Basic Roundness

© 2001 Taylor Hobson Korea Inc.

 Roundness Contents
Introduction Data Points

Measurement
Slope and DFTC
Methods
Reference
Asperity Effects
Circles
Eccentricity Flatness
and Run-out Measurement
Straightness
Filters and Harmonics
Measurement

Distortion due to
Cosine Error
Magnification
 Roundness Contents
Stylus
Force
Measurement of
Interrupted Surfaces

Error Separation

Kinematic
Mounting
 Cylindricity Contents
Methods of cylindricity
Introduction
Measurement
Instrument Measurement
Requirements Problems
Reference Straightness to
Cylinders Cylinder Axes
Cylindricity
Terminology

Cylindricity
Measurement
Technique
 Why Measure Roundness ?

Functionality
 Why Measure Roundness ?

Functionality

Running cost
 Why Measure Roundness ?

Functionality

Running Cost

Cosmetics
 Why Measure Roundness ?

Efficiency
 Effects Out of Roundness

Vibration
A A A
A
B B
B
B
 Effects Out of Roundness

Vibration

Wear A A A
A
B B
B
B
Main
Menu

Effects Out of Roundness


Vibration

Wear A A A
A

Noise B B
B
B
Methods of Roundness Measurement
Workbench Methods

• Three point method

– Simple but ...

Workbench Methods

• Three point method

MAXIMUM
MEASURED
MOVEMENT
– Simple but . . .

– Has limitations

VERTICAL MOVEMENT OF WORKPIECE

How do we measure roundness
How do we measure roundness
How do we measure roundness
 How do we measure roundness

Plug gauge

Centre established by point probe Centre established by point probe

 How do we measure roundness

Dial test indicator, used on lathe

show eccentricity errors
 How do we measure roundness

Spindle

GAUGE

SPINDLE AND COLUMN

 How do we measure roundness
Adjustable Table Top

Spindle
 How do we measure roundness

Spindle

Gauge

GAUGE

SPINDLE AND COLUMN

 How do we measure roundness
• The Gauge
How do we measure roundness
 How do we measure roundness

Spindle

Gauge

Stylus

GAUGE

SPINDLE AND COLUMN

 How do we measure roundness
• The Stylus
Pivot
X point

Effective Length

Stylus Tip
Main
Menu

100mm

± 1mm

200mm

± 2mm

Click Here For

Further Information
How do we measure roundness
THP TR265

10 µm

90°

180° 0°

270°
 How do we measure roundness

Spindle

Gauge

Stylus

Processing

GAUGE

SPINDLE AND COLUMN

DATA POINTS
How do we measure roundness
90°

Data point 1

180° 0°
Component
centre

270°
How do we measure roundness
90°

Spindle
Axis

180° 0°
Component
centre

270°
 How do we measure roundness

Table
Rotation

GAUGE

SPINDLE AND COLUMN

ROTATING TABLE ROTATING SPINDLE

Main
Menu

How do we measure roundness


Table
Rotation

Spindle
Rotation

ROTATING TABLE ROTATING SPINDLE

Reference Circles
 1-15 U.P.R FILTER

Reference Circles

Least Squares Circle

Minimum Zone

Maximum Inscribed

Minimum
Circumscribed
 Reference Circles

Least Squares Circle LEAST SQUARES CIRCLE.

MAX. VALLEY

MAX. PEAK
OUT OF ROUNDNESS = P + V.
 Reference Circles
OUT OF ROUNDNESS = R

Minimum Zone Circle R

MINIMUM ZONE CIRCLES

 Reference Circles

Maximum Inscribed
Circle

R
OUT OF ROUNDNESS = R

MAXIMUM INSCRIBED CIRCLE

Main
Menu

Reference Circles

Minimum R
Circumscribed Circle

Click Here For MINIMUM CIRCUMSCRIBED CIRCLE

Further Information
Eccentricity and Run-out
 Eccentricity
90

Eccentricity PROFILE
CENTRE

Concentricity E

180 0

DATUM POINT
E = ECCENTRICITY VALUE
O = ECCENTRICITY ANGLE
(IN THIS CASE 130 )

270
 90°

180° 0°

270°
 THP TR265

E 10 µm
135 deg

90°

Wrong Position

180° 0°

270°
 THP TR265 90°

E 10 µm
135 deg

90°

180° 0°
180° 0°

270°

270°
 THP TR265

E 10 µm
135 deg

90°

135 deg

180° 0°

270°
 Run-Out

Dial test indicator, used on lathe

showing eccentricity and roundness errors
Main
Menu

Run-Out
NEAREST POINT

ON PROFILE.
R = RUNOUT

DATUM POINT

Click Here For FARTHEST POINT

Further Information ON PROFILE.

Filters and Harmonics
 Filters and Harmonics

Undulations per
revolution UPR
 Filters and Harmonics

Undulations per
revolution UPR

Harmonics
 90°

Component
180° centre 0°

Datum
Axis

270°

1 st Harmonic
 2nd Harmonic
SPINDLE
AXIS
3rd Harmonic
 Wheel

Wheel

3rd Harmonic
4th Harmonic
Machine
Chatter
 Filters and Harmonics

Undulations per
revolution UPR

Harmonic

Filters
 Filters and Harmonics

Unfiltered

PROFILE SHOWING
8th AND 60th
HARMONICS
 Filters and Harmonics

1-15 upr filter

1-15 U.P.R FILTER

Main
Menu

Filters and Harmonics


15-500 upr filter

15-500 U.P.R
FILTER
 Stylus tip diameter

Click Here For

Further Information
 Grinding Wheel Component

Eccentricity of wheel

x
100 RPM

6000 RPM
Main
Menu

60th
Harmonic
Distortion due to Magnification
Distortion due to Magnification
Distortion due to Magnification
Distortion due to Magnification
x1
Distortion due to Magnification
x10
Distortion due to Magnification

x20
Distortion due to Magnification

x35
Main
Menu

Distortion due to Magnification

x50

Click Here For

Further Information
Data Points
Data Points
Main
Menu

Data Points

LSC

To Define the True Shape of The Signal

Slope and Dftc
Slope
Slope
Slope

Decceleration
Acceleration
Slope
Slope
Slope = R - r
O

O R
r
Main
Menu

DFTC

Leakage
Asperity Effects
Asperity Effects

Original Datum

Shifted Datum
 Asperity Effects
LEAST SQUARES CIRCLE. LEAST SQUARES CIRCLE.
Main
Menu

Asperity Effects
LEAST SQUARES CIRCLE.

LSC Centre

MC Centre MINIMUM CIRCUMSCRIBED CIRCLE

Flatness Measurement
Flatness Measurement
 Flatness Measurement

LS Reference Plane

Flatness P-V
 Flatness Measurement

Radius of Measurement

Run-out
Main
Menu

Flatness Measurement

Radius of Measurement

Squareness
Datum Axis
Straightness Measurement
Main
Menu

Click Here For

Further Information
Cylindricity Introduction
 What is Cylindricity ?

Definition

© 2001 Taylor Hobson Korea

Cylindricity Tolerance

0.02
mm
How is cylindricity different
from other Parameters ?
Combination of Errors
 Why measure Cylindricity ?


Component
mating FUEL LEAKAGE
 Why Measure Cylindricity ?


Component
Mating
Main
Menu

Why measure Cylindricity ?


Component
mating

Increased
Efficiency
Instrument Requirements
Instrument Requirements
 Instrument Requirements


Radial Form
COMPONENT

GAUGE

SPINDLE
 Instrument Requirements

Radial Form

Axial Form

COMPONENT VERTICAL
STRAIGHTNESS
UNIT
Main
Menu

Instrument Requirements

Radial Form

Axial Form

Positioning
Reference Cylinders
 Reference Cylinders

CYLINDER

Minimum Zone AXIS

P-V
 Reference Cylinders
CYLINDER
AXIS

Minimum Zone P-V

Minimum
Circumscribed
 Reference Cylinders

CYLINDER

Minimum Zone AXIS

Minimum
Circumscribed

Maximum Inscribed

P-V
 Reference Cylinders


Minimum Zone

Minimum
Circumscribed

Maximum Inscribed

Least Squares

CYLINDER
AXIS
Main
Menu

Reference Cylinders
CYLINDER
AXIS

P
V
Cylindricity Terminology
Cylinder parallelism

D1

LEAST SQUARES

LINE THROUGH

PROFILE DATA

AT CROSS SECTION

D2

CYLINDER PARALLELISM = D1-D2

 Cylindricity Terminology

DATUM

Total Run-out AXIS
TOTAL
RUN-OUT

CYLINDER
AXIS
 Cylindricity Terminology
DATUM
AXIS

Total Run-out

Co-axiality
(DIN)

COMPONENT
AXIS

CO-AXIALITY
VALUE
Main
Menu

Cylindricity Terminology

DATUM AXIS

Total Run-out

Coaxiality
(DIN) COMPONENT
AXIS

Coaxiality
(ISO)

Click Here For CO-AXIALITY

Further Information AXIS
Cylindricity Measurement
technique
Measurement Technique
 Measurement Technique


Axis
planes

CURVED WAISTED BARRELED

 Measurement Technique


Radial
Departure 1

4
Main
Menu

Measurement Technique


Vertical
accuracy COMPONENT
RESULT

COLUMN
Methods Of Cylindricity
Measurement
Circumferential section Method
Bird Cage Method
Wire Cage view
Generatrix Method
Points Method
Helical line method
Main
Menu

Circumferential section Method

4
Cylindricity measurement
Problems
Tilt Correction
Instability of the MC Cylinder
 Effects of Asperities
ASPERITY

SHIFTED ORIGINAL
DATUM DATUM
Error in cylinder Error in cylinder
+ unknown + unknown
Main
Menu

Error in cylinder Error in cylinder

+ unknown + unknown
Measurement Of Straightness
With respect to Cylinder axes
Main
Menu
Cosine Error
 Cosine Errors

90°

180° 0° Measurement direction

270°
 Cosine Errors

90°

180° 0°
Measurement direction

Point of contact

270°
 Cosine Errors

90°

45°
180° 0° Measurement direction

Point of contact

270°
 Cosine Errors

Deviation

90°
45°

Deflection

45°
0°
Cosine Errors
Main
Menu

Cosine Errors

Measuring direction

Click Here For

Further Information
Effects of Stylus Force
Effects of Stylus Force
Effects of Stylus Force
Effects of Stylus Force
Effects of Stylus Force
Effects of Stylus Force
Main
Menu

Effects of Stylus Force

Further
Information
 Measurement of
Interrupted surfaces
Interrupted surfaces
Interrupted surfaces

Click Here For

Further Information
Interrupted surfaces
Interrupted surfaces
Interrupted surfaces
Interrupted surfaces

Base Line
Total data removed

Edge level

Gauge underrange

Hole deletion angle

Interrupted surfaces
Interrupted surfaces
Interrupted surfaces

Total data removed

Gauge underrange
Main
Menu

Interrupted surfaces

Total data removed

Gauge underrange
Error Separation
 Error Separation

Component Error Spindle Error

 Error Separation

Component Error
and spindle error Combined error
 Error Separation

Component Error Spindle Error

 Error Separation

Component Error Combined Error

 Error Separation

Combined Error Combined error

 Error Separation

90°
135° 45°

180° 0°
Hemisphere

Rotary Table
 Error separation

+2 +3

-3 -2 -2
45° -1 45°

0° +2 0° +1
+3 +4

+0 -3 +1
-2
-1 -2
Component Error Spindle Error
 Error separation
Component/Table position
0 45 90 135 180 225 270 315 Spindle
error

0 3 0 3 -2 4 -1 0 1 1
Spindle position

45 -3 0 -5 1 -4 -3 -2 0 -2
90 5 0 6 1 2 3 5 2 3
135 -5 1 -4 -3 -2 0 -3 0 -2
180 7 2 3 4 6 3 6 1 4
225 -5 -4 -3 -1 -4 -1 -6 0 -3
270 -3 -2 0 -3 0 -5 1 -4 -2
315 1 3 0 3 -2 4 -1 0 1
Total error 0 0 0 0 0 0 0 0 0
Main
Menu

Error separation
Combined Error Spindle error Component error
0 3 1 2
45 -3 -2 -1
90 5 3 2
135 -5 -2 -3
180 7 4 3
225 -5 -3 -2
270 -3 -2 -1
315 1 1 0
Kinematic Mounting
Kinematic Mounting
Kinematic Mounting
Kinematic Mounting
Main
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Kinematic Mounting
 Ruby and sapphire styli

1 st Measurement repeated Measurement

Effects of Ruby and Sapphire Styli tips on Aliminium components

Hatchet and bar styli
Hatchet and bar styli
 Hatchet and bar styli

Effective stylus
tip radius

Hatchet radius
Hatchet and bar styli

GAUGE

SPINDLE AND COLUMN

Hatchet and bar styli

Metal Air
Hatchet and bar styli
Hatchet and bar styli

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THE END