How do we measure surface texture?

In the past surface texture has been assessed by the judgement of the inspector either by eye or even
fingernail. In order to put a number to the surface texture, we need to use a more accurate means of
measurement. A typical surface measuring instrument will consist of a stylus with a small tip (fingernail), a
gauge or transducer, a traverse datum and a processor. The surface is measured by moving the stylus
across the surface. As the stylus moves up and down along the surface, the transducer converts this
movement into a signal which is then exported to a processor which converts this into a number and
usually a visual profile.

For correct data collection, the gauge needs to pass over the surface in a straight line such that only the
stylus tip follows the surface under test. This is done using a straightness datum. This can consist of
some form of datum bar that is usually lapped or precision ground to a high straightness tolerance. On
small portable instruments this is not always a good option and can add to the expense of the instrument.
In these cases, it is possible to use an alternative means of datum. This is a skid.

How do we separate Roughness, Waviness and Form?

In order to separate the three elements, we use filters. On most surface texture measuring instruments
we can select either Roughness or Waviness Filters.

Selecting a Roughness Filter will remove waviness elements, leaving the roughness profile for evaluation.
Selecting a Waviness Filter will remove roughness elements, leaving the waviness profile for evaluation.
Separating the roughness and waviness is achieved by using filter cut-offs.
What are filters?

Electronic or mathematical methods or algorithms which separate out different wavelengths and allow us
to see only the wavelengths we are interested in.

What is a skid?

A skid is a part of the gauge that has a radius large enough to prevent movement in and out the
roughness characteristics of the surface. The stylus and the skid are usually independent in their height
(Z) movement but move together in the measurement direction. Surface deviations are recorded as the
difference between the stylus and the skid movement in the Z direction. In other words, the skid acts as
the straightness datum ? it ?skids? over the top of the surface.

What is a cut-off?

In basic terms, a cut-off is a filter and is used as a means of separating or filtering the wavelengths of a
component. Cut-offs have a numerical value that when selected will reduce or remove the unwanted
wavelengths on the surface. For example, a roughness filter cut-off with a numeric value of 0.8mm will
allow wavelengths below 0.8mm to be assessed with wavelengths above 0.8mm being reduced in
amplitude; the greater the wavelength, the more severe the reduction. For a waviness filter cut-off with a
numeric value of 0.8mm, wavelengths above 0.8mm will be assessed with wavelengths below 0.8mm
being reduced in amplitude.

What is a sample length?

After the data has been filtered with a cut off, we then sample it. Sampling is done by breaking the data
into equal sample lengths. The sample lengths have the same numeric value as the cut-off. In other
words, if you use a 0.8mm cut-off, then the filtered data will be broken down into 0.8mm sample lengths.
These sample lengths are chosen in such a way that a good statistical analysis can be made of the
surface. In most cases, five sample lengths are used for analysis.
RMR

Material Ratio Rmr is the length of material surface (expressed as a percentage of the evaluation length
L) at a depth (d) below a reference level (c)

Material Ratio Rmr (c) is the length of material surface (expressed as a percentage of the evaluation
length L) at a depth (c) below the highest peak.

Note: Most analysis packages allow the reference line for Rmr to be set from various levels such as using
the mean line, the lowest valley, the highest peak or even from a material ratio level.

What measurement length should I make?

The measurement length is dictated by the numerical value of the cut-off, which itself is dictated by the
type of surface under inspection.
Typically, a measurement may consist of a traverse of 6-7 times the cut-off selected. Foe example, 7 cut-
offs at 0.8mm = 5.6mm. One or two cut-offs will then be removed according to the filter type and the
remaining cut-offs used for assessment. This only applies when measuring roughness.

For measuring waviness or primary profiles, the data length is chosen according to application and the
nature of the surface. In general, the data length needs to be sufficient to give a true representation of
the texture of the surface.

7.8. Error Proofing (Poka Yoke)

Error proofing is the result of using knowledge and ingenuity to create methods or devices that
prevent errors. The objective is to focus on the error/problem and identify steps / actions / tools
to minimize the probability of an error to occur.
There are 3 levels of error proofing:
• Level 1: Prevent an error from occurring at the source (e.g. one-way assemblies, automatic
calculations)
• Level 2: Detect the error as it is being made (e.g. alarms sound)
• Level 3: Stop the defect from reaching the next operation providing the mistake proof solution
is used (e.g. checklist)
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The Corrective Action process should include an assessment of the levels of error proofing utilized for
both corrective and preventive actions. Organizations should drive toward level 1