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Roles and Motivations for Roundness Instrumentation Metrology

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Chrome Publishing
Journal of Control Engineering and Instrumentation
2015, Volume 1, Issue 1, pp. 11-28

Research Article Roles and Motivations for Roundness Instrumentation

Metrology
Author:
Salah H.R. Ali
Engineering and Surface Metrology Laboratory, National Institute for Standards (NIS), Giza, Egypt

Correspondence:
Salah H.R. Ali,
SalahAli20@yahoo.com;
Dr_Salah@nis.sci.eg

Publication Date:
18 March 2015

Keywords:
Roundness;
Coordinate Metrology;
Surface Coating;
New Instrumentation
Abstract Measurement plays a key role in human’s life. Without measurement there will be
no human life environment. Engineering science and technologies with their applications
based on measurement, allow for decision of the development of our civilization. The role of
metrology is constantly increasing, especially in such fields as industry, energy,
transportation, education, health, agriculture and trade even ethics. The BIPM (Bureau
International des Poids et Mesures) has established the world day of metrology in the May
th
20 every year. In 2015, the world day of metrology has adopted the theme “Measurements
and Light”. This is due to mark the passage of the thousand years anniversary for authorship
Ibn Al-Haytham book in the optics. The organizers of this event are professional
organizations, communities, educational organizations, non-profit ones, technological clusters
and platforms, but also private sector. The aim is to increase the social consciousness about
the role of standardization and metrology in knowledge background of our civilization
globalization. This sort of recognition is necessary as a needed component of the
development process of societies. Introduction of new technologies, like completely new kind
of design, new diagnostic and identification methods, new sources of energy, etc., must meet
with social acceptance. On the other hand, development of life infrastructure will be effected
by obstacles. In Egypt, the professional events, technical, trade fairs and outreach ones, are
organized in the framework of the World Metrology Day 2015 by NIS under the umbrella of
the Egyptian Ministry of Scientific Research. This paper summarizes the basic roles and
motivations in roundness metrology issue combined with the organization of the occasion of
the anniversary of the world metrology day globally and in Egypt. Moreover, latest
technologies of new generation for roundness measurement instrumentation have been
discussed. Importance of roundness in engineering industries has been presented. Extended
version of this paper will published in Arabic. The paper is a part of a cycle of articles devoted
to simplify and understand roundness metrology development through analysis of global
processes.

1. Introduction

Light is the base of optic science, comes from outside the Earth is the province of Astronomy. Optic has become
one of the vital requirements for the Advancement of metrology systems. From earliest times, people observed
the succession of night and day, the waning of the moon, and the relation of the constellations to the seasons on
Earth. Early astronomers were needed to produce scientific calendars to mark the passing of time. The great truth
of Allah when said: "In the creation of the heavens and the earth and the alternation of night and day are signs for
men of understanding" verse 190 of Surah Al-Imran.

th
The year 2015 marks the 1000 anniversary of the appearance of a remarkable seven volume treatise on Kitab
Al-Manathir (Book of Optics) written by Abu Ali Al-Hassan Ibn Al-Haytham. The Arab polymath Ibn Al-Haytham
was born in 965 in Basra city (Southern Iraq). He lived in Iraq and Egypt. Ibn Al-Haytham is often referred to as
the first real scientist, whose works were based on careful experimentation and rigorous recording of his results.
His greatest work, the Kitab Al-Manathir is a real science textbook, with detailed descriptions of experiments,
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including the apparatus and the way it was set up, the measurements taken and the results. These were then
used to test his theories, which he developed using mathematical (geometrical) models into 7 volume books.
Books 1 to 3 are devoted to the physiology of the eye and the theory of perception. Books 4 to 7 cover physical
optics. The work debunks classical theories which maintained that light from the eye illuminated an object, and
demonstrates that light is reflected from an object to the eye. Ibn Al-Haythem also explained the phenomenon
“moon illusion” and interpretation (where the moon appears larger near the horizon than when higher in the sky),
understood the phenomenon of light travelling at different speeds in different media, introduced the concept of
atmospheric refraction (the bending of light received on the surface of the earth from celestial bodies), carried out
some of the first experiments on the dispersion of light into its constituent colors, studied shadows, rainbows and
eclipses, and developed the mathematical equations to explain the reflection of light from curved mirrors. He went
on to write 25 works on astronomy, including treatises on cosmology, astronomical observation and calculation,
and technical applications such as the determination of meridians, the direction of Mecca and the design of
sundials. Ibn Al-Haytham's influence on experiment and theory in optics is truly remarkable. He is considered the
father of modern optics, ophthalmology, experimental physics and scientific methodology [1-2].

Kitab Al-Manathir flows through about 500 pages of fascinating scientific texts strictly and summarized the author
ideas. While from the good written, the reader almost feeling hear the voice of the author. Thus, if the American
scientific journalist "Jennifer Ouellette" had read a few pages of this old great book puts the screenplay for the
scientific movie magician. Ouellette (born in 1964) is working as an American science journalist. Her writings are
aimed at mainstream audiences unfamiliar with complex scientific issues. Ouellette is the former director of the
Science & Entertainment Exchange, an initiative of the National Academy of Sciences (NAS) designed to connect
entertainment industry professionals with top scientists and engineers to help the creators of television shows,
films, video games, and other productions incorporate science into their work [3].

Nowadays, metrology plays a basic key role in handle daily life since ancient times. Let alone about the
importance of metrology in modern industrial applications, especially geometrical metrology. Geometrical form
metrology of engineering features is vital branch in the dimensional metrology. Dimensional metrology is the
oldest metrology branch in the worldwide began at the hands of the ancient Egyptian Pharaohs on the Giza land
in Egypt. Where the metrology word comes from two words are "meter" and "ology". Meter is the unit of length
quantity. Ology is the Greek word means science. Dimensional metrology can be used in design, manufacturing,
inspection and diagnostic methods for any system besides our dealing in buying and selling daily. Accurate and
precise measurements in dimensions are necessary to investigate the right, high performance, safely,
comfortability and beauty requirements to satisfy the human satisfaction. Geometry is the most important science
and not easy in dimensional shapes. Dimensional geometry deals with physical space, the kind that you have
been used since birth. Things we see around us cannot see without geometry. All these things concern geometric
objects almost always in relationship to one another that sometimes requires us to make sense of it all. In other
words, we use dimensional metrology for try to solve geometric problems in engineering science. Dimensional
geometry deals with manually solving problems in 3D geometry by generating 2D. Dimensional geometrical
specifications are wide research topic all around the world. Study of geometrical parameters is important because
there significant influence on the design, performance and quality. The coordinate measurement system has been
used to uniquely determine the position of a point or geometric element and complex forms. Geometry of form,
location, position or orientation has been performed for the basic geometric elements and forms analyses. The
geometrical specifications are commonly used in the design, manufacturing, special extended for product quality
according to ISO Standards. Standard is necessary to create global common specifications. Importance of the
standard of engineering applications saving best performance of products starting on the following basic steps [4]:

• Describe what an engineering drawing in production.

• Explain the importance of an engineering drawing.
• List four consequences of engineering drawing errors.
• List the two primary dimensioning and tolerancing standards used globally.
• Describe which ASME standards cover dimensioning and tolerancing.
• Describe the role of dimensioning and tolerancing standards.
• Identify which dimensioning and tolerancing standards in design.

On the other hand, the process capable tolerancing methodology (PCT) requires that the design engineer verify
that each assigned tolerance be process capable. PCT is the one activity which links design, manufacturing and
quality. It must passing through accurately measurements. These activities are part of any product development
process to succeed in the quality. Manufacturing and quality comes after gathering massive amounts of

Journal of Control Engineering and Instrumentation 12

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measurement results. The PCT methodology is illustrated in Figure 1. It is shown against the background of the
product introduction process, illustrating phases of operation, including verification phase using measurement.
The process involves setting process capability targets for the design characteristics, measurement process,
assessing process capability or allocating process capable tolerances based on process variation and assessing
the effects of design geometry and material on tolerance capability. Therefore, we can say that the dimensional
specifications of product design provide estimates of what the next process will require to ultimately produce
desired finished product specifications. In another word, tolerance revisions and adjustments are a key step in the
validation process of a new product. This will achieved after rely accurate measurements in accordance with
standard specifications.

Figure 1: PCT Methodology Including System Validation Using Accurate Measurement [5].

Standard is necessary reference to promote common interpretation practices. The geometrical product
specification (GPS) standard is an international standard to be regarded as a general GPS standard. Sometimes
is called geometric dimensioning tolerancing (GT&D). The ISO 1101:2005 is manly concentrated on the
geometrical product specifications (GPS), geometrical tolerancing (GT) and tolerances of form, orientation,
location and run-out. The ISO 1101:2005 include: scope, normative references, terms and definitions, basic
concepts, symbols, tolerance frame, toleranced features, tolerance zones, datums, supplementary indications,
theoretically exact dimensions, restrictive specifications, projected tolerance zone, free-state condition,
interrelationship of geometrical tolerances, intersection planes, orientation planes, and definitions of geometrical
tolerances. The basics fundamentals of geometric dimensioning symbols are classified as shown in the Figure 2
[6].

Figure 2: The Standard Categories of GD&T Symbols [6]

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The first group of standard symbols defines the geometrical form of the component include straightness, flatness,
roundness (circularity) and cylindricity. Simple definitions of GD&T are described as follows:

• Straightness is the tolerance of form which specifies tolerance limits for line elements on a surface, a
central axis, or a median plane. It is the only form control that may be applied to either a surface.
• Flatness of a surface has a tolerance zone formed by two parallel planes separated by the tolerance value.
• Roundness is a tolerance of form that checks the periphery of any circular cross section taken
perpendicular to the axis of a cylinder or cone, or through the center of a sphere to ensure that all elements
are within a two concentric circle tolerance zones.
• Cylindricity is a tolerance of form that checks cylindrical features only. All circular and longitudinal elements
on the surface of the cylinder must lie within two concentric cylinders separated by the value of the
cylindricity tolerance which is measured on radius.

The next group "orientation" focuses on geometrical orientation as follows:

• Angularity is represented by two lines/planes connected at an angle within a rectangle and gives the angle
that two lines form in relation to each other.
• Perpendicularity is the symbol for perpendicularity between two lines connected at 90 degree angles within
a rectangular box and indicates how closely the connection between two parts approaches a ninety degree
or right angle.
• Parallelism is the symbol for parallelism for two parallel lines/planes within a rectangle and defines a key
parameter where two lines within a design will not ever meet.
• Squareness is the symbol for square two parallel lines/planes within a rectangle and defines a key
parameter where two lines within a design will not ever meet.

Geometrical location, runout and profile are the last group as follows:

• Concentricity is indicated by two concentric circles or two circles where one is smaller than the other and is
inside the larger circle all within a rectangle and means that they share the same center axis.
• Symmetry is the symbol for three parallel lines with different lengths all within a rectangle and means and
defines the relationship between different measurements within a part.
• Total runout is represented by a rectangle with a single or double arrow within a rectangle and specifies
the amount of inaccuracy allowed in a rotating mechanical system. Basically runout is measured by
rotating a part, (keeping a fixed plane to the datum that is given in the symbol) and measuring how mush
variance is in the part using a gauge. The part cannot go above or below a given limit.
• Profile symbol is a half circle within a rectangle and describes the topology of a part.
• Runout–controls the amount of surface variation on a part rotating about a datum axis

All of these definitions, symbols and more beside roundness are available for designer, metrology and production
engineers to describe all the key parameters for components, parts and equipment that are used in the design,
measurement and production of mechanical systems.

Addition of the need always to develop, the American society for mechanical engineers (ASME) has developed
the standards of geometric dimensioning and tolerancing which commonly used in the automotive industry on all
engineering documents and drawings [7]. This development includes change in standards such as structural or
formatting changes, new symbology, terminology or definition changes, non-uniform zone profile and custom
datum reference frames. The ASME Y14.5-2009 is the most recent version of the GPS specification [8]. This is
typically used on mechanical engineering drawings to define the size, shape, feature relationships, and allowable
variation of a workpiece. This development concentrated on the dimensioning of rounded-ends, spot-faces,
chamfers and slotted holes as shown an example in Figure 3. Typical virtual and resultant condition boundaries
(envelope) of internal form are presented in Figure 4 [9]. Where MMC is the maximum material condition limit and
LMC is the least material condition limit [10]. The development process targeted the follows:

• Engineering and surface laboratories in the national metrology institutes (NMIs),

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• Universities and higher technical institutes,

• Industries represented in aerospace, automotive and earth moving machinery etc.,
• Manufactures represented in office furniture, photographer, office reproduction; dimensional analysis
software.

(a) Spot-Faced Holes (b) Partially Rounded Ends

Figure 3: Technical Development in the Drawing of Geometric Dimensioning [9]

Figure 4: Development in the Virtual of Geometric Dimensioning [9]

2. Roundness Metrology

Roundness is an essential geometrical feature in precision engineering especially for rotating parts. Roundness
feature (in European definition) is called circularity (in American definition). Roundness form in the dimensional
metrology is the very important feature of quality control for mechanical products. Roundness is an essential
geometrical feature especially for aerospace, nuclear reactors and automotive applications, which need accuracy
and precision within minimum deviation in the measurement. In manufacturing metrology, the roundness feature
can be checked using modern intelligent systems. In addition, many dynamic operations require examining
roundness form of rotating parts to ensure their validity to work by roundness instruments which describe the

Journal of Control Engineering and Instrumentation 15

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condition on a rotating surface, where all points of the surface must intersect. The production quality of rotating
parts is typically influenced by many different parameters related to workpiece finishing, environmental interaction,
measuring machine performance and operator experience. The importance of the study for roundness deviation in
measurement of circle feature is a vital part to avoid the excessive lateral or axial runout deviation of rotating and
reciprocating parts during machining process, dynamic operation and calibration method. The calibration of
standard reference artifact that is used in the accuracy verification of roundness instrument is also very an
important requirement. Therefore, the verification accuracy of software strategies for measuring machine
becomes very important [11].

Standard measuring methods for roundness measurement are commonly using in CMM, continuous (scanning)
and discontinuous (discrete) method. Continuous method is individual mode, because positions of data results are
consecutive at measuring surface. Therefore, the idea of roundness measurement using Talyrond machine builds
on the way continuous (scanning) method. Generally, there are many sources of error in measurement methods.
Researchers found: it is difficult to separate the error resulting from the stylus vibration and the measured surface
in roundness measurement [12-14]. High attention is dedicated for evaluation methods to be suitable use for
roundness measuring instruments.

The quantum metrology is the physical study of high-resolution systems and highly sensitive measurements
depends on quantum theory to describe the physical systems, particularly exploiting quantum entanglement [15],
where the measurement of deviation error is classified as an approach of quantum metrology.

2.1. The Basic Roles in Roundness Measurement

The history of roundness measurement systems is reviewed in this section, and then the stages of software filters
that use in the Talyrond machine are also reviewed. In order to gives a scientific background for readers.
Historically, roundness measurement was based on use of simple tools such as dial indicator. While from the
achievement of the industrial revolution, roundness instruments were setup based on one of two types of
machines. The first one is called Talyrond machine, model RTH (Rank Taylor Hobson Ltd). While the second way
is coordinate measuring machine (CMM). Roundness measurement using Talyrond machine is based on one of
two versions of configuration. Configurations of Talyrond machine have either rotating table or rotating spindle
(hydrostatic). The most common type is the hydrostatic spindle configuration version. The rotating pick-up version
of the instrument was first made; this was termed ‘RTH Talyrond-1’ was developed later. The instrument like RTH
Talyrond-TR 73 HPR (high precision roundness) machine becomes one of important tools in national metrology
institutes (NMIs) [16-17]. The standard RTH Talyrond-TR 73 machine has three accurate orthogonal axes and
equipped with high sensitive touch probe. Therefore, it is much distinguished of Talyrond-TR 73 machine that the
force of touch probe tip to the object surface is very small up to less than one Newton. The Talyrond-TR 73 probe
cantilever is brought into contact with the inner or outer circular surface of object being measured at a recorded
position. In the measurement process, the probe of stylus profiler senses the surface height through mechanical
contact directly, while the stylus traverses the peaks and valleys of the circular surface of the object with very
small contacting force. The horizontal motion of the stylus tip is converted to an electronic signal by a transducer.
A number of points are taken around the component and these are then combined in computer software to
determine the roundness form of the object, which represents the curricular surface profile. The study of the
Talyrond-TR 73 machine software is very important from the metrological point of view to find an optimum strategy
in roundness measurement. Therefore, the data analysis of the Talyrond-TR 73 software can contribute
significantly to the roundness measurement accuracy. It can be said that some influencing parameters of
measuring machine software strategy and metrolgest experience have effective reactions on the quality of
measurement.

Beside the aforementioned approach, the standardization of filtration techniques is also important issue. The
ISO/TS 16610 presents a category of modern advanced filtration techniques technology in surface metrology.
These filters include Gaussian filter, spline filter, robust filter, morphological fitter, wavelet filter, cascading filter
and other segmentation filters [18-19]. It provides a powerful and useful software toolbox of filtration techniques,
allowing metrologists to analyze various surface characteristics. Most of fitting filters could date back to two basic
traditional filtration techniques emerged since 1950s, i.e., the Mean-line based system (M-system) and the
Envelope based system (E-system) [18]. The M-system generates a reference line passing through the measured
profile from which the surface waviness was assessed. The reference line was called the mean line due to the fact
that the profile portions above and below the reference line are equal in the sum of their areas, see Figure 5.

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The first practical mean-line filter used in surface characteristic measurement is the analogue filter proposed by
Reason in 1961 [20], which was constructed by a two-resistor-capacity (2RC) network. However, this 2RC filter
was suffered by the phase error and profile deformation due to filtering. Whitehouse and Reason [21] simulated a
research work in 1963, the 2RC filter digitally. This work described the filter using a weighting function that
depended on the cutoff wavelength. While, Whitehouse in 1967 [22], made digital filters and introduced phase-
corrected filter also. While, the phase-corrected digital filter was still has some problems, such as it badly distorted
the profile at the end. After that, the Gaussian filter was chosen as the new filter for separating differing
wavelengths [23]. The Gaussian filter is a typical mean-line based filter whose process is a convolution operation
of the surface under evaluation and the Gaussian weighting function [18]. In 1965, the E-system was initially
developed by H. von Weingraber [24]. The E-system is acting totally differently than the M-System. It appeared as
a large disk rolling across over the profile from above, and the covering envelope formed by the rolling disk
followed by the compensation of disk radius. The envelope was viewed as the reference profile. The E-system
gains its basis from the simulation of the contact phenomenon of two mating surfaces, whereby peak features of
the surface play a principal role in the interaction operation, see Fig. 6. Between 1955 and 1966 [25], some
arguments between the M-system and the E-system in terms of their capability and superiority have been made.
When that time, the difficulty appeared in building practical instruments for the E-system as two elements were
needed: a spherical skid to approximate the enveloping circle" and a needle-shaped stylus moving in a diametral
hole of the skid to measure the surface waviness or roughness as deviation with respect to the generated
envelope. The standing objection from Reason [21] was that the choice of the rolling circle radius is as arbitrary as
the choice of cutoff in the M-system, and no practical instrument using mechanical filters could be made.
However, the facts proved that the M-system and the E-system are complement to each other, rather than
compete against each other and none of them can fulfill all the practical demands by themselves alone [18, 26].

Figure 5: The Mean-Line System (M-system) Figure 6: The Envelope System (E-system)

Motivated by modern product design plans, modern products and measurement machines are equipped with
sophisticated surfaces to achieve desired functions. In response to these technology advancements, filtration
techniques are motivated to be enhanced in their capability and performance with dealing with functional surfaces.
Thus, the M-system was greatly enriched by incorporating advanced mathematical theories. The Gaussian
regression filter overcame the problem of end distortion and poor performance of the Gaussian filter in the
presence of significant form component [18, 27], while the robust Gaussian regression filter solved the problem of
outlier distortion in addition [28-29]. The spline filter is a pure digital filter, more suitable for form measurement
[30]. The robust spline filter is insensitive with respect to outliers due to their closed loping [31-32]. Nowadays,
research funding is still going on in full swing to innovate combined filters by software designers in R&D
departments [18, 33-36]. The E-system is also experienced significant improvements [33]. By introducing
mathematical modeling, morphological filters emerged as the superset of the early envelope filter, but offering
more tools and capabilities. The basic variation function of morphological filters includes the closing filter and
opening filter. Morphological filters could be combined to achieve superimposed effects, referred as the alternating
symmetrical filters leads to scale-space techniques [34]. On the other hand, Gaussian- and 2CR-filter are currently
standardized fitting filters [37] and still working in newly instruments such as CMM machine and Talyrond-TR 73
machine because their simplicity, accuracy and flexibility. The transmission characteristics of amplitude wave
response for 2RC- and Gaussian-filter are given in frequency domain as follows [38].

2.1.1. 2RC Filter

2RC low pass filtering is based on the amplitude transmission function given in Figure 7. The cutoff frequency in
undulations per revolution (upr) is defined as the frequency at which the transmission is 75%.

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Figure 7: Characteristic for 2RC Filter Having Cut-Off Frequencies, fc = 15, 50 and 150 upr.

2.1.2. Gaussian Filter

The Gaussian filter transmits waves from 1 upr and attenuates profile undulations progressively in the undulation
region around the characteristic cut-off upr number. The cut-off frequency is defined as the frequency at which the
transmission is 50%, see Figure 8. The attenuation function (transmission characteristic) is given by the following:

Where: aO = amplitude of sine wave undulation before filtering. a1 = amplitude of a given sine wave of frequency,
f, after filtering. fc= cut-off frequency of the low pass filter. f = frequency of a given sine wave.

Figure 8: Characteristic for Gaussian Filter Having Cut-Off Frequencies, fc = 15; 50; 150; 500; 1500 upr.

3. Background and Motivation

Great benefits of manmade have been achieved from alphabet to wheel invention passing rotating parts. The final
quality of an engineering rotating product as used in airplane and motor vehicle is influenced by many different
factors [39-41]. The required tolerances for dynamic rotating parts continuously have to be very fine, whereas the
complexity of work pieces increases. While, the selected technique for measurement have to be applied in order
to achieve precision measurements and sufficient accurate results. The measurement quality of TR-73 instrument

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can be resultant related to the operator behavior, environmental interaction, work piece finishing, and the machine
accuracy. It can be assume that some influence factors of operator behavior and TR-73 machine software
accuracy have effective reactions on the measurement quality. There are two disadvantages of the stylus
instruments that the probe tip may damage the scanned surface (depending on the hardness of the surface
relative to the stylus normal force) and the stylus tip size [40]. Wherefore, distinguish of Talyrond TR-73 machine
that the force of touch probe tip to the sample surface is very small up to less than one Newton. Moreover, the
author et al. and other researchers find, it is difficult to separate the error resulting from the stylus vibration and
the result of measured surface in roundness measurement [41-43].

Roundness feature means the change in radius of object and usually referred to as "circularity" or "out-of-
roundness". The measure of roundness is expressed as the difference between the smallest and largest
diameters which can be expressed by peak and valley in metrology. To assist this measurement, a mathematical
reference circle is used through machine software. The position of the reference circle to the measured profile and
its center are not arbitrary, and should be selected by the metrology engineer to ensure the measurement result
that meets required specifications [44]. The software package of Talyrond machine includes specific important
strategical techniques of measurement can be used in roundness assessment.

3.1. Fitting Filters

Other important parameter in the TR-37 machine during measurement is the fitting filters. Generally, fitting filters
are used to separate the number of lobes exiting a component’s of measured surface. These use to eliminate
sources of error and an attempt to avoid one or more reasons like swarf machining. It also uses to remove the
unwanted noise signal from the measurement results. Noise often results from vibration dynamics in the
machining process and from other processes or from the measurement instrument itself. Moreover, filters are
used for separate low-frequency from high-frequency data signals to simplifying the evaluation of measurement
results. Filters are also used for separate different lobbing frequencies to evaluate the process and to assure
highly reliable measuring results.

3.2. Fitting Spectral Wave Responses

Other important parameter in the TR-37 machine based on the operator use is the suitable selection of spectral
wave numbers in measurement strategy. The frequently undulations per revolutions are the number of surface-
profile deviations from a true circle in one revolution. Electronic filters, with different frequency responses of
spectral waves are used to evaluate the surface profile. Standard filter responses are used in the rages of 1 to 15,
1 to 50, 1 to 150, and 1 to 500 upr. Figure 9 illustrates the electronic ranges of fitting filters with varying frequency
responses are used to evaluate the roundness feature in measurement. For example, a 1 to 50 filter removes
undulations above 50 per revolution from the measured feature profile. Without filtering, the high frequency waves
can make evaluating the out-of-roundness difficult because they can conceal the lower frequencies. Often the low-
frequency waves are of larger amplitude and thus of greater importance to the manufacturer.

Figure 9: Electronic Ranges of Fitting Spectra Wave Numbers Responses in the Roundness Profile

LS algorithm MZ algorithm MC algorithm MI algorithm

Figure 10: Reference Software Fitting Circles Used in Roundness Measurement

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3.3. Fitting Algorithms

Fitting algorithm is one of the most important themes in modern dimensional metrology machines. Fitting
algorithm software is particularly true of coordinate measurement systems such as CMMs and Talyrond machine.
It works based on computations and convert the collected raw data to report results can be a major source of error
in measurement techniques. The role of geometric fitting for roundness feature is to reduce measured point
coordinates to curve and surface parameters. The resulting curves of surface are called the substitute geometry
for the roundness measurement. In further processing, the computed parameters are compared to the tolerance
limits for the measured part. Thus, it was found that the error estimation of the computed substitute geometry is
important to determine the quality of a measurement. There is no obligatory standard or accepted method for
evaluating the effects of fitting software on the error estimation for Talyrond measurements. ISO/TS 12181-1 and
12181-2 standard defines four mean specific reference fitting software methods [45-46]. Fig.10 shows the basic
idea of four internationally defined fitting algorithm techniques of circles that used in roundness measurement in
NMIs and industry today [39, 47]. Least square circle (LS) is well-suited for establishing a datum axis; maximum
inscribed circle (MI) is the largest true circle that will fit inside the measured profile; minimum circumscribed circle
(MC) is the smallest true circle that will contain the measured profile; and minimum zone circles (MZ) are two
concentric circles having the same center, which enclose the measured profile and have a minimum radial
separation. Four fitting algorithms for roundness are included in this package, see Fig.10.

3.3.1. Least Square Circle (LS)

For least squares best fitting, we start off with the basic linear equation of eccentric circle as follows:

r( ) = R + A cos + B sin

For a set of measured data points, (R, A, B) are obtained as the following:

Where ri represents the individual measured data points with index i, φi is the angle of data points, and n is the
number of data points.

3.3.2. Minimum Zone Circle (MZ)

The minimum zone limacon can be visualized by replacing two concentric figures generating a zone by the
equivalent form of a single figure and a zone width “h” referred to that figure. The single reference limacon will be
defined with a symmetrically placed zone ± h. The MZ problem then becomes that of minimizing h subject to the
constraints as follows:

R + A cos i+ B sin i + h ≥ ri ;

R + A cos i+ B sin i - h ≤ ri

for data points in polar form (ri i) and i= 1, 2, 3, … n.

Figure 11 Shows the Minimum Zone Fitting Result for a Set of Roundness Data.

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Figure 11: Minimum Zone Circle Fitting

3.3.3. Minimum Circumscribed Circle (MC)

The MC fit requires finding a limacon of minimum radius such that the limacon lies completely outside the data
representing the nominal circle being measured. The mathematical representation of the above definition based
on the equation of a limacon would be as follows.

R + A cos φi + B sin φi ≥ ri

Where (ri i) for data points in polar form, when i= 1, 2, 3,… n.

3.2.4. Maximum Inscribed Circle (MI)

The MI fit is one in which all data points lie outside the reference limacon. This can be viewed as an extension of
the MC fit described above, where the signs are reversed in the basic limacon equation. The formulation for the
MI limacon will be as follows:

R + A cos φi + B sin φi ≤ ri

which is essentially the same as -(R + A cos φi + B sinφi ≥ ri for all i. Fitting algorithms proposed by D.G.
Chetwynd [48] were used for the different limacon fits described above [38].

3.4. Types of Errors

In fact, machined engineering surface not have perfect form due to various error sources such as machining
process, finishing quality. Addition parameters likes measuring instrument accuracy and strategy of measurement
besides human and environmental conditions are common types affecting the result of measurement errors. The
purpose of TR-73 fitting software strategy is to determine the final fine feature of the object. There are many
different sources of errors which may influence roundness measurements [49-53]. Some typical sources of these
errors are hysteresis sensitivity, probe tip size, contacting force, spindle motions (axial, radial and tilt), alignment
of artifact, thermal drift, closing error, electrical noise, mechanical vibration and work-piece contamination [54-55].
The standard uncertainty budget of a roundness measurement using TR-73 instrument has been estimated within
1.3 nm [50]. Another research work estimates the combined uncertainty in measurement at 95% certainty to be
8.01 nm [51]. Consequently, in this work, the sources of roundness errors will be study and analyze to avoid two
main practical errors in measurement which called instrumentation error and human error. These two common

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types of errors with some others exist in all real measurement scenarios. The error at use instrumentation
generates when data points are collected due to scanning of an object surface. TR-73 hardware adaptation
induces different sources of error based on spindle error, probe system and transmutation system imperfections
led to some inaccuracies in the measured points. Measurement error in the measuring process comes mainly
from curve fit and computational resolution based on software adaptation. The human error arises when the
operator prefers impossible strategic parameters in measurement of an object. Therefore, TR-73 operator skills
and behaviors have a direct significant effect on the roundness error in future measurement. Through this
research will provide an analytical study to avoid the sources of errors which have direct impact on form metrology
in order to improve the quality of roundness accuracy in measurement method.

4. New Generation Instrumentation of Roundness Measurement

With currently production technology revolution, must know the latest technology in the measurement of
roundness features. Simply, it can be displayed as follows:

4.1. Talyrond 365

An example of modern instrument dedicated to measurements of roundness deviations by the radial method is
Talyrond 365 by Taylor Hobson as shown in Figure 12. Where the fundamental components: 1) column, 2)
horizontal arm and 3) rotary table. Talyrond 365 is equipped with an inductive sensor, whose range is ±1 μm and
its minimum resolution is 0.012 μm. The configuration of the measuring tip can be changed according to
measurement type to be conducted. In the case of roundness and cylindricity deviations the stylus is vertical and
when measurements of flatness or straightness of the face of the cylinder are to be carried out then the stylus is
horizontal [40-56].

Figure 12: Talyrond 365 System for Roundness Measurements

4.2. XENOS CMM

The new VAST gold probe form ZEISS was developed to meet maximum demands on sensitivity, accuracy in
dimensional and roundedness measurement [57-58]. One of these new types called XENOS CMM with the high
resolution scales. The coordinate measuring range is 900 x 1 500 x 700 mm with maximum permissible error is
0.3 + L/1,000 μm. The XENOS CMM stands for accuracy and future proofness thanks to the use of innovative
technologies and materials, which also pushed the limits of technology. At first glance, the new measuring
machine clearly distances itself from its predecessor ZEISS PRISMO ultra as shown in Figure 13. The mechanical
concept was derived from the successful ZEISS CenterMax inline system: the reference machine for production
measuring. New Computer-Aided Accuracy (CAA) acceptance methods and additional CAA corrections are
playing an increasingly vital role in achieving maximum accuracy.

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Figure 13: The New VAST Gold Probe form ZEISS "XENOS CMM" [58].

5. Importance of Roundness in Industry

Roundness measurement is a wide necessary parameter for rotating elements in mechanical systems diagnosing,
consequently, their evaluation are important. Geometry of roundness and there significant influence on practical
tests are presented in this paper. Some measurement results of roundness using Talyrond machine and CMM
machine have been discussed. Many spare part components in automotive industry must evaluate before used by
roundness measurements, see Figure 14.

Figure 14: Common Used Spare Parts Components in Automotive Industry

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Figure 15: Automotive Petrol Engine as a Harmony Complete Set

6. Conclusion

This article has been able to summarizes and discuss the roles, motivations and update of instrumentation
technology in strategic roundness metrology issue occasion of the anniversary of the world metrology day globally
and in Egypt. The conclusion can be drawing as follows:

1- Geometrical measurement devices are the most important engineering-dimensional measuring devices.
Correct measurement of roundness form deviation for machine parts is the matter of great importance in
modern manufacturing technology.
2- Really, accurate and precise in measurement for roundness fits and tolerance gives great harmony,
especially in airspace, missiles and automotive industries in the present era.
3- Hopes to see an increase in the cultural and technical awareness among professionals of the importance of
roundness measurements.
4- We hope to see a marked improvement in the explanation and analysis of roundness and results of
measurements of the benefit of the mechanical industries in the future.
5- All researchers and experts are invited to joint scientific cooperation to innovated new optico-mechanical
instrument to be more accurate and precise in roundness measurement.

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