1.0 Title : M6 Roughness Measurement 2.0 Objective of Experiment : i. To understand the operation and application of the equipment ii.

To determine the roundness of the work piece 3.0 Introduction and Theory : The FORM-PC The FORM-PC is a measuring, control and evacuation software program for Formtesters. The FORM-PC controls the Formtester, records the measuring values, process the measuring values, determines the form and position deviations, documents and logs the measuring result. The FORM-PC with its three modes of operation, namely “Quick&Easy” for quick results and unexperienced users, “Teach-in Programming” for running highly complex measuring programs without any programming knowledge and “Measuring run” for running measuring programs provides solutions for any problem. Measuring Station The standard measuring station comprises the : i. Formtester All formtester are measuring machines for determining deviations of form and position on axis-symmetrical testpieces. They essentially consist of a centering and tilting table, the measuring and positoning axes, the keypad with joystick, and the EMERGENCY switch. ii. FORM-PC interface The FORM-PC interface enavles communication between the Formtester and the FORM-PC. It edits the data transmitted from the Formtester to the FORM-PC and vice versa. The interface is only required for specific measuring station combinations. 4.0 Experiment Equipment : Formtester MMQ -10, FORM-PC and workpiece

2 : Probe IMPORTANT : Probes are high–precision element which must be handled with care.1.2 Tracing force and tracing direction The tracing force is adjusted on the T2W with the knurled knob (22) such that the mark points to the first scale division above or below the zero point of the scale : . oil or any fluid to get inside the probes.1 Probe The Probe arm is first positioned vertically and then slightly inclined towards the workpiece.1 Preparation 5.1. FORM-PC and workpiece 5. Do not allow grease. The angle α should be in the range of 10 ° . 5.0 Procedures : 5.1 : Formtester MMQ -10.Figure 6. Figure 6. Probe failures are mainly caused by improper handling.

the test element (the form element to be tested on the workpiece) must be aligned. Long form elements have to be aligned with the “centering & tilting” rountie. the eccentricity is assessed.3 Turntable The turntable features centering and tilting facilities. In case the table is to be rotated manually.3 turntable and T2W 5. the centering rountine is started in which the test element is centered with respect to the C-axis in the given measuring plane. they have to be centered first with respect to the C-axis before their axes of rotation are aligned parallel to the C-axis.1.For the measuring tasks depicted in this booklet please use : For external measurements : first scale division (21) above the zero point For internal measurement : first scale division (23) below the zero point 5.1. • Do only rotate it clockwise Figure 6. For this purpose. • Do never use the rotary knobs as points of attack. This requires measurements in two planes of different height after which the eccentricity is .e. Afterwards. • Centering with the rotary knobs X and Y • Tilting with the rotary knobs A and B The measuring station indicates both the rotary knob to be used and how much it must be turned.4 Setting up the Workpiece Before measurement may commence. the operator prompting outputs information on how to turn the rotary knobs X and Y for the centering axes to reduce the assesses eccentricity. i. During the centering process.

(Read off the value at mark (9). i.4. 5. the diameter of the form element in the measuring plane (50mm).e.1.e. new measurements are necessary thereafter to correct the workpiece position once again. Enter the workpice diameter. Use the rotary knob (11) to move the probe to the height of the centering plane. Clamp the workpiece roughly precentered (visual estimate). iv. Set the probe signal to zero v.4 : workpiece set up i.1 Workpiece setting-up through Centering Figure 6. Afterwards the form element is centered with the rotary knobs X and Y and then titled with the rotary knobs A and B. Select the centering rountie : vi. ii.) iii. Since the centering and tilting rountines mutually influence one another.5 µm remains. Enter the height of the measuring plane (165mm) : a) Take the measurement : o Press .calculated. i. The model workpiece is to be centered with respect to the C-axis such that a residual eccentricity of only 0. to 165mm.

5 µm. o If Yes : Complete the centering rountie and if No : Continue with b).5 : turntable 5. Enter the workpiece diameter. 135mm. Set the probe signal to zero vi.The measurement is carried out. Select the centering and tilting rountie : . o Press. ii. v. Clamp the workpiece roughly precentered (visual estimate). i. the diameter of the form element in the measuring plane (50mm). b) Centering rountie: o Move the turntable (2) to the angular position 315 ° . o Turn the rotary knob “Y” such that the arrow approximately points to “0”. o Turn the rotary knob “X” such that the arrow approximately points to “0”.e. iv. i.e. Figure 6. The assessed eccentricity is indicated. the result indicated.5 µm. iii.1. Use the rotary knob (11) to move the probe to the height of the first measuring plane. The model workpiece is to be aligned with respect to the C-axis such that the eccentricity over two measuring planes is smaller than 5 µm.2 Workpiece Setting-up through Centering and Tilting i.4. o Check whether the assessed eccentricity value is smaller than the given value of 0. Continue with a) Repeat the steps a) and b) until the assessed eccentricity value is smaller than 0.

a) Tilting rountie : o Move the turntable (2) to the angular position 135 ° . 190mm. 135mm. o Turn the rotary knob “X” such that the arrow approximately points to “0”. (Rotate clockwise. a) Centering rountie : o Move the turntable (2) to the angular position 315 ° .a) Enter the height of the first measuring plane (135mm) : o Take the measurement (in the 1st measuring plane) o Use the rotary knob (11) to move the probe to the height of the second measuring plane.2 Measurement a) Roundness . o Use the rotary knob (11) to move the probe the height of the first measuring plane. do not use the rotary knobs as points of attack) o Turn the rotary knob “A” such that the arrow approximately points to “0”. i. o Turn the rotary knob “Y” such that the arrow approximately points to “0”.e. 5. o If Yes : Complete the “centering & tilting” rountie with and if No: Continue with b). Repeat the entire process starting with “a) Enter the height of the first measuring plane (135mm)” until the eccentricity over the first and second measuring plane is smaller than 5µm. o Take the measurement (in the 2nd measuring plane) o Check whether the assessed eccentricity value is smaller than the given value of 5µm.e. i. o Turn the rotary knob “B” such that the arrow approximately points to “0”.

160mm. Enter the workpiece diameter. The assessed roundness error should lie within a tolerance of 10µm.) iii.The roundness error is to be determined in the middle of the lower cylinder of your model workpiece. The assessed roundness error should lie within a tolerance of 10µm. Use the rotary knob (11) to move the probe to the height of the measuring plane. . i. Enter the tolerance value (10µm) according to the drawing specification (top left figure) vii.e.e. the workpiece diameter must be entered as precisely as possible. Select the roundness feature : v. Set-up the form element to be tested (i. the roundness error is to be determined at the height of the groove (i.e.e on an interrupted form element). b) Roughness on an Interrupted Form Element On the upper cylinder. the lower cylinder) ii.) iv. the diameter of the form element in the measuring plane (50mm) (In order to determine profile edge zones correctly. a height of 160mm has to be approached. i. Take the measurement.6 : Roundness of workpiece i. The zero point of the workpiece coordinate system is at about 130mm of the machine coordinate system. Figure 6. Since the measuring station operates in the machine coordinate system. (The middle of the lower cylinder is about 30mm above the base of the model workpiece. Enter the height of the measuring plane (160mm) vi.

e.) Enter the undulation cutoff for the filter: (With an undulation cutoff of 15 upr. Select the roundness feature : Enter the height of the measuring plane (235mm) : Enter the tolerance value (10µm) according to the drawing specification (top left figure) Enter the width of the profile edge zone ( 10 ° ) : (Within the specified “prf. iv. i. v.7 : Roundness on an interrupted form element i. viii.e. iii. 235mm.) Take the measurement. these zones are situated at the edges of profile interruptions. the profile is not evaluated. As a rule. the diameter of the form element in the measuring plane (30mm) Use the rotary knob (11) to move the the probe to the height of the measuring plane. Enter the workpiece diameter. vii. vi. ii. the roughness and waviness components of the profile are suppresses such that basically only the form components remain.Figure 6. Align the form element to be tested (i. ix. i. the upper cylinder).e. .edge zone”.

Roundness testing system often referred to as form measurements system because of the several part features they’re capable of measuring. Along with roundness. Is the characteristic that all parts of a circle are identical The precaution steps or ways to improve the result of the experiment : a. and FORM-PC and the result is printed. Never use rotary knobs as points of attack when rotate the turntable c. Make sure the surface of the workpiece and all the equipment is cleaned before the experiment started. ii. and etc as showed in the table below : iii. temperature change and air flow e. Rotate clockwise -the turntable only can be rotated in the direction of clockwise b. today’s roundness testing are equipped to measure flatness. The Definition of roughness is : a.0 Discussion : i. Minimize vibration. iv. The roundness of the work piece is determined by using Formtester MMQ -10. The experiment is repeated several times in order to improve the result of the experiment Advantages of Roundness measurement : a. Is measure to make sure that the round object is round from inside and outside b. Data collection -Capable of continuous form measurement -Thousand of data points around the circumference of part giving the ability to map the part’s form accurately b. squareness. d. .6.

Figure 6.8 : Several uses of Roundness testing system .

Machine tool Mfg. etc. Serope Kalpakjian. and FORM-PC and the result is printed. b. Manufacturing -Bearing.0 References : i. From this experiment. we have learnt about the Roughness Measurement process including industrial applications.emigage.com/lab. Lab sheet Manufacturing Engineering and Technology.htm .v. -for checking the roughness of components -for checking the straightness of shafts used in precision application such as cam shaft. c. iii. http://www. Applications of roundness measurement on fields : a. Steven R. automotive. Military -used by the Air Force and other branches of the military to check the quality of incoming or reconditioned aircraft and defense parts. we have understood the operation and application of the equipment used in this experiment. d. hydraulics etc. centrifuge.qualitydigest. aerospace. ii.shtml b. and its advantages through laboratory work and its precaution step. Medical -Form or shape of artificial ball joints. Prentice Hall.com/dec02/articles/01_article. Internet : a. -Any major tool maker supplying precision manufacturing equipment. 5th edition in SI units. 7. 8. http://www. Besides that. Schmid.0 Conclusion : As a conclusion. the roundness of the work piece is determined by using Formtester MMQ -10.

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