 MZC 50
The above feature control frame requires the evaluation of
Roundness (also called Circularity or Out-Of-Roundness)

Data Density:

It is important to understand that the use Filters and Outliers

are really best applied to scanned features.

From the Calypso on-line help:

It is advisable to restrict the use of filters to instances in
which the number of points is high, in other words they
should be used only for scanned features. All features
measured using scanning methods can be filtered.

Calypso also requires a minimum of 5 (soon to be changed to

7) points per Lambda c (cutoff) or Undulations Per Revolution
(UPR) frequency.

Use of insufficient data density will result in the filter not being
applied and a message printed in the default printout.

If for instance you choose to evaluate roundness with 100

data points and a UPR of 50, no filter will be applied, and a
message will be reported in the default printout:

Incorrect filter value (Lambda_c or UPR)

Increasing the data to a range of 101 to 250 points and once

again no filter will be applied. The default printout message:

Filtering with less than 5 points per undulation.

Increasing the number of points to 251 or greater and a filter

will be applied. A message reporting the filter type and cutoff
will be reported in the default printout:

Low-pass (Form):Gauss Undulations Per Revolution:50

Other Messages

• The Compact Protocol shows when a filter has been

applied, but no error messages.

• If a filter is selected but not applied, the plot window

shows “none”, otherwise it reports the filter being
used.

• The Custom Printout never shows filter messages.

Setting Filters in Calypso

.02 MZC 50
Select the Roundness Characteristic and
scan the required feature. Check the box to
apply the filter.

Notice the evaluation method is shown next

to the check box.

In this case the default setting matches the

Standard. That is, Minimum Zone Center
with a Gauss filter at 50 UPR.

Of course, all of these settings are user

definable. They can be specified by the
operator either here, in the characteristic,
within the feature or as a Calypso default
filter setting.

The above feature control frame specifies

the method to be used for the evaluation is
a Minimum Zone Center (MZC). Let’s look
at the other possibilities.

Evaluation Methods

Click on the Evaluation Method Parameters

button to open the Evaluation Methods
window.

This displays several selections:

• LSQ Element (Standard)… aka, Gauss.
• Minimum-Element… aka, MZC
• Minimum Circumscribed Element
• Maximum Inscribed Element
• Inner Tangential Element
• Outer Tangential Element

It is of interest here to consider the use of the word “Ele-

ment” in this dialog window. For example, one might think
that the selection Maximum Inscribed Element might better
be called Maximum Inscribed Circle. However, Calypso can
apply filters and outliers to a variety of features beyond the
circle we are considering here.

From the Calypso on-line help:

Individual measuring points of the geometric features 2d
straight, plane, circle, cone, cylinder and sphere can be
purged from the measured values as Outliers.
Centers for Out-of-Roundness Measurement
(4 possibilities)

The centers of the measured polar profile which may be used

to determine the Out-of-Roundness value when specified are
those related to one of the following alternative methods of
Out-of-Roundness assessment:

2.8.1 Minimum Radial Separation (, MRS, Minimum Zone

Center, MZC, Tschebyscheff)
This center is that for which the radial difference between
two concentric circles which just contain the measured Minimum Radial Separation (, MRS,
Minimum Zone Center, MZC, Tschebyscheff)
polar profile is minimum.
This is also known as the center for minimal Total
Indicator Reading (TIR). The British Standards Institution
publication 3730:1964 refers to it as Minimum Zone
Center (MZC).

2.8.2 Least Squares Center (LSC, Gauss)

This Center is that of from which the sum of the squares
of the radial ordinates of the measured polar profile has a
minimum value.

2.8.3 Maximim Inscribed Circle (MIC)

This center is that of the largest circle which can be Least Squares Center (LSC, Gauss)
inscribed within the measured polar profile.
This is also known as the plug gage center and is
generally used for internal diameters.

2.8.4 Minimum Circumscribed Circle (MCC)

This center is that of the smallest circle which will just
contain the measured profile.
This is also known as the ring gage center and is gener-
ally used for external diameters.

2.9 Preferred Center

The center from which the out- of-roundness value shall Maximim Inscribed Circle (MIC)
be determined unless specified otherwise is the Minimal
Radial Separation Center.

In Calypso the MZC or Tschebyscheff is correctly used by

default for Roundness evaluation. Other centers are user
selectable.

In Calypso versions 3.0 and higher, within the characteristics

feature selection window, there is a button for Evaluation
Parameters.

Minimum Circumscribed Circle (MCC)

Instrument Response (Cutoff)

Cycles Per Revolution (Undulations Per

Revolution, UPR)

If all of the radial deviations of a circular cross

section were fully and completely represented by
a measured profile, the presence of high fre-
quency surface irregularities could mask any
lobing conditions or the form of the profile.

In the ANSI standard the term used is Cycles

Per Revolution Response, in Calypso it is called
Undulation Per Revolution.

A UPR filter of 50 means that the measured

profile has been attenuated by a filter which has
reduced by a percentage (Gauss 50%, 2RC
75%) the amplitude of the sinusoidal lobing
which occurred at a regular interval of 50 lobes
per revolution. Note that the 50 UPR frequency is
base on angular displacement rather than time.

It might be expressed that the cut-off of 50UPR represents 50

segments of the circle.

Reducing the number of UPR will tend to smooth out small

scale irregularities while higher frequency are more inclusive
of total surface texture.

At least 5 measuring points are required per undulation.

Wavelength Lc (Lambda cutoff)

Profiles at three different UPR settings
Flatness and straightness are evaluated with a cut-off de-
scribe by a linier dimension. The default for Calypso is
2.5mm.

A Wavelength Lc of 2.5 means that the measured profile has

been attenuated by a filter which has reduced by a percent-
age (Gauss 50%, 2RC 75%) the amplitude of the sinusoidal
profile which occurred at a regular interval of 2.5mm.
Filter Methods:

Gauss

The Gaussian filter has been adapted as the industry

standard for the measurement of roundness and
surface geometry. It is a digital, phase corrected filter.
Its quick frequency response allows the accurate
assessment of the surface profile.

The Gaussian filter is defined to have 50% transmis-

sion at the cutoff wavelength. In other words; a mea-
sured sine with 50 UPR and an amplitude of 1.0 has
after filtering with gauss filter (50 UPR) an amplitude of
0.5.

2-RC-Filter (2-CR)

The 2RC (or 2CR) filter is an older standard filter used

in surface roughness measurements. It Is typically
implemented as an analog electrical filter, 2 RC filters
in series, separated by a buffer. It Is not phase-correct,
and it has a frequency transmission of 75% at the 2RC
cutoff wavelength. The 75% level was apparently
chosen because the 2RC filter has a long “tail” in its
frequency response, and, therefore, much of the long
wavelength components above the 50% cutoff remains
in the roughness. The cutoff at 75% more accurately Gauss
retains the intuitive sense of being the wavelength
boundary between roughness and waviness.

Some refer to the above filter as a 2CR filter because

the capacitor comes before the resistor in each pair.
However, electrical engineers refer to either order as
an RC filter and distinguish between the two by calling
one a high pass filter and one a low pass filter. “Pass”
refers to what frequencies make it through the filter.
Comparrison of Gauss vs. 2RC frequency responce
Both the Gauss and 2RC filters separate roughness
from the form error.

Surface Profile

Waviness Form
Lowpass, Highpass Filter Types

You may select a Lowpass or a Highpass filter. The

Calypso default is Lowpass.

A Lowpass filter type reduces the short-wave surface

phenomena (High frequency) and does not disrupt the
long-wave (Low frequency) effects of waviness and
geometric deviation.

Caution Should be Used!!

Caution should be used when changing from the default

Lowpass to Highpass filter. Selecting the Highpass filter
will remove all waviness (what you’re trying to evaluate
with roundness, flatness, straightness, etc.) leaving only
the high frequency surface roughness. Rather than using
a CMM, surface texture might be better evaluated with a
dedicated surface finish gage such as those in our TSK
product line.

That said, an experienced metrologist might glean insight

into a process with the cautious use of the Highpass filter. Example of a Out-of-Round feature with a form error of
4.8mm. A Lowpass plot must be reduced to a magnification
of two or it’s off the chart. This obscures all high frequency
In the instance where the measured feature has extremely form deviations.
poor geometry the low frequency deviation will prevent the
use of a adequate magnification factor for plotting. Re-
moving the low frequency form deviation will allow a much
higher magnification, possibly revealing, machining, tool
path or other process problems.

However, as this custom printout shows, care must be

taken. Two evaluations of the same feature produce two
extremely different results!!

By selecting a Highpass the magnification can be increased

to 400 revealing tool marks and chatter.
Connect Segments

From time to time it may be necessary to scan a

feature with interrupted paths. Possibly keyways inside
a bore. Because of the limitations of 5 data points per
cutoff (UPR or Wavelength Lc) filtering might not work.

If you activate this checkbox the segments of an

interrupted contour are connected to form a continuous
contour during filtration with as many points as possible
being taken into account. This means that you can
select a stronger filter.

Eliminating Outliers
A measured point is tagged as an outlier if it is further
than a defined threshold (threshold = factor * standard
deviation) from the computed Gaussian element. Outliers
are geometric points that differ significantly from the
geometric form yielded by the other measured points and
as such, they can produce a large error when the com-
pensatory element is calculated. An error of this nature
easily propagates through the actual-value determination
of the corresponding characteristic.

Why is Outlier Elimination Necessary?

If, for instance, you are checking roundness on a

dedicated form tester, you are probably in a inspection lab
doing the work. If the characteristic is out of tolerance the
inspector might clean and recheck the feature.

Often, with CMM’s, there may not be this opportunity. With

outlier elimination, and user definable parameters, the
feature data can be “cleaned” by the software.

Additionally, you do not want to make a process change

based on a piece of dirt or imperfection in part material.
Selecting Outlier Elimination In Calypso

As with filters there are several different points in Calypso at

which you can parameterize and activate outlier elimination:
– For an individual characteristic.
– For an individual feature.
– As defaults for the characteristic groups.

At each of these points the Outlier Mode dialog window can

be accessed.

Factor For Outlier

Sets the outlier factor (factor * standard deviation) for outlier

elimination. This factor can be set, individually, for inside and
outside the material.

Range of Data Reduction

Only Outlier – Removes only the outlier then recalculates

the feature. Additional outliers may be eliminated in subse-
quent iterations.

Include Adjacent Points – Operator can determine and

number of points on each side of the outlier to also be
eliminated.

To Computed Feature – Eliminates the outlier and all point

to the computed (Gaussian) feature.

Outlier Elimination is reported on the Default Printout,

Custom Protocol (see next page) and graphically repre-
sented on plots by the absence of deviation lines (below).
 Calypso Compact Protocal - Range of Data Reduction example

One plane with three evaluations. See bold print.

==============================================================================================
C A R L Z E I S S / C A L Y P S O 3.2.-beta30 COMPACT PROTOCOL -1-
———————————————————————————————————————————————
Measurement Plan Operator Date Part Number
Filters and Outliers Master July 21, 2001 32
CONTURA
———————————————————————————————————————————————
Names Description Actual Nominal Utol Ltol Deviat. Histogr.
==============================================================================================

Plane4(Only Outlier)
Minimum Zone Plane #P (222)
S = 0.0020 Min = (3) -0.0030 Max = (57) 0.0030 Form = 0.0061
Z 0.0373 0.1000
X -83.5389 -82.5000
Y 4.8318 5.0000
A1- X/Z -0.0171 0.0000
A2- Y/Z -0.1664 -0.1000
Outlier Elimination Inside Workpiece : 2 Outside Workpiece : 2
No Filter Only Outlier GDT Flat 0.0100 0.0061 |—

______________________________________________________________________________________________
Plane4(Outlier & Adjacent Points 4)
Minimum Zone Plane #P (217)
S = 0.0018 Min = (3) -0.0029 Max = (57) 0.0029 Form = 0.0057
Z 0.0376 0.1000
X -83.5389 -82.5000
Y 4.8317 5.0000
A1- X/Z -0.0169 0.0000
A2- Y/Z -0.1580 -0.1000
Outlier Elimination Inside Workpiece : 0 Outside Workpiece : 9
No Filter AP4 Outlier GDT Flat 0.0100 0.0057 |—

______________________________________________________________________________________________
Plane4(Outlier to Computed Feature)
Minimum Zone Plane #P (217)
S = 0.0015 Min = (3) -0.0026 Max = (57) 0.0026 Form = 0.0051
Z 0.0381 0.1000
X -83.5390 -82.5000
Y 4.8315 5.0000
A1- X/Z -0.0166 0.0000
A2- Y/Z -0.1443 -0.1000
Outlier Elimination Inside Workpiece : 4 Outside Workpiece : 5
No Filter CF Outlier GDT Flat 0.0100 0.0051 |—

______________________________________________________________________________________________