calibrate surface plates in the plant October 1955 The Tool Engineer By J.C. Moody 1d Electrical Standarde Dept. Albuquerque, Ne M. Swce seasonsannrs ee no snore slab than the surface pate on which they are referenced, ii important 1s know exaciy the sora ofthe plate Being wed. Surface plats are manufactred to tccaraie varying from 0:02 to 0.005 inch of Geviatin fom a tre plane, The user should chock ech plats ater tiled 4 determine winter it mes wpecfaions and rom tne tte there ther to lea the eet of weet and envirnmnt Tho dock monomer info. pstiol por pes be done inthe work environment predicable method of osurlely calling surface platen in ovllble to ndutry. ‘Te methed used in the mavalogy labortory a Sandia Corp. is highly accurate yo can be per formed by semiilled personne uring istruments set toany nde hod is an application and extension of procedures de Neloped by K. J. Hume (British metrologit) and deal, th calibeton choo. ba. ecirm ka 2 room in which the temperature of the pate can be kept in ogulibrium and from ‘which thermal carrots can be exloded. Hower inary ue jal laboratory. This 116 Fig. 2. Mirror mount, reflector mounts ar ‘surface plates under conditions that are less than ideal. These plates can be satisfactorily calibrated under the same conditions. Extremes of tempera- ture changes, thermal currents, and vibration are obviously to be avoided. Calibration Method: Equipment needed for this method is shown in Fig. 1. The autocollimator jis exsentially an optical lens system from which parallel rays are emitted. ‘These rays strike the surface of a steel optical at and are reflected back into the autocollimator. The reflected rays produce image at the focal plane of the autocollimator Ja angular displacements can be accurate: ly determined. ‘The reflector is mounted on a bracket, the sup: port pads of which are separated by # distance Fig. 3. Positions of autocollimator daring readings for the eight principal lines, Eos! optical las used for calibrating surface plates. arbitrarily chosen so that it will divide evenly into the dimensions of the surface plate. This distance should be about 8 percent ofthe length of the short side of the plate. Various reflector mounts needed for different size plates are shown in Fig. 2. The mirror mounting bracket is so designed that the mirror mounting is normal to the surface plate. Steel optical flats, the faces of which do not deviate from a plane by more than 0,000003 inch, are used for both the mirror and reflector. In addition, 4 straight edge, graduated in increments equal to the distance between the support pads of the re flector stand, is used, ‘A total of eight lines of readings are taken: four perimeter lines, two diagonal Tines, and two center lines, Fig. 3. The perimeter lines are laid out one increment from the edge of the plate. The precise stations at which readings along all eight lines are taken are measured off in steps equal to the incre: ments on the straight edge. Many more readings could be taken, but « reasonable compromise be tween accuracy and economy is achieved by this method. Detailed instructions for using an autocollimator are supplied with the instrument and should be studied carefully. The position of the autocoli- rmator for each line of readings is shown in Fig. 3. ‘The readings along the north perimeter line, for ‘example, are taken with the autocollimator in the southwest corner of the plate. The reflector is moved along the line and readings are taken at each station. These readings are entered directly ‘on the properly identified work sheet, Fig. 4 After cach line is completed, the reflector is moved back to the first station on that line and another reading taken. If this does not agree within + 0.3 sec. of ‘The Tool EngineerFig. 4. Diagram showing relationship of profile of northwest to southeast diagonal {o line of first reading and datum plane. Datum plane 3 7 Il 15 19 23 27 31 35 39 43 47 51 55 59 6367 71 75 79 83 are with the first reading taken at the same station, the operation must be repeated. Autocollimator readings entered on the work sheet show only angular displacement in tenths of a second of are in relation to the line of first read- ing. To be readily meaningful, these must be con- verted to linear deviations from a base plane. The procedure for these conversions and their presenta- tion will be discussed in the following paragraphs. ‘Though care must be exercised in each step, the conversion is not a formidable task. Readings ean be made in about two hours; an intelligent, proper: ly instructed clerk can reduce the data to an ac: curate profile of the surface plate in an equal time. implified Data Conversion Procedure: Directions for converting. autocellimator readings into linear displacement in hundred-thousandths of an inch are given without any attempt at theoretical justification. One line of each class will be ex- plained in detail. The reader who is interested in the theoretical considerations should read K. J Hume's Engineering Mesrology or the author's paper, The Metrology of Surface Plates, copies of ‘which are available upon request ‘The person who is to reduce the data is given a work sheet for each of the eight lines, TABLE 1 On these, the stations at which readings were taken fare indicated in Column 1 in terms of inches from the edge of the plate in the direction in which the line was read, The autocollimator readings are centered in Column 2. No reading is entered for the firs station on the line, Convension FoR DiscoNALs: To process the Northwest to Southeast diagonal line data, the fol- lowing steps should be taken in order: October 1955, 1. Convert the sutocllimator readings into angular displacement by determining the amount by which tach value in Column 2 is greater or less than the first value in Column 2. Do this at each station: enter the result in Column 3, paying the sign 2. New, determine the algebraic sum of the at displacement at each station and enter this valve jn Column 4. To do this, add the values in Column 3 down to and incleding each station. Divide the last value in Column 4 by the total num: her minus one of the stations on the line to deter- mine the correction factor. (in the example shown there are 21 stations. Hence, ~280/20 = —14.) 4 Set up an arithmetic progression in Column 5. Re- verse the sign of the value in Column 4 opperit the midstaton and enter it opposite the same sta in Column 5. Working up Colun dstation, add the correction factor cusmuatively at each station. Return to the midstation and sub: tact the correction factor cumulatively at each ta- tion to the bottom of the column, The resulting arithmetical progression is the cums tion factor for each station, ion, add algebraically the 5 from the Columa 6. (The datum plane, Fig. is that plane in which the center point of the rarface plate lee parallel 10 the lines containing the end of each diagonal.) Proceed ‘completed, enmpata enter lines must be catried to this point. Do the Perimeter lines next. Converston ror Norrit Periwerer Ling: 1. Proceed exactly as with the diagonals through Column 4 foreach of the perimeter lines 2 Prepare a chart of the surface plate ae illustrated in Fig. 5. Enter the physical center, 0, and the values found for the ends of the "‘Table 1—Work Sheets for Calibrating a 48 x 78-Inch Surface Plate* 7 Z z z ¢ emg has at jaagael Tsai | mes Se fie Sadie ce. aetna en Commitee a = ae Paes nei) cmea aetna ae Oo Taga Noe San = z 5 & j ‘ e 3 ‘ z 2 t & fs A 5 4 3 3 - x 3 ‘ g s : f 3 k 3 3 3 i i = > ‘ x = 3 5 = $ 3 = 5 i ¢ 3 z , f 3 3 i > 3 z : 5 3 z i z s t : ‘ ey A 7 s = 3 = # : ‘ z te 3 % » ‘ 5 « 3 = fe u x at $ t & 3 : 3 & = z : a Faia iw Ra Sate 7 = = = a = z 7 : = = = ‘4 A a i a 3 H i ‘ 3 eH = ; i $ z = Ee i ‘ 2 3 os —« 8 2 “ 8 =a a 2 6 ‘The Tool Engineer‘Table 1 (Continued) * 0 7 2 3 + 3 . 7 ° font orlnne man ae (i wolfe sein rani iiae Tiron ot, dk tate South Prince Line Eat to West a ‘s x te ue o & = = nal ™ x a =i ts oi 3 a & = Bote = * ve ae tie (3 * * ® ‘s = im i x : * a8 he a ‘ 3 3 8 ty Hee ey 3 3 = a ee 2 " 5 St ae ine 2 t a =x an Oe z ‘ & 3 = iz 8 3 3 hw Sth 7 zn = e = me = A 2 fe a a = 3 2 ct % $ a 3 aH = a ‘ » « a a a 3 ® : x 5 = a an 3 a : 3 3 a =F 7 = : ; 2 > = = 4 = : ' x 3 : 3 th a : : & : 3 te s : % s = s ue a 1g Cente Une East West 5 es == ae 7 Y +3 a 3 op < ‘ uM = =a. oe : » tn ws tog " x pe = =e % 3 Bes 3 ae 3 2 Be = og 3 3 aS ‘ 3 OS u & ad : e 0 1 3 & 7 = > : a z = « ° x é & a $ " x e * + a He TAIT vateee exept Colne 1 October 1955 1920 Conversion For East ro West Cexten Live: Column 6 in the work sheets a8 shown. This ch ie important as without it there i danger of eon- Sasing the figures 3. Enter the value for the NE ead of the NESW di agonal in Colurnne 5 and 6 opposite the frst station. Enter the value of the NW end of the NW-SE di agonal opposite the last station in Column 6 on 44 Next in! the correction factor. Subtract the value fopperite the last station in Column 4 from the value ‘opposite the same station in Column 6 [—36 199) = 163]. Enter this value opposite the last station in Column 5, Subtract this value from that opposite the frst station in Column 5 (—53 =I6d = —216) and divide the result by the total number of stations on the Tine minus one (—216/ 16 = —135}.. The result is the correction factor. 5. Beginning atthe lest station in Column 5, add the re tach station. (Since the correction factor in the example is 135 to avoid decimals —13 and —14 ace used altermately.) 6. To find the anguler displacement from the datum plane, algebraically add the values opposite each Station in Columns 4 and 5 and enter the results in Column 6. Complete the conversion for each of the perimeter Tines to this point and enter the values atthe mid> points in Fig. 8. Now proceed with the center line 1. Carry the conversion through Column 4 ‘The proce dre for the center lines is exactly the same as for the diagonal and perimeter lines to this point, 2, From Fig. 5, enter the value for the midpoint of the fast perimeter Tine opposite the fist station in Columns 5 and 6. Enter the valve for the mid- int of the west perimeter Tine opposite the last Station in Column 6 ony. 4 Subtract the value opposite the last station in Column 4 from the valie opposite the same sta: tion in Column 6 and enter this value at the last station in Column 5. 4, Subtract the last value ia Calumn 5 from the and divide the result by th total number of stations ‘onthe line minus one, The result isthe correction factor 5. Beginning at the last station in Column 5, add the correction factor up the Column in an arithmetic progression to find the cumulative correction factor for each station. 6. At each sation, algebraically ad the values in Columns 4 and 3 and enter the result jn Column 6. ‘This i the angular displacement frofh the datum plane. 1, Change the sign ofthe value opposite the {in Colin 6 aid add it to the value opposite each sation in Column 6, Enter the sum in Columa 6a. ‘A word of explanation is necessary at this point. ‘The center line check is the criterion of accuracy for the entire operation. The value at the point at which the center lines and diagonals intersect is physically zero, If everything were done perfectly, the value opposite the center station would be zero. But this is not possible because each slight error in reading the instrument is reflected at the midstation of the center lines. If the magnitude of 1 ation may be regarded as ‘satisfactory; job must be done over. “Column 6a, which appears only in the work sheets for the center lines, is used to move the error away from the center, which is known to be zero, ‘out to the perimeter. Final Steps in Conversion: The work sheets for the eight lines are now completed through Column 6, inckuding Column 6a for the center lines. ‘The procedure for Columns 7 and & is identical for all work sheets and must be done together. 1. Seach through Column 6 for all work sheets, Column Gn of the center lines, for the lowest value in all fof the 8 enlomns. Add this value to the value ‘opposite each station in Column 6 (6a for the center Tines) end enter the sums in Column 7. This The Tool Engineer[rates Cater] oo N24 Se " 15 wo se eoRremunne is wae 3 6 e138 7 7 Oe wo7 63 a, ° 2 ' Fig. 6. Linear deviations from base plane indicated ° slong. the ight principal, peace ata ines of x 48. x" T2inch 2 8 0 Banos Figure is the displacement from the true base plane This is defined as that plane containing the point of lowest reading and parallel to the datum plane 2. Next, convert the values in Column 7 to linear values in 000001 inch. To do this, multiply the of the sine of 1 second (0.000005) times enter lines of the mi example) (0.000005 % 4 (0.00002) by the values in Column 7 at each ata the values in Cal tenths of 4 second of are, itis necessary to divide the produet at each station by 10 to got the decimal point in the right place. Round out the anewer to the nearest indredthousandth af an inch, drop out the des mal point and enter the value in Calum 8. Ociober 1955 Conclusion: ‘The data from Column 8, when reported on the form shown in Fig. 6, allows the user to see at a glance the features of the surface plate he is using. It shows not only the extremes of variation, but also the est areas on the plate, Acknowledgments: ‘The author wishes to ac: knowledge the technical assistance given to work by J. M. Bunch, physical standards Sandia Corp. and A. R. Darling, formerly of Sandia Corp. Appreciation is also expressed for the e' torial efforts of W. F. Carstens, reports and et torial division, Sandia Corp. a