Surface Roughness Measuring

Instrument
Prof. Tanmoy Majhi
 DIRECT INSTRUMENT
MEASUREMENTS
 Direct methods enable to determine a numerical value of the surface finish of any surface.
 These methods are quantitative analysis methods and the output is used to operate
recording or indicating instrument.
 Direct Instruments are operated by electrical principles. These instruments are classified into
two types according to the operating principle.
 In this is operated by carrier-modulating principle and the other is operated by voltage-
generating principle, and in the both types the output is amplified.
 Some of the direct measurement instruments are
 1. Stylus probe instruments.
 2. Tomlinson surface meter.
 3. Profilometer.
 4. Taylor-Hobson Talysurf
 1. Stylus Probe Instrument
• Skids are rounded at the bottom and fixed to the pickup unit. Skid or shoe which is drawn
slowly over the surface either by hand or by motor drive. The skid when moved over the
surface follows its general contours and provides a datum for the measurements.
• A stylus or probe which moves over the surface with the skid. The stylus should be cone
shaped with a spherical tip. This records the micro-geometrical form of the surface. It moves
vertically up and down relative to skid movement due to roughness of the surface.
• As the stylus tracks the surface peaks and valleys, its vertical motion is converted to a time
varying electrical signal that represent surface profile.
• Generally it is desired that if the skid is moving up then the stylus must also be moving up.
 Stylus Probe Instrument
• The stylus is typically a diamond having a cone angle of 90° and a spherical tip radius of 1–5
µm or even less.
• While a pointed stylus is used to measure roughness, a blunt stylus is required to plot the
waviness.
 2. Profilometer
• Profilometer is also called as Abbot Profilometer.
• It consist of a diamond stylus (radius of the tip end is about 0.012 )and a spring attached to it
which used to vibrates when this meter moves on the surface of the measuring object.
• This type of measurement is used to measure the accurate and a clear surface roughness.
• The profilometer is capable of measuring roughness together with waviness and any other
surface flaws.
• An electrical pickup attached to the stylus amplifies the signal and feeds it to either an
indicating unit or a recording unit. The stylus may be moved either by hand or by a
motorized mechanism.
• When the profilometer moves on the surface of the work the
stylus gets vibrated. Due to the presence of irregularities on
the surface, vibrations occur. This vibration transfers to the
coil which is present in the magnetic field and with
the help of galvanometer the measurement is done due to the
induced current.
3. Tomlinson Surface Meter
 Tomlinson Surface Meter
• A Tomlinson Surface Meter is a mechanical instrument used to measure the surface
roughness of a material. It operates by tracing the profile of the surface with a stylus and
amplifying the vertical displacement, which is then recorded as a trace on smoked glass.
• The Tomlinson Surface Meter consists of several key components that work together to
amplify and record surface deviations:
 Stylus: A diamond-tipped probe that moves over the test surface. Detects even minor
surface irregularities.
 Diamond Probe: A specialized fine-tip probe that ensures precise contact with the surface.
 Skid: A reference support that maintains steady movement. Helps eliminate errors due to
unwanted lateral motion.
 Arm & Body: The arm transfers motion from the stylus to the scriber. The body houses the
internal mechanism.
 Fixed Rollers: A set of precision rollers that guide the movement of the system. Reduces
friction and ensures smooth displacement.
 Spring Mechanism: A spring maintains tension and helps control movement. Ensures the
stylus stays in contact with the surface.
 Leaf Spring: Helps in mechanical damping, preventing unwanted oscillations.
 Lapped Cylinder: A high-precision cylinder that supports the movement system.
 Diamond Scriber: A diamond-tipped marking tool that records the amplified movement.
Produces traces on smoked glass for visual analysis.
 Smoked Glass: A recording surface where the roughness profile is traced. The trace
represents peaks and valleys of the measured surface.
 Working Principle of Tomlinson
Surface Meter
• The Tomlinson Surface Meter works on the principle of mechanical amplification. The stylus
follows the surface irregularities, and these minute vertical displacements are transferred
through a system of levers and rollers, which then produce an amplified trace on a smoked
glass.
• The stylus is placed in contact with the surface to be measured.
• As the instrument moves, the stylus moves vertically due to surface irregularities.
• The vertical displacement is transferred to the pivoted arm.
• The arm, through a system of levers, rollers, and springs, amplifies the movement.
• The diamond scriber at the other end of the arm traces this movement onto smoked glass.
• The resulting trace provides a visual representation of surface roughness.
• The resulting trace represents the surface roughness profile.
• This mechanical system allows for high sensitivity, making it effective for detecting even
minor deviations in surface texture.
 4. Taylor–Hobson Talysurf
The Taylor–Hobson talysurf works on the same As the stylus moves up and down due to
principle as that of the Tomlinson surface meter. surface irregularities, the armature is
However, unlike the surface meter, which is purely a also displaced. This causes variation in
mechanical instrument, the talysurf is an electronic the air gap, leading to an imbalance in
instrument. This factor makes the talysurf a more the bridge circuit. The resulting bridge
versatile instrument and can be used in any condition, circuit output consists of only
be it a metrology laboratory or the factory shop floor. modulation. This is fed to an amplifier
The stylus is attached to an armature, which pivots and a pen recorder is used to make a
about the centre of piece of an E-shaped stamping. permanent record. The instrument has
The outer legs of the E-shaped stamping are wound the capability to calculate and display the
with electrical coils. A predetermined value of roughness value according to a standard
alternating current (excitation current) is supplied to formula.
the coils. The coils form part of a bridge circuit. A skid
or shoe provides the datum to plot surface roughness.
The measuring head can be traversed in a linear path
by an electric motor. The motor, which may be of a
variable speed type or provided with a gear box,
provides the required speed for the movement of the
measuring head.