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Flatness Measurement Techniques

How to measure surface flatness

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Haidy Nasser
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229 views19 pages

Flatness Measurement Techniques

How to measure surface flatness

Uploaded by

Haidy Nasser
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

FLATNESS MEASUREMENTS

Definition: Flatness is the departure from truly flat


surface. The maximum out of flatness (flatness
error) is defined as the minimum separation of
two parallel planes which totally enclose all the
irregularities of the surface under test.

Symbol:
Measuring Principle: The entire surface area is
divided into a series of imaginary straight lines
forming a grid and the variations in heights of the
points of intersections of the lines are found
relative to some datum plane. Theses heights may
be detected by using dial indicator, measuring
stylus, sensitive level, autocollimator, beam
comparator Etc.
The readings are then analyzed such that the
deviations of the points from a true mean plane
(reference plane) are determined. This is made to
eliminate the superimposed errors such as taper
error, the supporting error and the leveling error.
The flatness error value is the maximum peak to
valley deviation perpendicular to the mean plane.
Measuring Techniques

I) Using dial indicator

The surface is located on reference plate and the


heights of predefined points on the surface
relative to the surface plate datum are detected by
the dial indicator.

Fig. 2 Set-up for checking the straightness of a shaft using dial


indicator
By using least square method, the readings are
analyzed to determine the equation of the true
mean plane. Deviations of the surface points
relative to the true mean plane are then
determined. These deviations represent the
flatness error of each point (δi). The flatness error
is the sum of the absolute maximum positive and
negative deviations.

Experimental readings
Point location Indicator reading
( point height)
X mm Y mm Z mm

Analysis of the Readings and Results


The equation of the mean true plane

zi  axi  byi


xi 
 x i

yi 
 y i

zi 
 zi
n
x  x  x
y  y  y
z  z  z

a
  xz   xy yz
y  2

    xy
 
2 2 2
x y

b
  yz   xy xz
x  2

 x  y   xy
2 2 2
Out of flatness=
 i  zi  zi
Maximum out of flatness =``

 max  max    max  


Examples

Equation of the true mean plane=

zi  0.000625xi  0.0006yi


II) Using Beam Comparator.( Rochdale Arm)

Rochdale Arm.

Rochdale arm: consists of a light rigid beam, on the


underside of which are two fixed flat ended feet,
one at the center and the other near one end. At
the other end of the beam a dial indicator is fitted.
The central foot is positioned such that it is
accurately mid way between the end foot and the
plunger of the dial. The plunger axis is in one plane
with the two axes of the arm feet and
perpendicular to the line passing through the two
feet.
Experimental Procedure
 The entire surface area is divided into a series
of imaginary straight lines forming a grid of
equilateral triangles of side length equal to
the length of beam arm.
 The arm is calibrated either by placing on a
reference plate or by using a sensitive level as
explained before.

 The arm is made to rest on the tested surface


on its feet such that the feet are on two
successive marked points and the dial plunger
is on contact with the next point.

 The arm is then moved to another position till


the entire area is scanned.

 The reading of the dial is observed and


recorded. This reading is the height of the
point under the dial plunger w.r.t. the line
passing through the two points under the
feet. For example if the beam is on line ABC
such that the plunger is in contact with point
c, the reading is the level of point C either
above or below the line passing through
points A, and B.
 Readings
Position Reading Position Reading

Mm Mm

ABC 0.03 MNO 0.18

BCD 0.03 NOS -0.01

CDE -0.015 BFk -0.06

FGH 0.15 AFM -0.46

GHI 0.03 BGN 0.35

HMN -0.14 CGM 0.17

 A datum plane is defined as a plane passing


through three point of the grid.

 The height of the points relative to the


predefined datum plane is determined using
the mathematical formula.
Z= R+2Y-X
X is level of the point under the end foot
relative to the datum plane.
Y is level of the point under the middle foot
relative to the datum plane..
Z is level of the point under the plunger relative
to the datum plane.
R is dial reading which represents the height of
the point under the plunger (Z) relative to the
line joining the points under the arm feet (XY).
 Readings are then analyzed using least square
method to determine the heights of the points
relative to the true mean plane.

Example
Consider the above shown grid and the readings
listed on the above table.
Consider that the arm is set on a reference straight
edge and its reading is set to zero.
Applying the arm mathematical formula
Z=R+2Y-X
Consider the reading ABC= 0.03 mm
0=0.03+2B-0
B level = -0.015 mm
Consider the reading BCD= 0.03 mm
D=0.03+0+0.015
D level = 0.045 mm
Consider the reading CDE -0.015 mm
E=-0.015+0.09-0
E level = 0.075 mm
Consider the reading AFM -0.46 mm
0=-0.46+2F-0
F level = 0.23 mm
Consider the reading BFk -0.06 mm
k=-0.06+0.46+0.015
k level = 0.415 mm
Consider the reading CGM 0.17 mm
0=0.17+2G-0
G level = -0.085 mm
and so on
point Coordinates

X y z

A 0 0 0

B 200 0 -0.015

C 400 0 0

D 600 0 0.045

E 800 0 0.075

F 100 173.2 0.23

G 300 173.2 -0.085

H 500 173.2

I 700 173.2

k 0 346.41 0.415

M 200 346.41 0

N 400 346.41

O 600 346.41

S 800 346.41
 Finally by applying the least square
method, the levels of the points are related
to the true mean plane.
zi  axi  byi

xi 
x i

yi 
y i

zi 
 zi
n

x  x  x
y  y  y
z  z  z

a
 y  xz   xy yz
2

 x  y   xy
2 2 2

b
 x  yz   xy xz
2

 x  y   xy
2 2 2

Out of flatness=  i  zi  zi

Maximum out of flatness =  max  max    max  


III) Using Sensitive Level (Spirit Level)

Experimental procedure

 The surface area under test


is divided into a series of
imaginary straight lines
forming a grid of simple
squares of equal sides.
 Readings are taken by
sensitive level along each horizontal line as
well as along one vertical line.
 Readings are taken in forward and backward
direction and the average values are
considered.
Example : A table of upright drilling machines 550×550 mm was tested for
flatness error. A mesh consists of 12 similar squares of 100 mm side length is drawn
on the table. A sensitive level of constant 0.2 mm/m is used to measure the level of
each point relative to the preceding one as listed on the following table. Determine
the maximum out of flatness.

Readings

Along line ae: -1, -2, 1, -2 divs.

Along line fj: -2, 7,-3, 1 divs.

Along line ko: 9,2,-4,-1 divs.

Along line pt: 3, -2, -6, 7 divs.

Along line ap: -6, -3, 6 divs.

Solution

Readings Accumlated readings

Level constant = 0.2 mm/m


Grid side length = 100 mm
Z= 0.02 ×reading
Pt. X mm Y mm Z div Z mm X' Y' Z' X'Y' Y'Z' Z'X' X'2 Y'2 Z'' δ
a 0 0 0 0
b 100 0 -1 -0.02
c 200 0 -3 -0.06
d 300 0 -2 -0.04
e 400 0 -4 -0.08
f 0 100 -6 -0.12
g 100 100 -8 -0.16
h 200 100 -1 -0.02
I 300 100 -4 -0.08
j 400 100 -3 -0.06
K 0 200 -9 -0.18
l 100 200 0 0
m 200 200 2 0.04
n 300 200 -2 -0.04
o 400 200 -3 -0.06
p 0 300 -3 -0.06
q 100 300 0 0
r 200 300 -2 -0.04
s 300 300 -8 -0.16
t 400 300 -1 -0.02
zi  axi  byi

xi 
x i

yi 
y i

zi 
 zi
n

x  x  x
y  y  y
z  z  z
a
 y  xz   xy yz
2

 x  y   xy
2 2 2

b
 x  yz   xy xz
2

 x  y   xy
2 2 2

Out of flatness=  i  zi  zi


Maximum out of flatness =  max  max    max  

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