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Uncertainty
Name
& 0.01m
0.17m
Model
Make
Range &
Uncertainty
Form tester
Resolution
Height 300mm
0.17m
Form meter
Rotary table
Probe
F3P
T6W
Mahr perthen
Mahr perthen
Mahr perthen
& 10nm
10nm
Diameter 300mm
0.17m
The two basic types of high precision of roundness measuring instruments are one in which
high precision spindle carries a sensitive indicator around the circumference of the workpiece
which is stationary and another is one in which a high precision turntable rotates the
workpiece against a stylus which is held stationary. The work piece, object whose roundness
is to be measured, is first kept on the rotatory table of the form tester. The probe is made to
touch several points on the work piece. The surface of work piece deflects the probe and this
deflection is transferred as a graph of roundness profile of the work piece to the form meter.
The continuous trace got in the polar graph represents the radial deviation given by the work
piece when the probe was deflected. Magnification factor used exaggerates the profile in the
radial direction but the angular position on the graph of the profile is not magnified and is
same as that of the work piece. In some cases the output of a roundness trace consists not of a
polar graph but a set of numbers which represent radial deviation of the workpiece at equally
spaced points around the circumference. This is equivalent to a polar graph except that the
trace consists of a discrete number of points instead of a continuous curve. There are several
ways to assign numerical roundness value to the workpiece from its polar graph. One way is
to draw either the minimum circumscribing circle or maximum inscribed circle and state of
maximum departure from one or the other. Another way is to draw the pair of concentric
circles which enclose the graph and have minimum radial separation. This separation is then a
measure of the out of roundness. A slightly more sophisticated approach is the least squares
circle that fits to the data at equally spaced angles gives the estimates of P-R, the non
circularity, where R is the radius of the circle and P is the distance from the center of the
circle to the trace. Least squares analysis of the measurements enables the non circularity of
the spindle to be separated from the profile of the standard. Consider a polar graph given in
rectangular coordinate system. Let point 0 be the center of rotation of the spindle and yibe
thedistancefrom0topointPonthecurveattheangularposition i.Letpoint(a,b)bethe
centeroftheLeastSquaresCircle(LSC)andRbetheradiusofLSC.Let c2=a2+b2and
tan=b/a.thenthetrianglebetweenpoints0,Pand(a,b)hastherelationship:
yi= [(R+i)2 c2 sin2(i)]1/2+ccos(i)
Wherei isthedeviationofpointPfromtheLSC.Sincecismanyordersofmagnitudeless
thanR(inawellcenteredtrace),thetermc2 sin2(i)canbeneglected,thus
yi =R+ccos(i)+i
Since a = c cos and b = c sin this expression can be expanded to give
yi =R+ccosicos+csinisin+i
or
yi =R+acosi+bsini+i
let{i,I=1,n}benequallyspacedangles.Thenthesumofsquaresofthedeviations R=
1/nyi
a=2/nyi cosi
b=2/nyi sini
thedeviationsini aregivenbyi =yi Racosibsini
Wherei=1,n.
Whenroundnessvaluesareassignedfromasinglegraph,asintheabovecase,thegraph
containsboththeworkpieceprofileandthespindleprofile.Thecomputerprogramfordata
acquisition,profilefiltering,evaluationoftheroundnessparametersandgraphicaloutputof
theresultsaswellasfortheinstrumentcontrol(settingthemotorspeedandselectionofthe
amplifierrange)hasbeenrealized. The deflection of the probe is calibrated by the help of
gauge blocks, which is traceable from the gauge block interferometer. Some measurements of
roundness dont require a high level of precision, such as measurements on cylinder, sphere,
and ring gauges where roundness is not of prime importance. For this purpose a single trace
is made of the workpiece. High precision measurements of roundness are appropriate where
an object, such as a hemisphere, is intended to be used primarily as a roundness standard. The
measurement sequence involves making multiple traces of the roundness standard where the
standard is rotated between the traces.
Thespindleerrorisdeterminedbyapplicationofthewellknownmultisteperrorseparation
technique. A high quality roundness standard with small surface roughness and a low
harmoniccontentismeasuredin10angularpositionsevery36.Thespindleerrorisobtained
fromtheaverageofthetenprofiles.Byaveraginginthisway,theroundnessdeviationofthe
referenceartifactiscancelledexceptallmultiplesofthe10harmonic.Thedeterminationof
theroundnessdeviationofthereferencesphereismadebythesameway,butshiftingthe
measuredprofilesbythecorrespondingmultipleof36beforetakingtheaverage,andthus
eliminatingtherunouterrorofthespindle,againexceptallmultiplesofthe10harmonicof
thespindleerror.Ithastobenoted,thatusingasphereastheartifactyieldsonlytheradial
spindle error, whereas using a hemisphere, where the measurement is not taken in an
equatorialplane,alsoanaxialcomponentofthespindleerrorisdetermined.Inpractice,each
profileismeasuredfivetimesinordertoreducenoiseandtodetectanyirreproduciblepeaks
intheprofilecausedbydustoranyotherdisturbance.Specialattentionhastobegiventothe
alignmentoftheartifactwithrespecttothespindleandtheindexingtable.Oneofthemajor
problemsinroundnessmeasurementisthethermaldriftofthemeasuredobjectwithrespect
tothespindleduringthemeasurement.Themechanicalloopbetweenobjectandprobeis
alwaysratherlarge:itcomprisesthemeasurementtablewithpositioningstagesforadjusting
the object, the instruments column, the spindle and finally the probe with again some
adjustments.Forhighprecisionroundnessmeasurements,allthis isrequiredtobestable
withinabout1nmduringthemeasurementtimeofroughly10seconds.Mostofcommercial
software artificially close the beginning and the end of the measured profile taking into
accountasmalloverlapoftheprofileendsandthendeformtheprofileinordertoclosethe
circle.Ithastobenoted,thataradialdriftoftheeccentricityinthedirectionoftheprofile
start has a maximum effect on the closure error, whereas a drift perpendicular to that
direction cannot be seen as a closure error, but still considerably deform the roundness
profile, essentially to produce an elliptic shape. The eccentricity continuously during
successivemeasurementsandtotaketheprofiledataonlyoncethedriftoftheeccentricity
perrevolutionisbelowapresetvalue.Thismeansthattheinstrumentmuststabilizeatleast
onehourafterhavingdoneanyadjustments.Driftswellbelow1nmbetweensuccessive
roundnessmeasurementscanbeobtained.Theestimationofthemeasurementuncertaintyfor
roundnessmeasurementisextremelydifficultandcannotbebasedonananalyticalmodel
withoutsomesimplifyingassumptions.Themathematicalmodelingoftheeffectofdifferent
influence quantities and the combination of the distribution functions to the resulting
uncertaintyoftheindividualprofilepointandthepeaktovalleyroundnessdeviationshould
infactbecarriedoutratherbynumericalsimulation,takingintoaccounttheactualspindle
errorandtheroundnessdeviationofthemeasuredartifact.Thesimplifiedapproachoutlined
byNeugebaueressentiallydistinguishesbetweenshortwavedcontributions,consideredtobe
uncorrelatedandthusreducedbyfiltering,andcorrelatedlongwavedcontributions.Short
andlongwavedmeanfrequenciesconsiderablyhigherandlowerthanthecutofffrequency.
Correlationmeans,thattheuncertaintyofaprofilepointiscorrelatedtotheuncertaintyofthe
points in the neighborhood of the profile. We shall hereafter estimate the uncertainty of
measurementofaperfectlyroundidealartifact,theactualroundnessdeviationistherefore
notrelevantandnoinfluencefromtheimpossibilitytoreproduceexactlythesamelocation
ontheartifactorfromthelimitedbandwidthforthehigherharmonicsintheprofilewillbe
considered.Thesecontributionshavetobeevaluatedseparatelyandaddedtotheuncertainty
budget.
The machine is used to measure roundness, cylindricity, straightness, flatness,
concentricity, coaxiality, radial run-out, total radial run-out, axial run-out,
total axial run-out, parallelism, perpendicularity and angularity, while
adhering
to
both
National
and
International
Standards.
Whether
Mahr
perthen
6710217
Resolution
50m &
Uncertainty
6 percent
0.01m
standard groove marked 2.46m. The arithmetical mean deviation at 0.8mm cut off has been
determined, by reference to a master standard, at 25 locations distributed evenly over the
outlined area using a calibrated Talysurf 5 profile instrument with a nominal stylus radius of
2.5m. At 10 additional locations, 4096 ordinates were recorded by a numerical process at a
spacing of 1m and the Ra value calculated after numerically applying a filter with a standard
instrument cut off of 0.8mm. The analyzed profiles were taken in the direction of the arrows
on the outlined area.
From the recorded data, the following results were obtained:
Marked Ra value
Mean measured Ra value
Standard deviation
Range of measured Ra values
0.78m
0.788m
0.003m
0.782m 0.794m
The value quoted above for the mean measured Ra value has an estimated uncertainty of
0.03m.
Groove depths: Using the Talysurf instrument described above, determinations were made
of the total height of the central of each of the two sets of three grooves. Profiles of these
grooves were recorded at 5 locations and the depths calculated from the recorded profile
ordinates. From these values the following results were obtained:
Marked groove depth
Mean measured groove depth
Range of measured groove depth
2.46m
2.45m
2.40 2.48m
0.33m
0.34m
0.333 0.343m
The values quoted above for the mean depth of grooves have an estimated uncertainty of 3
percent. Profile graphs of the Ra standard were taken normal to the lay at a horizontal
magnification of 100 and a vertical magnification of 5000. The profile graphs showed no
irregularities.
Autocollima
tor
Tilting Table
with Drum
Micrometer
Angle
Measurin
g
Instrume
nt
Angle
Gauges
Indexing
Table
Autocollimator
Autocollimators are optical instruments capable of measuring small angles of tilt of a
reflecting face. There is no restriction on direction but many autocollimators are constructed
for measurement in planes close to the horizontal and/or vertical. Some autocollimators are
visual types incorporating a micrometer eyepiece. Others are photoelectric types either with
null setting of an electrical meter by means of a micrometer drum or with direct analogue or
digital readout. Autocollimators are typically used as reading devices in the calibration of
precision polygons and angle gauges.
Name of instrument
Model
Make
Serial no.
Range & Resolution
Uncertainty
Name
Autocollimator
ELCOMAT 2000
MOLLER WEDEL
294
1050 arc seconds & 0.01 seconds
0.03 seconds
Model
Make
Range &
Autocollimation
ELCOMAT
MOLLER
measuring head
Evaluation unit
ELCOMAT
WEDEL
MOLLER
Uncertainty
Resolution
1000 seconds &
0.05 seconds
WEDEL
The measuring principle is based on auto collimation. The image of an illuminated object,
located in the posterior focal plane of the collimator lens, is projected to infinity and reflected
via mirror. A light-sensitive receiver picks up the image. A slight alteration of the angle
between the optical axis of the autocollimator and the mirror causes a deviation, which can be
determined very precisely.
Deviation, = y/ (2*f)
The electronic autocollimator provides measurement of smallest deviation of direction and
inclination in fractions of arc seconds. It can simultaneously measure height and width. The
measurements are performed without physical contact and in the visual spectral range. The
receiver is a CCD line sensor. The completely digital signal reception and processing
guarantees exact linear behavior in the entire measuring range. The integrated
microelectronics provides precise evaluation and presentation of the measuring signals very
reliably. Data processing is controlled by an integrated microprocessor.
Each autocollimator is calibrated and contains one calibrated X-axis and one calibrated Yaxis. A computer interface is also available in the evaluation head for data transfer of the
measuring values to the computer.
Autocollimators are typically used to align components and measure deflections in optical or
mechanical systems. The electronic autocollimator is a complete measuring station for high
precision angle measurement. It is used for
a. Quality assurance for machine tools (straightness, parallelism, rectangularity, position
uncertainty (rotational), flatness)
b. Automatic angle adjustment
c. Optics (angle measurement)
d. Monitoring of positions (angles)
Angle Gauges
A practical form of angle standards was devised by G. A. Tomlinson at the NPL, UK, in
1941. Sets of these standards, known as combination angle blocks, are nowadays widely used
in industry. These comprise hardened steel blocks, having two highly finished faces mutually
inclined so as to form included angles of selected nominal sizes. These faces are flat to within
a few hundredths of a micrometer, posses a wringing property similar to that of slip gauges
and, in addition, have a high degree of reflectivity which enables them to be used with an
autocollimator. The set consists of thirteen blocks by means of which any required angle,
between 0 to 360 degree in steps of 3 seconds of arc, can be quickly built up, as with a set of
slip gauges.
Name of instrument
Model
Make
Range & Resolution
Uncertainty
Angle Gauges
3 arc second
Combinations of blocks are formed by wringing them together; advantage being that a block
may be wrung to another block so as to increase or decrease the angular size of the
combination depending in which sense it is wrung. The nominal values of the blocks are as
follows:
3
1
1
9
3
3
27
9
9
seconds
27
27
minutes
41
degrees
Indexing Table
Indexing table is an important instrument to be used in angle measurement. Indexing table
has a rotatory indexing device constructed with two matched sets of equally spaced radial
face teeth (serregations) arranged in a circle mounted in the fixed base and the upper rotable
table.
Name of instrument
Model
Make
Range & Resolution
Uncertainty
Indexing Table
1440
A A Moore ,USA
15 arc minute
0.1 arc second
The indexing device is based on the principle of circle divider. Two faces gears are generated,
each identical in diameter, shape and number of teeth. When the two opposite faces of the
gears are brought in contact face to face, that is root to crest, they lock together and prevent
any rotation or side movement, unless they are disengaged, rotated and brought in contact
again. The angular displacement corresponds to the number of teeth through which the table
has been indexed. Indexing plate is used along with autocollimator for calibration of
polygons.
Tilting Table with Drum Micrometer
Tilting table along with the drum micrometer is used for the calibration of electronic levels,
which are further used in industries to find out the tilt or perpendicularity of any material
surface.
Name of instrument
Make
Range & Resolution
Uncertainty
Name
Drum micrometer
Steel scale
Tilting table
NPL workshop
Length 850mm & 0.002mm
(210-6L/m)
Model
Make
Range &
810879
B259
Mitutoyo
Resolution
0-10mm &
Chesterman
0.002mm
100cm & 1cm
Uncertainty
(2106
L/m)
The drum micrometer is attached on the one end of the 850mm long tilting table apparatus.
The object to be calibrated is kept fixed on the tilting table. The laser interferometer and the
drum micrometer together with tilting table are used in calibration of electronic levels. The
drum micrometer offers circular motion in both clockwise and anticlockwise direction. The
rotation leads to tilting of the table in either direction. On moving the drum micrometer, the
table is tilted by some arc seconds, which is displayed in millimeter units by the object
(electronic level), kept on the tilting table. The laser source and the two optics are set in a
straight line on the tilting table. The two interference optics are placed such that one is fixed
near drum micrometer and the other is kept on tilting table. The other reading, which is in arc
seconds, is given by the computer attached to the laser interferometer. When the table is
parallel to the ground, the interference pattern shows zero arc seconds but when the table is
tilted the position of one of the reflector changes with respect to other and a different position
shows a value in arc seconds. The computer shows the reading in arc seconds. For different
drum micrometer reading different amount of tilting is there and for these different tilts the
object to be calibrated shows different values. The readings are noted down and further
calculations are done to find out the uncertainty and the error. The difference in the readings
of laser interferometer and the electronic level is known as deviation.
Experiment
Reference
Polygons and angle blocks are the most important transfer standards in the field of angle
metrology. Polygons are used by National Metrology Institutes (NMIs) as transfer standards
to industry, where they are used in conjunction with autocollimators to calibrate index tables,
rotary tables and other forms of angle measuring instruments. Polygons and angle blocks are
also the most common angle standards in comparisons of angle measurements between NMIs
and accredited laboratories.
Autocollimators, the main instruments used in the measurement of angle, are calibrated with
small angle generators, using laser interferometers. A vast amount of time is invested in their
calibration. Index tables are usually calibrated using another index table and an
autocollimator with a mirror. To measure the angle differences between the tables all the steps
(i.e. every 30o) are measured. Research has shown that it is possible to calibrate both
autocollimators and index tables very accurately.
Appendix
References
1. P.C. Jain, Weights, Measures and Dimensional Metrology, Pragati Prakashan Meerut.
2. Operating Manual AUTOCOLLIMATOR ELCOMAT 2000
3. Operating Manual ELECTRONICS LEVEL
4. Indian Journal of Pure & Applied Physics, Vol. 43, May 2005, pp. 319-328