Date: -

Experiment No: 8
AIM: Performance on surface measurements.

Objective:
1. To know about the surface measurement instrument.

Relevant CO: Apply concepts of metrology for gears, threads and surface finish.

Equipment:
Surface roughness tester.

Theory: -

Elements of Surface Roughness:

Roughness:
Roughness is a measure of the texture of a surface. It is quantified by the vertical deviations of a
real surface from its ideal form. If these deviations are large, the surface is rough; if they are small,
the surface is smooth. Roughness is typically considered the high frequency, short wavelength
component of a measured surface.
Roughness height:
It is defined as the arithmetical average deviation expressed in micrometers normal to an imaginary
centerline, running through the roughness profile.
Roughness width:
The distance parallel to the nominal surface between successive peaks or ridges which constitute
the predominant pattern of the roughness.
Roughness-width cutoff:
The maximum width of surface irregularities that is included in the measurement of average
roughness height. Roughness-width cutoff is rated in inches. Roughness-width cutoff must always
be greater than the roughness width in order to obtain the total roughness height rating. Standard
tables list roughness-width cutoff values of 0.003, 0.010.
Waviness:
Waviness is the measure of the more widely spaced component of surface texture. It is a broader
view of roughness because it is more strictly defined as "the irregularities whose spacing is greater
than the roughness “sampling length".
Lay:
It is the direction of predominant surface pattern produced by tool marks or scratches. It is
determined by the method of production used.
Flaws:
They are Irregularities, which occur at one place or at relatively infrequent or widely varying
intervals in a surface

Mechanical Measurement and Metrology (3141901)

The factors affecting surface roughness are:

• Type of coolant used.

• Cutting parameters such as feed, speed and depth of cut.
• Type of machining.
• Rigidity of the system, consisting of machine tool, fixture, cutting tool and work.
• Vibrations.
• Material of tool and work piece.
The surface roughness has been experienced and understood by the sense of light and touch. Any
material being machined by conventional machining process cannot be finished perfectly.
The surface generated will have some irregularities and these geometrical irregularities could be
classified as follows.
(i) First order: It includes the irregularities developed due to the inaccuracies in the
machine tool such as lack of straightness of guide ways, on which tool post is moving.
(ii) Second order: It includes the irregularities developed due to the vibrations and rigidity
of the machine tools.
(iii) Third order: It includes the irregularities developed due to the cutting parameters such
as cutting speed, feed and depth of cut.
(iv) Fourth order: It includes the irregularities developed due to the rupture of the material
during the separation of the chip from the already finished surface of the work piece.
Methods of Measuring Surface Finish:
There are two methods used for measuring the finish of machined part:
1. Surface Inspection by Comparison Methods.
2. Direct Instrument Measurements.

In comparative methods, the surface texture is assessed by observation of the surface. However,
these methods are not reliable as they can be misleading if comparison is not made with surfaces
produced by same techniques.

The various methods available under comparison methods are:

(i) Touch Inspection & Visual inspection.
(ii) Scratch Inspection.
(iii) Microscopic Inspection.
(iv) Surface Photographs.

Direct Instrument Measurements:

These methods enable to determine a numerical value of the surface finish of any surface.
(i) Tomlinson Meter
(ii) Taly-surf Meter

Conventional method for designing surface finish:

As per TS-696, surface texture specified by indicating the following main characteristics in the
symbols.
a) Roughness value i.e. Ra value in µm.
b) Machining allowance in mm.
c) Sampling length or instrument cut-off length in mm.
Mechanical Measurement and Metrology (3141901)
d) Machining/production method, and
e) Direction of lay in the symbol form as (//, ┴, ×, M, C, R.)

For example, a milled surface with 1.2 mm machining allowance having Ra value 6.3 µm, with cut-
off length 2.5 mm and direction of lay parallel will be represented.

The Tomlinson Surface Meter:

Inventor: Dr. Thomas Tomlinson In 1999
Principal: “The stylus movement is restricted in vertical direction only with the help of coil and
leaf spring. The variation in the surface is sensed by probe and is magnified on a smoked glass.”

Construction:
The diamond stylus on the surface finish recorder is held by spring pressure against the
surface of a lapped steel cylinder. The stylus is also attached to the body of the instrument by a leaf
spring and its height is adjustable to enable the diamond to be positioned conveniently. The lapped
cylinder is supported on one side by the stylus and on the other side by two fixed rollers as shown
in Fig. The stylus is restrained from all motion except the vertical one by the tensions in coil and
leaf spring. The tensile forces in these two springs also keep the lapped steel cylinder in position
between the stylus and it carries at its tip a diamond scriber, which bears against a smoked glass.
Working:
When measuring surface finish, body is traversed across the surface by a screw rotated by a
synchronous motor. Any vertical movement of the stylus caused by the surface irregularities causes
the magnified movement on a smoked glass plate. This vertical movement coupled with the
horizontal in horizontal direction. The smoked glass trace is then, further projected at × 50 or × 100
magnifications for examination by an optical projector. This instrument is comparatively cheap one
and gives reliable results.

Mechanical Measurement and Metrology (3141901)

Advantages:
• It is simple.
• It has low cost.
• It gives reliable results.

Disadvantages:
• It is delicate and requires great care.
• It is slow in operation.
• It is not suitable for rapid and continues use on the shop floor.

The Taylor-Hobson Taly-surf meter

Taylor-Hobson Taly-surf is a stylus and skid type of instrument working on carrier modulating
principle.
Principle: It working on the carrier modulating & the variation in the surface profile is sensed by
the probe, which is attached to the armature.
Its response is more rapid and accurate as compare to Tomlinson is more rapid and accurate as
compared to Tomlinson surface meter.

Schematic layout of Taly-surf meter

Construction:
The measuring head of this instrument consists of a sharply pointed diamond stylus of about 0.002
mm tip radius and skid or shoe, which is drawn across the surface by means of a motorized driving
unit. In this instrument, the stylus is made to trace the profile of the surface irregularities and the
oscillatory movement of the stylus is converted into changes in electric current by the arrangement
as in figure.
Mechanical Measurement and Metrology (3141901)
The arm carrying the stylus forms an armature, which pivots about the centerpiece of E-shaped
stamping on two legs the E-shaped stamping there are coils carrying an AC current. These two coils
with two resistances from an oscillator. As the armature is pivoted about the central leg, any
movement of the stylus causes the air gap to vary and thus the amplitude of the original AC current
flowing in the coils is modulated.

Working:
A downward movement of the stylus results in decreasing the air gap at the secondary coil. Thus,
the amplitude of the original A.C. current flowing in the coils is modulated. The output of the bridge
thus consists of modulation only as shown in fig. This is further demodulated so that the current is
now directly proportional to the vertical displacement of the stylus only. The demodulated output
is caused to operate a pen recorder to produce a permanent record & the meter to give a numerical
assessment directly.

Application:
The talysurf meter can be used to measure etch depths, deposited film thickness and surface
roughness.

Mechanical Measurement and Metrology (3141901)

 Questions

1. Define term: (i) Primary texture, (ii) Secondary texture.

2. Define the following elements of surface texture: (i) Roughness (ii) Flaws (iii) Lay (iv)
Waviness (iv) mean line profile (vi) Sampling length.
3. Define the following with reference to surface texture: (i) Peak to valley height, (ii) C.L.A
(iii) R.M.S

Suggested Reference:
1) Mechanical Measurement and Metrology, R K Jain, Khanna Publisher
2) Mechanical Measurement and Metrology, Er. R K Rajput, Kataria Publication.
References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 Total
Marks

Signature of faculty: __________________

Mechanical Measurement and Metrology (3141901)