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Measurement
journal homepage: www.elsevier.com/locate/measurement
Adnan Menderes University, Faculty of Engineering, Department of Mechanical Engineering, 09010 Aydin, Turkey
Vienna University of Technology, Institute for Production Engineering and Laser Technology, Department of Interchangeable
Manufacturing and Industrial Metrology, Karlsplatz 13/311, 1040 Wien, Vienna, Austria
a r t i c l e
i n f o
Article history:
Received 10 November 2009
Accepted 14 December 2010
Available online 19 January 2011
Keywords:
Surface metrology
Surface roughness
Comparative study
Stylus and 3D optical methods
Statistical analysis
a b s t r a c t
The measurement of roughness on machined metal surfaces is of considerable importance
to manufacturing industries as the roughness of a surface has a signicant inuence on its
quality and function of products. In this paper, an experimental approach for surface
roughness measurement has been based on the comparison of roughness values taken
from the stylus and optical type instruments on the machined metal surfaces (turning,
grinding and milling) is presented.
Following this experimental study, all measured surface roughness parameters have
been analyzed by using Statistical Package for Social Science (SPSS 15.0) statistically and
mathematical models for the two most important and commonly used roughness parameters Ra and Rz have been developed so that Ra = Ra (F, P, C) and Rz = Rz (F, P, C, M), whereas F
expresses feed, P periodicity, C contrast and M the type of material. The statistical results
from numerous tests showed that there has been a correlation between the surface roughness and the properties of the surface topography and there have been slight differences
among three measurement instruments on machined metal surfaces in this experimental
study.
2010 Elsevier Ltd. All rights reserved.
1. Introduction
Surface roughness plays a vital role in determining the
desired quality of a machined metal surface for todays
engineering industry. The quality of assessment of engineering surfaces with respect to their functional and optical properties for different loading conditions is inuenced
by roughness parameters characterizing basically the surface microtopography [1]. It is traditionally dened by
two parameters: arithmetical mean deviation of the assessed prole Ra and average maximum height of assessed
prole Rz as they are one of the most commonly used and
accepted by researchers and in industry as well. Surface
Corresponding author.
E-mail address: durakbasa@mail.ift.tuwien.ac.at (M.N. Durakbasa).
0263-2241/$ - see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.measurement.2010.12.001
Ra
1
lr
lr
jzxjdx
612
The more common parameter for roughness is maximum height of prole (Rz). Rz is calculated by measuring
the vertical distance from the highest peak to the lowest
valley within ve sampling lengths, then averaging these
distances. Rz averages only the ve highest peaks and the
ve deepest valleys therefore extremes have a much
greater inuence on the nal value.
The goal of this research work is to obtain mathematical
models of Ra and Rz estimating the coefcients of the linear
equation, involving a few independent variables (feed in
mm, periodicity, type of material, contrasting, type of production process, etc.) with an analysis of variance (ANOVA)
and regression analysis.
2. Surface topography techniques for the comparative
study
Conventionally, surface roughness measurement has
been performed by using a stylus instrument [3,4]. When
a stylus traverses a surface, the vertical motion of the stylus is converted by way of a pick-up into an electrical signal. The pick-up is generally a linear variable differential
transducer (LVDT). The electric signal is amplied and processed or converted into a digital signal via an A/D converter and then analysed using a computer. A schematic
diagram of such a system is shown in Fig. 1.
In the diagram shown, the stylus is held stationary
while the specimen surface is moved in a raster scan using
precision X, Y-tables. The movement of the table is controlled via a computer, allowing numerous combinations
of area size and data sample spacing to be selected [6].
The stylus measurement method is a contact type, the
main drawback of which is that the loaded stylus can damage or scratch the surface being measured, especially on
soft surfaces [7]. The transducer and stylus tips are often
fragile, hence the instrument must be applied in a fairly
vibration free environment. Consequently, this direct con-
Fig. 1. Schematic diagram illustrating the major constituents of a stylus-type of surface texture measuring instrument [5].
613
six-place nosepiece. The specimens reected light is projected through the beam splitter onto a color digital sensor
(Fig. 2).
The other one is a scanning type confocal laser microscope with high resolution, high contrast and drastically
enhanced resolution in light axis direction via confocal optics. Confocal optics are designed to have almost innite
small depth of focus. Thats why, not only the variation of
focus, but also the absolute maximum value is analysed
[10]. The scanning type confocal laser microscope targets
laser beam at a very small spot with objective lens and
scans over the specimen in XY directions. It then captures
a light from specimen with detector and outputs the image
of specimen on monitor [13]. A schematic diagram of such
a system is illustrated in Fig. 3.
In this experimental study, measurements by stylus
type instrument were performed with Form Talysurf Intra
50, which is skidless and can be used for waviness, prole
and other parameters such as material ratio with absolute
condence in the measurement results and measurements
by optical 3D surface measurement devices, the innite
focus microscope and the confocal laser scanning
microscope.
3. Conditions of experiment
In this experimental study, the measurements were
made with commercially available Form Talysurf Intra 50
by Taylor Hobson GmbH for the tactile surface evaluation
with a high resolution, in 1.0 mm range 16 nm. By its software ultra it is possible to analyze and monitor operations. It was used 60 mm stylus arm length, 2 lm radius
conisphere diamond stylus tip size, 1 mN force
(speed = 1 mm/s) and Gaussian lter in all measurements
by the stylus instrument [2,14,15]. Each measurement
614
2)
(o
2)
M
ea
n
(o
2)
3
(o
2)
1
(o
(c
6
(c
)
(c
2
Ra
3,000
Rz
2,000
1,000
6
(
M o1)
ea
n
(o
1)
1
(c
)
2
(c
)
3
(c
)
4
(c
)
5
(c
)
6
(c
)
M
ea
n
(c
)
1
(o
2)
2
(o
2)
3
(o
2)
4
(o
2)
5
(o
2)
6
(o
2
M
ea )
n
(o
2)
1)
(o
(o
1)
5
1)
(o
(o
(o
3
1)
0,000
1)
ea
n
(o
1)
1)
(o
5
(o
3
(o
1)
RSm (m)
1)
Roughness values ( m)
Fig. 5. Diagrams of roughness prole belonging to face turning steel shiny sample 1 respectively obtained them from the contact stylus measuring system
(on the right), the innite focus microscope (in the middle) and the confocal laser scanning microscope (on the left) [10].
Fig. 6. Comparisons of the roughness values belonging to face turning steel shiny sample 1 taken from the contact stylus and two optical measuring
systems in terms of the parameter RSm, Ra and Rz [10].
615
1.031 lm; for the innite focus microscope, 1.113 lm; for
the confocal laser scanning microscope, 1.111 lm were taken). The standard deviation of the data belonging to the
face turning steel shiny sample 1 is also similar. It was also
taken compatible results for RSm and Rz values according to
the ISO standards.
used in order to strengthen this study. In this group of proles there will be couples with roughness class difference
of one. Comparability for six specimens with random surfaces will be veried as a result of the experiments. The
diagrams of roughness prole and values belonging to
peripheral milling steel browned sample 1 (Fig. 7) taken
from both systems were obtained as shown in Fig. 8. Comparisons of roughness values taken from both measurement systems in terms of parameters Ra and Rz are given
in Fig. 9.
For the peripheral milling steel browned sample 1, it
was taken comparable results for mean values of Ra parameters (For the stylus system, 1.031 lm; for the innite focus microscope, 1.113 lm; for the confocal laser scanning
microscope, 1.111 lm were taken.). It was also taken compatible results for Rz values according to the ISO standards.
5. Experimental results
Ra
3,000
Rz
2,000
1,000
1
ea )
n
(o
1)
1
(c
)
2
(c
)
3
(c
)
4
(c
)
5
(c
)
6
(c
)
M
ea
n
(c
)
1
(o
2)
2
(o
2)
3
(o
2)
4
(o
2)
5
(o
2)
6
(o
2
M
ea )
n
(o
2)
)
(o
1
(o
1)
(o
(o
1
(o
1
(o
2
1)
0,000
Fig. 8. Diagrams of roughness prole belonging to peripheral milling steel browned sample 1 respectively obtained them from the contact stylus measuring
system (a), the innite focus microscope (b) and the confocal laser scanning microscope (c) [10].
Fig. 9. Comparisons of the roughness values belonging to peripheral milling steel browned sample 1 taken from the contact stylus and two optical
measuring systems in terms of the parameter Ra and Rz [10].
616
Fig. 10. The distribution curves (Frequency Histograms) of the descriptive statistical results belonging to the measurements of face turning aluminum shiny
sample 1, face turning steel shiny sample 1 and face turning steel browned sample 1 in terms of Ra and Rz parameters.
Fig. 11. The distribution curves (Frequency Histograms) of the descriptive statistical results belonging to the measurements of peripheral milling steel
browned sample 1, peripheral milling steel browned sample 2, front milling steel browned sample 1, front milling steel browned sample 2 in terms of Ra
and Rz parameters.
617
Table 1
The coefcients of the linear equation, involving a few independent variables (feed in mm, periodicity, type of material, contrast, type of production process,
etc.), that best predicted the value of the dependent variable Ra.
Model
(Constant)
Periodic surface proles
The type of material
Contrast
The type of production processes
Feed
The type of machine
Unstandardized coefcients
Standardized coefcients
Std. Error
Beta
1.314
1.279
0.059
0.188
0.024
9.097
0.025
0.244
0.283
0.087
0.087
0.106
0.124
0.036
0.234
0.010
0.037
0.011
1.097
0.008
Sig.
5.396
4.525
0.680
2.166
0.227
73,633
0.687
0.000
0.000
0.497
0.031
0.821
0.000
0.493
Fig. 12. The distribution curves of Ra with descriptive statistic values for measurement data [10].
Table 2
The coefcients of the linear equation, involving a few independent variables (feed in mm, periodicity, type of material, contrast, type of production process,
etc.), that best predicted the value of the dependent variable Rz.
Model
(Constant)
Periodic surface proles
The type of material
Contrast
The type of production processes
Feed
The type of machine
Unstandardized coefcients
Standardized coefcients
Sig.
Std. error
Beta
Std. error
3.258
4.495
.906
1.500
.067
38.059
.051
.960
1.113
.342
.342
.419
.487
.142
.194
.036
.070
.007
1.082
.004
3.395
4.038
2.648
4.386
.159
78.203
.357
.001
.000
.009
.000
.874
.000
.721
618
Fig. 13. The distribution curves of Rz with descriptive statistic values for measurement data [10].
9
8
7
6
5
Sa
Ra
4
3
2
1
15
14
13
12
11
10
6. Conclusion
This paper is an experimental study of the roughness
analyses of the conventionally machined samples with at
surfaces in order to compare the data obtained from the
contact stylus measurement device with two non-contact
optical surface measurement instruments and the capabilities of three measurement systems were noted in terms of
their similarities and differences. The major disadvantage
of using a stylus instrument is that it requires direct physical contact, which limits the measuring speed. In addition,
the instrument readings are based on a limited number of
line samplings, which may not represent the real characteristics of the surface. This kind of deviation may cause
serious errors in the surface quality assessment especially
when the surface prole is periodic.
It is observed that three devices are giving comparable
results if the surface has a good reection value, is not very
ne machined surface with a periodic prole and not
ruined or scratched. According to the presumptions, the
problem with the ne machined samples having periodic
proles is that contact system can not detect the extreme
619
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