Flatness Testing (Metrology)
Flatness Testing (Metrology)
Flatness Testing (Metrology)
7.4.
Like straightness testing, the simplest form of flatness testing is possible by comparing
the surface with an accurate surface. One of the surfaces is marked with Prussian blue and
the other surface rubbed over it. The distribution of colour over the other surface gives a
rough idea of high and low points on the surface. This method is usually suitable for small
plates and not for large surfaces.
Mathematically, flatness error of a surface states that the departure from flatness is
the minimum separation of a pair of parallel planes which will just contain all points on the
surface. The deviation of a large surface such as surface table or machine table from the true
plane may be determined by the use of either a spirit level or an auto-collimator. The
principle of the method is same, whether the apparatus used is auto-collimator or spirit level.
According to IS : 2063—1962, a surface is deemed to be flat within a given range of
measurement when the variation of the perpendicular distance of its points from a
geometrical plane (this plane should be exterior to the surface to be tested) parallel to the
general trajectory of the plane to be tested remains below a given value. The geometrical
plane may be represented either by means of a surface plane or a family of straight lines
obtained by the
displacement of a straight edge or a spirit level or a light beam :
Flatness deviations (errors of flatness) are indicated as follows :
(i) … µor mm per metre when convexities are allowed as well as concavities ;
(ii) concave to … |x or mm, when, between the ends, only concave surfaces are allowed ;
and
(iii) convex to … \x. or mm, when, between the ends, only convex surfaces are allowed.
It is well known that a surface can be considered to be composed of an infinitely large
number of lines. The surface will be truly flat only if all the lines are straight and they lie in
the same plane. Let us study the case of rectangular table. From Fig. 7.4, it is obvious that all
the generators (lines) are straight and parallel to the sides of the rectangle in both the
perpendicular directions. Even then it is not truly flat, but concave and convex along two
diagonals. Thus for the verification of a surface to be truly flat, it is essential to measure the
straightness of diagonals
in addition to the lines parallel to the sides. Thus the whole
of the surface is divided by straight lines as shown in Fig.
7.5. The end lines AB and AD etc., are drawn away from the
edges as the edges of the surface are not flat but get worn
out by use and can fall off little in accuracy. The straightness
of all these lines is determined and then those lines are related with each other in order to
verify whether they lie in the same plane or not. In above setting of the lines, it should be
kept in mind that the lines are whole multiples of the length of base of spirit level or reflector
stand and the centre of the diagonals. I must be one of the contact points of the feet of the
block.
7.4.1. Procedure for determining flatness (Fig. 7.5).
The procedure for determining flatness is as follows :
(1) Carry out the straightness test already described on all the lines AB, BC, AC etc.
and tabulate the readings upto the cumulative error column.
(2) Let a plane passing through the points A, B and D be assumed to be an arbitrary
plane, relative to which the heights of all other points may be determined. For it, the ends of
lines AB, AD and BD are corrected to zero and thus the height of points A, B and D are zero.
(3) The height of point / is determined relative to the arbitrary plane ABD = 000. As I is the
mid-point of lineAC also, all the points on AC can be fixed relative to the arbitrary plane by
assumingA = 0 and correcting / on AC to coincide with the mid-point J on BD. In this
way, all points on AC are corrected by amounts propor- tionate to the movement of its mid-
point. A hint could be taken here that C is twice as far from A as the
mid-point, the correction for C will be double that oil.
(4) Point C is now fixed relative to the arbitrary plane and points B and D are set at
zero, all intermediate points on BC and DC can be corrected accordingly.
(5) The positions of H and G, E and F are known, so it is now possible to fit in lines HG
and EF. This also provides a check on previous evaluation since the mid-point of these lines
should coincide with the known position of mid-point I.