ME 3592 - Metrology and

Measurements

By
Dr S.Nanthakumar
ASP
Department of Mechanical Engineering
PSG ITech, Cbe.
Unit IV Metrology of Surfaces

Syllabus
Fundamentals of GD & T- Conventional vs Geometric tolerance, Datums,
Inspection of geometric deviations like straightness, flatness,
roundness deviations; Simple problems – Measurement of Surface
finish – Functionality of surfaces, Parameters, Comparative, Stylus
based and Optical Measurement techniques, Filters, Introduction to 3D
surface metrology- Parameters.

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Important Topics

Tomilson Methods Autocollimator

surface meter method

3
Flatness
Talysurf Devices measuring
method

1. 2. 3.

Surface finish Roundness Straightness/

Measurement Measurement Flatness
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Science of roundness

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Need for roundness measurement

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Errors in Circularity

• Many people wrongly believe that it is

sufficient to measure the diameter of a
workpiece
in several places – the difference in readings
equating to the out-of-roundness.
• Perhaps the easiest way to dispel ideas that
such a methodology is valid is the example
of measuring a British 50 pence coin.
• In Figure it can be seen that the caliper
reading when measuring the coin is identical
irrespective of the coin’s orientation, and yet
it can be seen to be “out-of-round”.

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Roundness measurement

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Errors in Circularity

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Errors in Circularity

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Sources of out-of- roundness

• Clamping distortion, spindle run-out.

• Presence of dirts and chips on clamping surface.
• Imbalance, heat and vibrations.
• Shafts ground between centers can be out-of-round due to poor
alignment of the center or deflection of shafts.
• A round bar or ring-type part held in a 3-or-5-jaw chuck is
compressed at the points of contact.

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Measurement of roundness – reference Circles

1.Least square Circle

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2. Minimum Radial separation Circle

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3.Maximum Inscribed Circle

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• 4.Minimium Circumscribed Circle

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Devices for measurement of roundness
2. Rotating on Centers
1. Circumferential confining gauge

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3.Assessment using V-block

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4. Roundness measuring 5. Roundness measuring
spindle-fixed table spindle-overhead spindle

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Roundness Measurement – Taylor Hobson

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Straightness
Measurement
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Definition of Straightness

• A line is said to be straight over a given length, if the variation of the

distance of its from two planes perpendicular to each other and parallel to
the general direction of the line remains within the specified tolerance
limits

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Straightness Measurement

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Why Straightness Measurement?

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Measurement methods

Using Autocollimator Using straight edge

Total indicated readout Methods Using straight edge and

(TIR) test slip gauge

Using CMM Using Sprit level

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Using straight edge

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Using straight edge & Light

• For checking the straightness of any surface, the straight edge is placed
over the surface and two are viewed against the light, which clearly
indicate the straightness.

• If the colour of light be red, it indicates a gap of 0.0012 to 0.0017mm.

• If the colour of light be blue, it indicates a gap is approximately

0.0075mm.

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Using Feeler gauge

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Using Dial Indicator

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Using Laser

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Test for straightness by using Autocollimator

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Test for straightness by using Autocollimator

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Cumulative error ; and error w.r.t. straight edge

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Flatness Measurement
Flatness Measurement

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Flatness Measurement

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Application of flatness

Positioning

Sealing Mating

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How to make a surface flat?

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Flatness Testing - Autocollimator

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Flatness Testing

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Measurement of flatness

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Flatness measurement using optical flat

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Surface Finish Measurement

Department of Mechanical Engineering ME3592 METROLOGY & MEASUREMENTS

Taylor Hobson

Taylor Hobson began in 1886 when

brothers William and Thomas
Smithies Taylor started a company to
make lenses.

Department of Mechanical Engineering ME3592 METROLOGY & MEASUREMENTS 42

Science of Golf ball

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Science of swing

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Why Surface finish?

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Reasons for Controlling Surface Texture

1. To improve the service life of the components

2. To improve the fatigue resistance
3. To reduce initial wear of parts
4. To have a close dimensional tolerance on the parts
5. To reduce frictional wear
6. To reduce corrosion by minimizing depth of irregularities
7. For good appearance

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Applications of Surface Finish

Shaft and Pulley Assembly

Engine Block

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Applications of Surface Finish

Medical Technology Automobile

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Applications of Surface Finish

Dental Implants Hard Disk Drive (HDD) Component

Cleaning

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Factors Affecting Surface Roughness

1. Vibrations

2. Material of the work piece

3. Type of machining.

4. Rigidity of the system consisting of machine tool, fixture

cutting tool and work

5. Type, form, material and sharpness of cutting tool

6. Cutting conditions i.e., feed, speed and depth of cut

7. Type of coolant used

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Different finishing Process
Grinding Process Lapping Process

Honing Process ME3592 Metrology and Measurements 52

Classifications of Geometrical Irregularities

1.First Order

• Irregularities caused due to lack of straightness of guide ways on which

the tool moves.

• Surface irregularities arising due to deformation of work under the

action of cutting forces, an due to the weight of the material itself.

2.Second Order

Irregularities caused due to vibrations.

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3.Third order
Due to machining itself (Characteristics of the process).

4.Fourth order
Arising from the rupture of material during the separation of
the chip.

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Elements of Surface Texture

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Roughness

• The irregularities on the surface of the part produced can also be grouped
into two categories:

(i) Primary texture (Roughness):

• The surface irregularities of small wavelength are called primary texture or

roughness. These are caused by direct action of the cutting elements on
the material i.e., cutting tool shape, tool feed rate or by some other
disturbances such as friction, wear or corrosion

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Waviness

(ii) Secondary texture (Waviness):

The surface irregularities of considerable wavelength of a periodic character
are called secondary texture or waviness. These irregularities result due to
inaccuracies of slides, wear of guides, misalignment of centers, non-linear
feed motion, deformation of work under the action of cutting forces,
vibrations of any kind etc.

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Surface Roughness Specification

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Surface Roughness Specification

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Surface Roughness Symbols

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?

?
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Evaluation of Surface Finish

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Evaluation of Surface Finish

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Evaluation of Surface Finish

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Evaluation of Surface Finish

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Evaluation of Surface Finish

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Methods of Measuring Surface Finish

1. Surface inspection of comparison methods.

2. Direct instrument measurements.

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1. Surface Inspection of comparison Methods

(i) Visual Inspection

(ii) Touch Inspection

(iii) Scratch Inspection

(iv) Microscopic Inspection

(v) Surface photographs

(vi) Micro-Interferometer

(vii) Wallace surface Dynamometer

(viii) Reflected Light Intensity.

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2. Direct instrument Measurements

(i)Skid and stylus

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(iii) The Tomlinson surface meter

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The Taylor Hobson Talysurf

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(iv)The Taylor Hobson Talysurf

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3D surface metrology

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3D surface metrology

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What is surface metrology and why is it useful?

• Topography plays a crucial role in determining the mechanical, thermal, optical,

and electrical properties of materials which are used for many modern
technologies, components, parts, and products, such as motors, coatings,
electronic devices, etc.

• For example, greater surface roughness often increases the friction between two
parts in contact which may not be desirable if smooth motion is required. Greater
friction between parts can also lead to faster wear and shorter lifetimes.

• The formation of small irregularities in a semiconducting surface can induce

charge localization and non-homogenous electrical properties.

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The 3-D approach has a number of clear advantages over 2-D
practice

• The 3-D approach comes closer to describing a "real" surface and the
parameters derived posses a greater functional significance

• Since the 3-D technique takes data from an area rather than a trace, the
parameters have a greater statistical significance and less variation

• 3-D measurements are visually more effective as a characterisation tool

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Methods of surface topography
• Contact/non-contact profilometry and probe microscopy where the
topography data is gathered by a fine probe scanning across the surface.

• Optical profilometry with interferometry, focus and phase detection, or

confocal microscopy, using light.

• Scanning electron microscopy (SEM) using electrons where normally a

special software is needed to display 3D topography.

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