A Brief Introduction To The

Measurement Of Roundness and

Spindle Error Separation

Matt Towery
December 14, 2000
Engineering Metrology
MEGR 6181
INTRODUCTION
Measuring roundness is one of the many aspects of metrology. As the

demand of high precision parts has increased so has the demand for higher

precision roundness measuring machines. Two established methods for the

measurement of roundness have been established.

The first method is the intrinsic datum method. In this method, the

surface of the part itself is used as a datum. This method of measuring parts is

quick and not very costly. It is also not as accurate as other methods.

The second method is the extrinsic datum method and will be discussed in

more detail. This method uses an external method as a datum. The extrinsic

method is more costly but yields higher quality results. The equipment for this

method varies but usually consists of a spindle and a stylus to collect points on

the surface.

Spindles used in the extrinsic datum method are sometimes required to be

very precise. One method of testing these spindles is to use a master test ball of

a know dimension. A problem exists that the best way of measuring the

roundness of the master is often by using the spindle that needs to be tested.

Therefore, a method to separate the error of the master test ball and the error of

the spindle itself is needed. The following sections discuss both methods for

testing roundness and spindle error separation.

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INSTRINSIC DATUM METHODS

This method is widely used throughout industry and contains several

techniques such as diametrical measurements, V-block measurements, and

bench center measurements. Intrinsic datum methods should be regarded as a

convenient, low-investment approximation of the true out-of-roundness

value [1].

Diametrical Measurements

This is one of the simplest and most common techniques of the intrinsic

methods. Diametrical measurements take comparisons of points measured in a

common cross-sectional plane; refer to Figure 1 for an illustration. This

measurement can be done with a micrometer, bore gage, air gage, or a similar

device. It is important to note the lobing condition of parts evaluated using this

technique. Parts with an odd number of lobes appear to have a smaller than

true out-of-roundness condition. The part will seem to have a larger than true

out-of-roundness condition if it has an odd number of lobes.

Figure 1 – Diametrical Measurement

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V-Block Measurements

This is a method that uses three points to obtain the out-of-roundness

conditions. It is suitable only for parts with an odd number of lobes. If the part

being measured in this technique has an even number of lobes then the true

out-of-roundness condition will be concealed. In the V-block technique, the part

is placed in a vee and then rotated. An indicator or similar device is placed

opposite of the vee and deflects when the part is rotated as seen in Figure 2.

The amount the indicator moves indicates the out-of-roundness condition of the

part. With this method the actual out-of-roundness condition is exaggerated,

therefore a conversion factor must be used to obtain the actual value.

Figure 2 – V-Block Measurement

Bench Center Measurements

In this technique a part is placed between two bench centers and rotated

while an indicator is in contact with the surface as seen in Figure 3. Since the

part has to be placed between two bench centers, this method is only suitable

for parts with machined centers. This method is the most unreliable of the

intrinsic method and is prone to many errors. Errors can cause a high degree of

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uncertainty of the true value of the out-of-roundness conditions and a part that

is actually within tolerances can appear to be bad. These errors include

improper alignment, inadequate surface condition of the centers, and bowed

parts.

Figure 3 – Bench Center Technique

EXTRINSIC DATUM METHODS

Extrinsic methods are by far superior to the intrinsic methods but require

costly precision equipment. In this method, the part is placed on a table that is

either stationary or rotating. Either the table or the part is then rotated with a

precision spindle and a stylus contacts the surface and takes data points. As the

stylus collects data points a polar chart is printed, on a magnified scale, that

represents the roundness condition of the part.

The polar graph is a representation of the displacement of the stylus as it

moves around the part. The magnification is very important here, because at

high levels of magnification the polar chart will give a false representation of the

true circularity condition. Magnification rates and suppression of inconsequential

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features can be varied to enhance the most meaningful aspects of circularity

condition [1].

Assessment Methods

Once the polar plot is produced a method for evaluating the out-of-

roundness condition of the part is needed. Research in the late 1970s and early

1980s suggested that a limacon as the best reference for small eccentricities [2]

but here the use of circles, with a common center, will be discussed as reference

figures. With circles as a reference, the minimum separation of the circles

represents the out-of-roundness condition. Several different methods of

choosing the common center are listed below.

Minimum Radial Separation

In this method, two concentric circles are drawn that enclose the entire

profile between them but maintain the least possible radial separation. The

radial distance between the two circles is taken to be the out-of-roundness of the

part being measured as shown in Figure 4. The location of the circles is usually

determined using transparent templates. This method requires that both two

inner and outer contact points must occur.

Figure 4 – Minimum Radial Separation [3]

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Least Squares Circles

The least squares circle (LSC) is fitted inside the profile such that the sum

of the squares of radial ordinates between the circle and profile is minimized as

illustrated in Figure 5. The center of the LSC is then used to draw a

circumscribed and an inscribed circle on the polar profile and the out-of-

roundness value is the radial separation of these two circles. The least squares

circle and its center are unique because there is only one that meets the

definition [1] and its accuracy depends on the number of points taken. Manual

calculation of the LSC is labored and time consuming but newer digital

instruments simplify the process dramatically.

Figure 5 – Least Squares Circle [3]

Maximum Inscribed Circle

This method fits the largest possible circle inside the profile figure as

shown in Figure 6. The circle can be determined by trial and error with a

compass or with a template. After the circle has been drawn, the out-of-

roundness value is the maximum distance between the profile and the inscribed

circle.

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 Figure 6 – Maximum Inscribed Circle [3]

Minimum Circumscribed Circle

A center is found by drawing a circle that has the smallest possible radius

but still contains the polar plot profile in this method as illustrated in Figure 7.

An inscribed circle is then drawn inside the profile based on the center of the

minimum circumscribed circle. The out-of-roundness value is the difference

between the radii of the inscribed and circumscribed circle.

Figure 7 – Maximum Circumscribed Circle [3]

Spindale Error Analysis

Although the spindles used in the measurement of roundness are

precision built, errors in the spindles do exist. Usually the errors in these

spindles are found by my measuring a master test ball of known dimensions.

However, the test ball itself has out-of-roundness errors. The problem arises

here that the best means of measuring the roundness of the master may be the

spindle that is in question. Another problem is that the errors of the spindle and

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the master may cancel each other out. This section is a brief summary of an

article written by R.R. Donaldson in 1972 [4] that discusses the separation of the

master test ball error P (θ) and spindle error S (θ).

The spindle error is the displacement along a radial line connecting the

axis of rotation and the stylus tip [4]. It is important to note that the spindle

error S (θ) will be referred to as radial motion. This distinguishes it from other

error such as axial or angular motion.

A measurement with two different setups is required. Marks are made on

the spindle shaft, part, and spindle housing as shown in Figure 8a and then a

polar record T1(θ) is recorded. Then, only the part and stylus are rotated 180

degrees and two polar traces are taken (T2P(θ) with normal polarity and T2S(θ)

with reversed polarity).

A B
Figure 8 – Spindle Error Separation Technique [4]

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 The polar traces can be expressed as:

T1 (θ) = P (θ) + S (θ) Eqn. 1

T2P (θ) = P (θ) – S (θ) Eqn. 2

T2S (θ) = -P (θ) + S (θ) Eqn. 3

Adding Eqn. 1 and Eqn. 2 and then Eqn. 1 and Eqn 3 produces the following:

P (θ) = ½ [T1 (θ) + T2P (θ)] Eqn. 4

S (θ) = ½ [T1 (θ) + T2S (θ)] Eqn 5.

In words, the error of the master can be found by drawing T1(θ) and

T2P(θ) on the same chart. P(θ) is just the average profile halfway between the

T1(θ) andT2P(θ). The same is true for the error of the spindle. S(θ) is the

average profile of T1(θ) and T2S(θ) when drawn on the same polar chart. Now,

the out-of-roundness condition of the master test ball and the radial error of the

spindle can be determined by one of the extrinsic methods discussed in the above

sections.

This method has been tested in practice on an assortment of instruments

and in a variety of situations. It is assumed in this method that the spindle with

repeat itself exactly each time. Taking a number of traces on the first try will test

the repeatability of the spindle. Other sources of error can include vibration,

thermal stability, electronic disturbances, and belt or gear forces.

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CONCLUSION

This discussion is provided to give the reader a general knowledge of the

measurement of roundness and spindle error separation. It should not be used

as a master reference for all techniques used in roundness assessments. Some

of the techniques above may no longer be practical since computers have greatly

improved the world of metrology.

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REFERENCES

[1] Class notes on The Measurement of Roundness, J. Raja, Engineering

Metrology, MEGR 6181 at the University of North Carolina at Charlotte,

Fall 2000.

[2] Jayaraman, Venkataramanan, A Unified Approach for Measurement and

Analysis of Roundness, Cylindricity and Conicity, Master’s Thesis at the

University of North Carolina at Charlotte, 1995.

[3] Litsikas, Mary, The Dos & Don’

ts of Roundness Measurement, Quality

Online, http://www.qualitymag.com/articles/1996/nov96/1196f1.html

[4] Donaldson, R.R., A Simple Method for Separating Spindle Error from Test

Ball Roundness Error, Universiy of California, Livermore CA, 1972.

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