Академический Документы
Профессиональный Документы
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2 7 12 17
Measurement Calibration Surface Finish
Parameters
Methods Methods Standards
3 8 13 18
Measurement Bearing Area Drawing
Datums (Material Ratio) Indication
4 9 14 19
Reproducing The Rk 3D (Areal)
The Surface Parameter Measurement
5 10 15 20
R&W Conics &
Terminology
Analysis Aspherics
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Mixer Nozzle
SF Standards
Why Measure Surface Finish?
Automotive & Steel Industry
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Con-rods Pistons & Rings Valves & Seats
Tappets
Reflectors / Headlights Camshafts
SF Standards
Why Measure Surface Finish?
Bearing Industry
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Ball Bearings
Roller Bearings
Large Bearings
Thrust Bearings
SF Standards
Why Measure Surface Finish?
Pharmaceutical Industry
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Razor Blades & Packages
Medical EquipmentTubes
Sieve Meshes
Teeth / Toothpaste
Plastic Packaging
Knee Joints
Hair / Cosmetics
Enzyme Circuits
Skin / Cosmetics
SF Standards
Why Measure Surface Finish?
Domestic & Food Industry
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Sprayer Nozzles Road
Razor Blades
Surfaces
Snooker Balls
Shaving Cream Containers
Drink Can Moulds
Sandpaper
Deodorant Balls Hand Tool Mouldings
Paper
Wine Glasses
Kettle Elements Bottle Dies
SF Standards
Why Measure Surface Finish?
Electronics / Computing / Printing / Photographic Ind.
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Rubber Drive Wheels Lead Frames
LCD Screens
SF Standards
Why Measure Surface Finish?
Aerospace & Defence Industry
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Gyro Parts Turbine Blades
Machine Tools
SF Standards
Why Measure Surface Finish?
Role of Surface Metrology
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Manufacture Function
Control Prediction
SF Standards
Why Measure Surface Finish?
Role of Surface Metrology
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Manufacture Function
◆ Predict Behaviour
SF Standards
Why Measure Surface Finish?
Role of Surface Metrology - Manufacture
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SF Standards
Why Measure Surface Finish?
Role of Surface Metrology - Manufacture
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The Reality:
Process Control
SF Standards
Why Measure Surface Finish?
Role of Surface Metrology - Function
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Predicting Component Behaviour
SF Standards
Why Measure Surface Finish?
Monitoring Component Performance
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Monitoring Component Performance
SF Standards
Why Measure Surface Finish?
Nature of Surfaces
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◆ The microstructure of the material
SF Standards
Why Measure Surface Finish?
Nature of Surfaces - The Microstructure of the Material
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SF Standards
Why Measure Surface Finish?
Nature of Surfaces - The Action of the Cutting Tool
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Built Up Edge
Deposit on Chip
TOOL
BUE
BUE Deposits On
Machined Surface
SF Standards
Why Measure Surface Finish?
Nature of Surfaces - The Instability of The Cutting Tool
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Milling
Regenerative Waviness.
SF Standards
Why Measure Surface Finish?
Nature of Surfaces - Stress Patterns In Components
Component
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Checks on raw material
SF Standards
Why Measure Surface Finish?
Nature of Surfaces
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◆ The microstructure of the material
SF Standards
Why Measure Surface Finish?
Wanted Properties on a Surface
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◆ Sufficient valleys for oil retention when lubrication is
an important factor
SF Standards
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◆ Comparison Plates
◆ Contact Methods
◆ Non-Contact Methods
SF Standards
Measurement Methods & Instrumentation
Initial Visual Inspection
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◆ Hold Part Up To Light
Observe:
◆ Direction Of Lay
◆ Process Marks
◆ Defects / Scratches
SF Standards
Measurement Methods & Instrumentation
Comparison Plates
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SF Standards
Measurement Methods & Instrumentation
Comparison Plates - ‘N’ Numbers (UK)
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2000
50 N12
1000
25 N11
12.5
500 N10
250
6.3 N9
125
3.2 N8
1.6
63 N7
Nominal Ra in µin
µm Roughness Grade Number
0.8
32 N6
0.4
16 N5
0.2
8 N4
0.1
4 N3
0.05
2 N2
0.025
1 N1
SF Standards
Measurement Methods & Instrumentation
Contact Type Instruments
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TRAVERSE UNIT
Pickup / Stylus
SF Standards
Measurement Methods & Instrumentation
Early Contact Type Instrument
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Talysurf 1 (1941)
SF Standards
Measurement Methods & Instrumentation
Recent Contact Type Instrument
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Form Talysurf Series PGI
SF Standards
Measurement Methods & Instrumentation
Instrument Using Variable Reluctance Transducer
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Surtronic 3+
SF Standards
Measurement Methods & Instrumentation
Instrument Using Inductive Transducer
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Form Talysurf Intra Inductive Transducer
Coil
Beam
Coil
Stylus
SF Standards
Measurement Methods & Instrumentation
Instrument Using Piezo-Electric Transducer
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Surtronic Duo Portable Roughness Measurement
Piezo Transducer
SF Standards
Measurement Methods & Instrumentation
Instrument Using Piezo-Electric Transducer
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Surtronic Duo
SF Standards
Measurement Methods & Instrumentation
Piezo-Electric Transducer
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Beam Piezo Element
Advantages
Ideal For Small Portable Instruments
Only Needs Simple Processing Electronics
Stylus Ideal for Small Stylus Movements
Good High Frequency Response
Disadvantages
Small Range
Low Linearity
Temperature / Humidity Sensitive
Limited Low frequency Response
SF Standards
Measurement Methods & Instrumentation
Interferometric Transducer - Laser
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Measurement Methods
C B
Laser F
Reference Beam Diodes
Beam
E
Stylus D
Interpolation SF Standards
Measurement Methods & Instrumentation
Interference Fringes (Laser and PGI Systems)
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SF Standards
Measurement Methods & Instrumentation
Phase Grating Interferometric Transducer (PGI)
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Advantages Output Phase and Frequency are
Extremely High Accuracy & Linearity Dependant Upon Grating Pitch
Not Laser Wavelength
Large Range and High Resolution
Resolution Independent of Gauge Range
SF Standards
Measurement Methods & Instrumentation
Phase Grating Interferometric Transducer (PGI)
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SF Standards
Measurement Methods & Instrumentation
Non-Contact : Scattering Laser Triangulation
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Advantages
Slopes up to 90 deg
Low cost
Disadvantages
Scattering only
Shadow areas
Limited Resolution
SF Standards
Measurement Methods & Instrumentation
Non-Contact : Scattering Laser Triangulation
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Laser
CCD Detector
X
Stepped Surface
Laser
CCD Detector
Stepped Surface
SF Standards
Measurement Methods & Instrumentation
Instrument Using Scattering Laser Triangulation
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Talyscan 250
SF Standards
Measurement Methods & Instrumentation
Atomic Force Microscope
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Spring Deflection
Sensor
Spring
Stylus Tip
SF Standards
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Measurement Datums
Measurement Datums
Skid (Surface) Datum
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Direction of Traverse
1 - Stylus
2 - Skid
SF Standards
Measurement Datums
Skid (Surface) Datum
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◆ Instrument Portability
◆ Robust Design
SF Standards
Measurement Datums
Effect of Skid To Stylus Pitch
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Apparent Height
Actual Height
+H
-H
SF Standards
Measurement Datums
Effect of Skid To Stylus Pitch
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P-V = 10µm
SF Standards
Measurement Datums
Independent Datums
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SF Standards
Measurement Datums
Independent Datums
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Datum Skid
Optical Flat
SF Standards
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X5
X 10K
X 50
X 10K
X
X 10K
200
SF Standards
Reproducing The Surface
The Stylus - Critical Dimensions
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Effective Length
Pivot Point
Shank
Clearance
Tip Radius r
Shank Length
SF Standards
Reproducing The Surface
Stylus Types - Standard & Recess Stylus
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Standard Stylus Recess Stylus
SF Standards
Reproducing The Surface
Stylus Types - Ball Stylus
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120mm Ball Stylus
500µm Radius. Ruby Ball Tip
SF Standards
Reproducing The Surface
Stylus Types - Miniature Bore Stylus
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Miniature Bore Stylus
SF Standards
Reproducing The Surface
Stylus Types - Nozzle Stylus
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Nozzle Stylus
2µm Conisphere Tip
SF Standards
Reproducing The Surface
Stylus Types - Chisel Edge Stylus
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Chisel Edge Stylus
20µm Tungsten Tip
15°
SF Standards
Reproducing The Surface
Gauge Range & Resolution
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Gauge
Resolution:
Smallest stylus
movement that can be
‘detected’ 0.8nm
SF Standards
Reproducing The Surface
Stylus Tip Geometry
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2µm
2µm
Traverse Direction
SF Standards
Reproducing The Surface
Filtering Effect of Stylus Tip
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Form Waviness Roughness
Conisphere Tip r = 2µm
X X
Ruby Ball Tip r = 500µm
SF Standards
Reproducing The Surface
Effects of Stylus Tip Size & Shape - ISO 3274
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Standardised Values of Stylus Tip Radius - unless otherwise specified
SF Standards
Reproducing The Surface
Stylus Force
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Typical Stylus Force
SF Standards
Reproducing The Surface
Surface Replication
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Accuracy
Typically, a difference of ±2% ±0.1µm
is introduced when compared to the
original sample.
SF Standards
Reproducing The Surface
Stylus Flanking - On A Curved Profile
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Bearing Race
Stylus Flanking !
SF Standards
Reproducing The Surface
Stylus Flanking - On A Slope
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Flanking graph - what it looks like
Stylus Flanking !
SF Standards
Reproducing The Surface
Stylus Flanking
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Tip Stylus
Of Stylus
Flanking
In Contact
!
SF Standards
Reproducing The Surface
Reproducing the Surface - Limitations
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Profile produced by Stylus
B
A
Stylus Tip
B
A
SF Standards
Reproducing The Surface
Data Points - Aliasing
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True Signal Aliasing Signal
Sampling Interval
SF Standards
Reproducing The Surface
Data Points - Reproducing Slopes
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Profile Insufficient Points
Result
Result
SF Standards
Reproducing The Surface
Tilting the Component
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SF Standards
Reproducing The Surface
Form Error Due To Component Misalignment
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Component Misaligned
Component Aligned
SF Standards
Reproducing The Surface
Fixture - For Component Alignment
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SF Standards
Reproducing The Surface
Other Fixtures
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SF Standards
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Terminology
Terminology
Roughness, Waviness & Form
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Roughness, Waviness & Form
SF Standards
Terminology
Roughness, Waviness & Form
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Roughness
SF Standards
Terminology
Roughness, Waviness & Form
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Waviness
SF Standards
Terminology
Roughness, Waviness & Form
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Form
SF Standards
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Filters
Filters
Filtering - Separates Roughness and Waviness
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Surface Interaction
SF Standards
Filters
Roughness, Waviness and Form
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RAW DATA
Form Removal
SF Standards
Filters
Filtering Using Graphical Techniques
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Sampling Length
SF Standards
Filters
Filter Types
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◆ Gaussian Filter
SF Standards
Filters
2CR Filters
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Profile Roughness
Profile Waviness
SF Standards
Filters
Typical 2CR Electronic Filter (Roughness)
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-
Vi Vo
SF Standards
Filters
Typical 2CR Filter - Step Response
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Settle
Overshoot
% Transmission
100
90
Rise Time
t
SF Standards
Filters
Distortion Caused By ISO 2CR Filter
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Unfiltered Profile
SF Standards
Filters
Distortion Caused By ISO 2CR Filter
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SF Standards
Filters
Filters - ISO 2CR PC
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SF Standards
Filters
ISO 2CR PC (Phase Corrected)
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Unfiltered Profile
SF Standards
Filters
Gaussian Filter
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Unfiltered Profile
90
80
0.08mm
cut-off
70
Percentage Transmission
0.25mm
60
cut-off
50
0.8mm
cut-off
40
2.5mm
30
cut-off
20
8mm cut-
off
10
0
1µm 10µm 0.1mm 1mm 10mm 100mm
Wavelength λ
SF Standards
Filters
Gaussian vs ISO 2CR Response
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100
0.8mm Roughness Filter
90
80
70
Percentage Transmission
60
ISO 2CR
50
40
The Gaussian Filter Has a Much Sharper
Transmission Characteristic
30
Gaussian
20
10
0
1µm 10µm 0.1mm 1mm 10mm 100mm
Wavelength λ
SF Standards
Filters
Gaussian Transmission Characteristic : Waviness
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100
80
Transmission
60
0
1µm 10µm 0.1mm 1mm 10mm
Wavelength
SF Standards
Filters
Example - Effect Of Roughness Filters
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Unfiltered Profile
SF Standards
Filters
Example - Effect Of Roughness Filters
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Unfiltered Profile
SF Standards
Filters
Example - Effect Of Roughness Filters (ISO 2CR)
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CUT-OFF
100
8mm
Percentage Transmission
80
2.5mm
60
0.8mm
40
0.25mm
20
0.08mm
0
1µm 10µm 0.1mm 1mm 10mm 100mm
Wavelength λ
SF Standards
Filters
Example - Effect Of Roughness Filters (ISO 2CR)
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CUT-OFF
100
8mm
Percentage Transmission
80
2.5mm
60
0.8mm
40
0.25mm
20
0.08mm
0
1µm 10µm 0.1mm 1mm 10mm 100mm
Wavelength λ
SF Standards
Filters
Example - Effect Of Roughness Filters (ISO 2CR)
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CUT-OFF
100
8mm
Percentage Transmission
80
2.5mm
60
0.8mm
40
0.25mm
20
0.08mm
0
1µm 10µm 0.1mm 1mm 10mm 100mm
Wavelength λ
SF Standards
Filters
Example - Effect Of Roughness Filters (ISO 2CR)
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CUT-OFF
100
8mm
Percentage Transmission
80
2.5mm
60
0.8mm
40
0.25mm
20
0.08mm
0
1µm 10µm 0.1mm 1mm 10mm 100mm
Wavelength λ
SF Standards
Filters
Example - Effect Of Roughness Filters (ISO 2CR)
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CUT-OFF
100
8mm
Percentage Transmission
80
2.5mm
60
0.8mm
40
0.25mm
20
0.08mm
0
1µm 10µm 0.1mm 1mm 10mm 100mm
Wavelength λ
SF Standards
Filters
Filter Types
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◆ ISO 2CR- 1st 2 Cut-offs Discarded
SF Standards
Filters
Sampling Length, Assessment Length, Traverse Length
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Traverse Length
ISO 2CR
SF Standards
Filters
Sampling Length, Assessment Length, Traverse Length
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Traverse Length
ISO 2CR PC
SF Standards
Filters
Sampling Length, Assessment Length, Traverse Length
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Traverse Length
GAUSSIAN
SF Standards
Filters
Choosing The Correct Filter (Cut-off) Value
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SF Standards
Filters
Choosing The Correct Filter (Cut-off) Value
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SF Standards
Filters
Choosing The Correct Filter (Cut-off) Value
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Traverse Direction
1.25 mm
SF Standards
Filters
Choosing The Correct Filter (Cut-off) Value
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R ecom m ended C ut-off (ISO 4 28 8-19 96 )
S pacing
D istance R z (µ m ) R a (µm ) גc (m m ) גc (m m )/L
RSm
(m m )
> 0.013 -0.04 To 0 .1 To 0 .0 2 0 .08 0 .08/0.4
SF Standards
Filters
Bandwidth (Lc/Ls)
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Ls Lc
SF Standards
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Parameters
Parameters
Parameter Types
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◆ Roughness : Prefix R
◆ Waviness : Prefix W
◆ Primary : Prefix P
SF Standards
Parameters
Parameter Types
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◆ Amplitude Parameters defined from
Z co-ordinates
SF Standards
Parameters
Amplitude Parameters - Ra
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Ra
Using Ra SF Standards
Parameters
Amplitude Parameters - Ra Limitations
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Ra
Ra
Ra
Ra
SF Standards
Parameters
Amplitude Parameters - Using Pa & ln to Calculate Area
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Using Pa and ln to Calculate Area
ln
Area
= Pa. ln
SF Standards
Parameters
Amplitude Parameters - Rq (rms)
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lr = Sampling Length
Using Rq SF Standards
Parameters
Amplitude Parameters - Rt
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Rt
Using Rt SF Standards
Parameters
Amplitude Parameters - Rt Results are Divergent
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SF Standards
Parameters
Amplitude Parameters - Rp
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Rp
Sampling Length
Using Rp SF Standards
Parameters
Amplitude Parameters - Rv
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Rv
Sampling Length
Using Rv SF Standards
Parameters
Amplitude Parameters - Rz
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Rz1 Rz2
Rz3 Rz4 Rz5
Using Rz SF Standards
Parameters
Amplitude Parameters - Rz1max, Rp1max, Rv1max
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Rz1max Rp1max
Rv1max
SF Standards
Parameters
Spacing Parameters - RPc (Peak Count)
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A = Selectable Bandwidth B = Mean Line
Painted Surface
SF Standards
Parameters
Spacing Parameters - RSm (Mean Spacing)
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Mean
Line
◆ Less suitable for extremely fine surfaces ◆ Most suitable for extremely fine surfaces
◆ More suitable for general engineering and ◆ More suitable for optical or electronic parts,
automotive components. where even small changes are important.
SF Standards
Parameters
Hybrid Parameters - Rda, Rdq, (Wda, Wdq, Pda, Pdq)
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Slope Parameters
SF Standards
Parameters
Hybrid Parameters - Rda, Rdq, (Wda, Wdq, Pda, Pdq)
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Effects of Surface Slopes - Vibration & Noise
SF Standards
Parameters
Hybrid Parameters - Rda, Rdq, (Wda, Wdq, Pda, Pdq)
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Effects of Surface Slopes - Appearance
SF Standards
Parameters
Hybrid Parameters - Rda, Rdq, (Wda, Wdq, Pda, Pdq)
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Effects of Surface Slopes - Slip Resistance
Ceramic Tiles
Typical
Parameters:
Rz, Rp, Rda, Rsk
SF Standards
Parameters
General Comments
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Useful Parameters
Ra & Rq
Rt & Rp & Rv
Rz
RHSC
RPc
RSm & RS
SF Standards
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SF Standards
Bearing Area (Material Ratio)
Rmr (tp%) and Rmr(c)
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Lapping Plate
Bearing
Line
Abbott-curve
SF Standards
Bearing Area (Material Ratio)
Bearing Area Curve
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0 Rmr(%) 100 %
SF Standards
Bearing Area (Material Ratio)
Bearing Area Curve
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0 Rmr(%) 100 %
SF Standards
Bearing Area (Material Ratio)
Bearing Area Curve
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0 Rmr(%) 100 %
SF Standards
Bearing Area (Material Ratio)
Amplitude Distribution Curve
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Amplitude Distribution Curve
Level p
0 number of peaks
SF Standards
Bearing Area (Material Ratio)
Relationship Between MR Curve & ADC Curve
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Material Ratio Curve Amplitude Distribution Curve
Differentiate
Integrate
SF Standards
Bearing Area (Material Ratio)
Associated MR Curve Parameters - Rsk (skew)
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SF Standards
Bearing Area (Material Ratio)
Associated MR Curve Parameters - Rsk (skew)
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SF Standards
Bearing Area (Material Ratio)
Associated ADC Curve Parameter - Rku (Kurtosis)
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Rku < 3
Rku = 3
Rku > 3
The Rk Parameter
The Rk Parameter
The Rk Filter
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Surface Interaction
SF Standards
The Rk Parameter
The Rk Filter
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Tilted Profile Material Ratio curve
0 Rmr(%) 100 %
SF Standards
The Rk Parameter
The Rk Filter
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Mean Line
SF Standards
The Rk Parameter
The Rk Filter
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SF Standards
The Rk Parameter
The Rk Filter
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SF Standards
The Rk Parameter
Rk Parameters
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40 %
Rdc
0 tp(%) 100 %
SF Standards
The Rk Parameter
Rk Parameters
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40 %
C
E
A Rdc
B
F D
0 Rmr(%) 100 %
SF Standards
The Rk Parameter
Rk Parameters
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40 %
C
E
Rk A Rdc
B
D1 F D
Mr1 Mr2
0 Rmr(%) 100 %
SF Standards
The Rk Parameter
Rk Parameters
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40 %
C E D
Rk A Rdc
Rpk B
D1 F D Rvk
C E
E
Mr1 Mr2
0 tp(%) 100 %
Area 1 Area 2
SF Standards
The Rk Parameter
Rk Parameters
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40 %
Rpk
Rk
Rvk
Mr1 Mr2
0 Rmr(%) 100 %
SF Standards
The Rk Parameter
Rk Associated Parameters
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Rk Core Roughness Depth
SF Standards
Bearing Area (Material Ratio)
Rk Associated Parameters
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Upper Surface - defines Body of Surface - defines
run-in characteristics wear / life characteristics
Rpk MR1 A1 Rk
SF Standards
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R & W Analysis
R & W Analysis
What Is It ?
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R & W Analysis
SF Standards
R & W Analysis
General Information
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1. Form Fit & Removal (eg LS Line) must be used for a
valid R & W Analysis. (The ‘DATUM’ option is not valid).
SF Standards
R & W Analysis
Definitions - Local Peaks
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SF Standards
R & W Analysis
Definitions - Local Valleys
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SF Standards
R & W Analysis
Definitions - Motif
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Local Peak 1
Local Peak 2
SF Standards
R & W Analysis
Roughness Motif
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Hj
Hj+1
ARi
SF Standards
R & W Analysis
Upper Envelope Line of Primary Profile
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Upper Envelope Line
SF Standards
R & W Analysis
Waviness Motif
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Hwj Hwj+1
Upper Envelope Line
AWi
SF Standards
R & W Analysis
R & W Parameters
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AR Mean Spacing of Roughness Motifs
SF Standards
R & W Analysis
R & W Parameter Definitions : AR
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SF Standards
R & W Analysis
R & W Parameter Definitions : R
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H2 H3 Hm-1
Hj
H1 Hj+1
Hm
SF Standards
R & W Analysis
R & W Parameter Definitions : Rx
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H2 H3 Hm-1
Hj
H1 Hj+1
Hm
SF Standards
R & W Analysis
R & W Parameter Definitions : AW
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Upper Envelope Line
AWi
2.5 µm
x
500 µm
SF Standards
R & W Analysis
R & W Parameter Definitions : W
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Upper Envelope Line
AWi
Hwj
2.5 µm
x
500 µm
SF Standards
R & W Analysis
R & W Parameter Definitions : Wx
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Upper Envelope Line
AWi
Hwj
Wx
2.5 µm
x
500 µm
SF Standards
R & W Analysis
R & W Parameter Definitions : Wte
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Upper Envelope Line
Wte
2.5 µm
x
500 µm
SF Standards
R & W Analysis
Recommended Measurement Conditions
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Traverse Evaluation Maximum
1 1
A B Length Length λS Stylus Tip Radius
(mm) (mm) (mm) (mm) (µm) (µm)
0.02 0.1 0.64 0.64 2.5 2 ± 0.5
0.1 0.5 3.2 3.2 2.5 2 ± 0.5
0.5 2.5 16 16 8 5±1
2.5 12.5 80 80 25 10 ± 2
Note 1: If not otherwise specified, default values are: A = 0.5mm and B = 2.5mm
0 ≤ spacing ≤ A A ≤ spacing ≤ B
SF Standards
R & W Analysis
Relating Motif Parameters To Function of Surfaces
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Most Important
Parameters:
Secondary
Parameters:
Specify if necessary
according to part
functions.
*)
Symbols (FS etc.)
are French
acronyms.
SF Standards
R & W Analysis
Further R & W Parameters
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SAR The Standard Deviation of AR
SF Standards
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Form Measurement
Form Measurement
Some Aspects Of Form Measurement
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SF Standards
Form Measurement
Form Fit : Least Squares Line
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a2 + b2+ c2 + d2 …. = minimum
SF Standards
Form Measurement
Straightness (LS Line)
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SF Standards
Form Measurement
Straightness (MZ Line)
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SF Standards
Form Measurement
Form Fit : Least Squares Arc
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R = Calculated LS Radius r-r = LS Arc
r
r
a2 + b2+ c2 + d2 …. = minimum
SF Standards
Form Measurement
Accuracy of Radius Measurement
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Factors Affecting Radius Accuracy
◆ Software Levelling
SF Standards
Form Measurement
Form Exclusions - Example
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Straightness On Interrupted Surface
SF Standards
Form Measurement
Form Exclusions - Example
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Straightness On Interrupted Surface
4 4
2 2
microns
microns
microns
0 0
-2 -2
-4 -4
-6 -6
SF Standards
Form Measurement
Dimensional Measurement
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SF Standards
Form Measurement
Dimensional Measurement - Example
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◆ Profile
◆ Angle
◆ Radius
SF Standards
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Calibration Methods
Calibration Methods
Calibration Balls - Known Radius & Form Error
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SF Standards
Calibration Methods
Calibration Balls - Known Radius & Form Error
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Traverse Direction
SF Standards
Calibration Methods
Gauge Linearity
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Indicated Gauge Reading
SF Standards
Calibration Methods
Software Corrections - Arcuate Errors
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Traverse Direction
dZ
dX
SF Standards
Calibration Methods
Software Corrections - Stylus Tip Errors
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Traverse Direction
SF Standards
Calibration Methods
Ra & Rz Roughness Standards
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SF Standards
Calibration Methods
Ra & Rz Roughness Standards
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SF Standards
Calibration Methods
3 Line (Step Height) Standard
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Traverse Direction
SF Standards
Calibration Methods
3 Line (Step Height) Standard
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A B
SF Standards
Calibration Methods
3 Line (Step Height) Standard
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3W
W/3 W/3
W
A B
C
h = Calibration Height
W/3
SF Standards
Calibration Methods
Reduction Lever
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SF Standards
Calibration Methods
Reduction Lever
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B C
A=B+C
6mm
20 2
12mm (b)
120mm (a)
SF Standards
Calibration Methods
Wear Gauge
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W1 W2 W3 W4
SF Standards
Calibration Methods
Wear Gauge
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SF Standards
Calibration Methods
Prism Standard - Angle Verification
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SF Standards
Calibration Methods
Datum Bar Straightness Correction
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System Requirements For Correction
◆ Low Noise.
◆ Good Environment.
SF Standards
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Drawing Indication
Drawing Indication
Considerations
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◆ Traverse Length ?
◆ Cut-off ?
◆ Form Type ?
◆ Filter type ?
◆ Number of Cut-offs ?
◆ Appropriate Parameters ?
◆ Tip Type / Radius ?
◆ Bandwidth ?
◆ Where to measure ?
◆ Lay / Direction Of Measurement
SF Standards
Drawing Indication
Early / Obsolete Methods
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Maximum Permissible Value Rt (µm)
SF Standards
Drawing Indication
Graphical Symbols For Surface Texture
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6.8
SF Standards
Drawing Indication
Graphical Symbols For Surface Texture
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1 2 3
Requirement for
Requirement for Requirement for
Surface Texture,
Surface Texture,
Surface Texture
Material
Material Removal
Removal
Not Permitted
Required
SF Standards
Drawing Indication
Graphical Symbols For Surface Texture
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(c) Turned
(a) 0.0025-0.8/Rz 6.8
(b) 0.0025-0.8/Ra 2.2
(e) 3 (d)
SF Standards
Drawing Indication
Drawing Indication of Surface Lay
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SF Standards
Drawing Indication
Graphical Symbols For Surface Texture
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Fe/Ni 15p cr
0.0025 - 0.8 / Rz 6.8
SF Standards
Drawing Indication
Graphical Symbols For Surface Texture
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U Ra 0.9
L Ra 0.3
Bi-Lateral Tolerancing
SF Standards
Drawing Indication
The 16% Rule (Default Rule)
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SF Standards
Drawing Indication
The MAX Rule
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Rz MAX 0.9
SF Standards
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3D (Areal) Measurement
3D (Areal Measurement)
3D (Areal) Measurement
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SF Standards
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3D (Areal Measurement)
Advantages of 3D (Areal) over 2D
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◆ Good Visualisation of the Surface
SF Standards
3D (Areal Measurement)
Disadvantages of 3D (Areal) over 2D
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◆ Longer Measurement Cycles
SF Standards
3D (Areal Measurement)
Contact Measurement Method
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Traverse Direction
SF Standards
3D (Areal Measurement)
Non-Contact Measurement Method
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CCD Detector Laser
SF Standards
3D (Areal Measurement)
Critical Dimensions for 3D Measurement
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Profile 2
Z2
∆Z
∆X
Z1
Profile 1 ∆Y
SF Standards
3D (Areal Measurement)
Data Analysis
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SF Standards
3D (Areal Measurement)
Levelling the Data
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SF Standards
3D (Areal Measurement)
Form Removal
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Cylinder Liner- Form Removed
SF Standards
3D (Areal Measurement)
Viewing 3D Data
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SF Standards
3D (Areal Measurement)
Viewing 3D Data
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Pseudo- Colour View
SF Standards
3D (Areal Measurement)
Viewing 3D Data
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Contour View
SF Standards
3D (Areal Measurement)
3D Filtering
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0.8mm
0.8mm
Sampling Area •
SF Standards
3D (Areal Measurement)
3D Parameter Types
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◆ Amplitude Parameters
◆ Spatial Parameters
◆ Hybrid Parameters
◆ Functional Parameters
SF Standards
3D (Areal Measurement)
3D Amplitude Parameters - Prefix: S
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Sa = arithmetic mean of the deviations from the mean plane
SF Standards
3D (Areal Measurement)
3D Spatial Parameters
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SPc = peak count between two selectable planes
SF Standards
3D (Areal Measurement)
3D Hybrid Parameters
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Sdr = developed interfacial area ratio of the surface
SF Standards
3D (Areal Measurement)
3D Functional Parameters
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Stp = surface bearing area ratio
SF Standards
3D (Areal Measurement)
Volume / Defect Analysis
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SF Standards
3D (Areal Measurement)
Example of Volume Analysis
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SF Standards
3D (Areal Measurement)
Step Height Analysis
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SF Standards
3D (Areal Measurement)
Example of Step Height Analysis
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SF Standards
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Aspherics
SF Standards
Conics & Aspherics
Technology Trends
Measurement of Aspherics
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m2
0 Deg m1 GLASS : 2 Measurements m1 & m2 90
deg apart
GERMANIUM
SF Standards
Conics & Aspherics
Technology Trends - Miniaturisation
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◆ Miniaturisation
– Consumer Electronics
– Military Applications
SF Standards
Conics & Aspherics
UV (Ultra Violet) Aspheric Applications
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◆ Lithography - UV (Ultra Violet) Aspheric Applications
– Ever Increasing Form Accuracy (eg λ/20)
– Larger Diameters (200mm+)
– Interesting Materials (eg CaF)
SF Standards
Conics & Aspherics
IR (Infra Red) Aspheric Applications
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◆ IR (Infra Red) Aspheric Applications
– Diffractive Optics
SF Standards
Conics & Aspherics
Technology Trends
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◆ Ophthalmics
– Shopfloor Applications
SF Standards
Conics & Aspherics
Opthalmics - Toric Lenses & Astigmatism
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SF Standards
Conics & Aspherics
Aspheric Measurement - Instrument Requirements
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Aspheric Measurement - Instrument Requirements
◆ Excellent Repeatability
◆ Low Noise
◆ Traceability
SF Standards
Conics & Aspherics
Aspherics Measurement System
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PGI plus
SF Standards
Conics & Aspherics
Conics Sections
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SF Standards
Conics & Aspherics
Conics Constants
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Ellipse: K< 0 Sphere: K= 0 Oblate Ellipse: K>0
Z2 + X2 = 1 Z2 + X2 = 1 Z2 + X2 = 1
R22 R12 R2 R2 R22 R12
SF Standards
Conics & Aspherics
Conics Constants
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Hyperbola: K< -1
Parabola: K= -1
Z2 + X2 = 1
Z = (Ax)2
R22 R12
SF Standards
Conics & Aspherics
What is an Aspheric?
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Conventional Spherical Lens
SF Standards
Conics & Aspherics
What is an Aspheric?
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Aspheric Lens
SF Standards
Conics & Aspherics
Reasons for Using an Aspheric?
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◆ Reduces Spherical Aberration
SF Standards
Conics & Aspherics
How is an Asphere Constructed?
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Z Axis
Z2 + X2 = 1
R2 R2
X Axis
SF Standards
Conics & Aspherics
How is an Asphere Constructed?
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Z Axis
Z=a8|x|8
X Axis
SF Standards
Conics & Aspherics
How is an Asphere Constructed?
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Z Axis
Aspheric Profile
SF Standards
Conics & Aspherics
How is an Asphere Constructed?
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Z Axis
Aspheric Profile
Aspheric Profile
SF Standards
Conics & Aspherics
Standard Equation for an Aspheric Surface
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cx2
Z(x)= +a1|x| +a2| x|2 + a3| x|3 … +a20 | x|20
1+ √ 1-(K+1) c2x2
SF Standards
Conics & Aspherics
Base Radius of Curvature
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SF Standards
Conics & Aspherics
How Do We Measure and Aspheric Surface?
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Aspheric Axis
Optical Flat
SF Standards
Conics & Aspherics
How Do We Measure and Aspheric Surface?
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Aspheric Data
Radius=40.0mm
K= -1
A4= 5.3188e-007
A6=5.5231e-009
A8=-1.6774e-011
A10=-6.3352e-014
SF Standards
Conics & Aspherics
Aspheric Form Fit
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B
A
Aspheric Axis
SF Standards
Conics & Aspherics
Residual Error After Aspheric Form Removal
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+Z Axis
Aspheric Axis
A
+X Axis
-X Axis
Aspheric Axis
-Z Axis
SF Standards
Conics & Aspherics
How Do We Analyse an Aspheric Surface?
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SF Standards
Conics & Aspherics
Aspheric Parameters
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SF Standards
Conics & Aspherics
Aspherics - Further Analysis
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SF Standards
Conics & Aspherics
Aspherics - Further Analysis
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SF Standards
Conics & Aspherics
Aspherics - Further Analysis
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SF Standards
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Ball Screw
CV Joint
SF Standards
Gothic Arch Analysis
What is a Gothic Arch?
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A Gothic Arch (as in Gothic Architecture) consists of two arcs which
meet at a point. In engineering, the ball bearings sit between two Gothic
Arches and one race rotates while the other is stationary.
SF Standards
Gothic Arch Analysis
Early Methods
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Historically, measurement involved the use of marking ink on a test ball placed
in the Gothic Arch. Contact points of the ball are made visible by the ink.
This method is time consuming and has limitations on further analysis. Very
small bearings are also difficult to measure in this way.
SF Standards
Gothic Arch Analysis
Left and Right Arc Radius Analysis
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Gothic Arch Analysis determines the radius of the left and right arcs of the
profile and the offsets between the centres of the two arcs.
SF Standards
Gothic Arch Analysis
Determination of Contact Points
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TEST BALL
BEARING
Contact points
SF Standards
Gothic Arch Analysis
Typical Results Display
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SF Standards
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sin f cos
o/p nf
Interpolation
(xn)
Up / Down Direction
Reproducing The Surface
‘Airy’ Diameter
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Glass Flat
“Airy” Diameter
Profile Filter
Unfiltered Profile
Sampling Length
X
Parameters
Ra - Applications
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•Ra is a controlling parameter,if the Ra value changes then the process it controls has
changed, e.g.Cutting tip, speeds, feeds and cutting fluid (lubricant).
•Ra is the most commonly used parameter in industry and is available in the simplest
and lowest priced instruments from all manufacturers.
•The averaging nature of Ra makes is a stable parameter which is not influenced by odd
or spurious spikes or scratches.
•For extremely fine surfaces Ra is not sensitive enough to pick out the odd or infrequent
defects that are important - See Rq
•The Primary version Pa is often used on very short surface such as ‘O’ ring grooves
where filtering would remove relevant detail affecting the performance of the seal.
•The Waviness version Wa can predict the performance of larger scale sealing faces as
those on gaskets such as cylinder heads. There is not enough compliance in the
components structure to flatten out large waviness features and thus the seal may fail.
Parameters
Rq (rms) - Applications
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•Rq has the effect of magnifying single or odd spikes and valleys, thus making it a
parameter which differentiates between very smooth surfaces with similar surface with
non typical marks or defects.
•For statistical work, Rq values are more meaningful than arithmetic averages ones. This
parameter is not used very much in general engineering, but is used more in the optical
and electronic substrates industry due to it’s ability to detect spurious peaks and
valleys.
•High Rq values on mirrors or lens surfaces will signal potential image quality reduction
and or local distortions.
•The Primary version Pq is used to assess the quality of seal in ‘O’ Ring Grooves and
the interaction between the rubber and metal surfaces.Such short length surfaces do not
require the normal roughness filters as they would remove relevant detail.
Parameters
Rt - Applications
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• Rt is the maximum peak to valley height of the profile in the evaluation length (ln),
however because this is a peak parameter it is subject to large variations and can be
unstable.It shows the extreme limits of the profile - but they may not be co-incident.
• Singular large peaks can also penetrate oil lubrication films increasing wear , debris
and damage to sliding surfaces.
• Electrical contact effectiveness and the risk of arcing or sparking from singular non
typical peaks.
• The Primary version Pt is used to quantify the overall Form Error of a component or
surface.
• Pt is also used in ‘O’ ring grooves where the surface is very short and filtering
becomes meaningless, to assess the adequacy of the surface to seal properly.
Parameters
Rp - Applications
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• Rp is the maximum height of the profile above the mean line within a sampling
length divided by n sampling lengths.
• Peaks are important when considering friction and wear properties, as the
interaction between surfaces concentrates around them. The presence of peaks can
make dimensional measurements on components that are subjected to wear
unreliable, as wear removes the peaks that were originally included in the
dimensional measurement.
Parameters
Rv - Applications
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• Rv is the maximum depth of the profile below the mean line within a
sampling length or averaged over ‘n’ sampling lengths.
• Singular large peaks can also penetrate oil lubrication films increasing wear , debris
and damage to sliding surfaces.
• Singular large peaks can also penetrate oil lubrication films increasing
wear , debris and damage to sliding surfaces.
• For a smooth waveform the values of these parameters will be similar to each
other.
• RSm can often be equated to the feed rate of a lathe or grinding machine ,
and in conjunction with RS can be used to monitor tool or grinding wheel
condition or material structure changes.
• RSm is also useful for deciding on the correct filter, for further information on
this subject consult the Taylor Hobson Surface Texture Parameter Guide or
ISO 4287 - 1997.
Parameters
Rmr - Applications
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• The Material Ratio (Rmr) is the ratio, expressed as a percentage, of the length
of the bearing surface at a specified depth into the profile, with respect to the
profile length. Although the Material Ratio parameter simulates the effect of
wear, it cannot normally replace actual running-in tests. This is because:
• Conversely an increase in the surface hardness of the workpiece can cause brittle
fracture and the cutting tool tip which will give a more peaky surface - the Rku value will
increase in this case.
• Often used in conjunction with Rsk (skewness) to monitor wear (e.g. engine wear) in
research projects.The effectiveness of oils and lubricant additives can be monitored from
the change of surface profile over extended periods.
• Surfaces with high Kurtosis are more difficult to clean and are thus prone to
contamination and important feature in liquid , chemical , photographic and other mass
process industries. Rku - Kurtosis - Sharpness
Forming, Casting,
Extrusion
Machining Processes
Cutting Tool - Primary & Secondary Cutting Edges
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Machining Processes
Surface Produced By Curved Tool
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Machining Processes
Built-up Edge as Function of Speed & Tool / Chip Temp.
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Machining Processes
Diamond Turning
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When Burnishing follows Cutting, the Surface Finish can be very fine.
SF Standards
Machining Processes
Milling
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t=34.501656mm
l=80mm
r-t
r=110mm
t=1.833462mm
l=20mm
r-t
r=110mm
l=20mm
r=109.9705mm