My work in inspection, and as a quality management system auditor, provides numerous opportunities to acquire knowledge. It also provides areas of risk for ensuring valid and reliable results. One risk that keeps repeating itself in my audit findings is the treatment of surface plates. Instead of being treated as a precision device, they are treated as an area to stack tools, parts and other debris. The root cause of this treatment is the lack of knowledge about the surface plate and its mistaken identity as just a table. Let&#;s take a journey of the history and recommended care for the surface plate.
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The surface plate was designed and developed as a precision tool by Henry Maudslay and Joseph Whitworth in order to ensure the production of identical tool parts. The first surface plate was composed of cast iron. The first surface plates were sold in by the Crown Windley company. During World War II, metal was in high demand which resulted in the introduction of using granite, a non-corroding metal that is extremely hard and non-magnetic.
A flatness check of a surface plate. Source: ASQ
Engineering and manufacturing specifications are demanding tighter tolerances, which elevate the importance of accurate measurements. To deliver measurements, each piece of metrology equipment requires a base plate.
Granite is the most common material used for surface plates. The surface plate does require maintenance. The following are recommendations for maintaining these precision instruments:
A surface plate on a CMM (r) and other surface plate devices (l). Source: ASQ
Along with checking the flatness of parts, surface plates can identify part warpage. The surface plate is the &#;0&#; reference point. If a height gage is used on the plate, the inspector can place the gage anywhere on the plate and zero the gage. This can be completed in conjunction with a gage block. The gage block is removed, and small parts can be accurately measured. This is also a technique to verify small parts for flatness.
The surface plate is an underrated metrology tool. It has been more than 80 years since granite was identified as an alternative to cast iron. Granite surface plates have become foundation for many standards in metrology. The coordinate measuring machine (CMM) does represent the acceptance of granite as the only material used in this vital area of metrology. Hopefully, you were able to obtain knowledge and insight on why I feel it is critical to properly maintain surface plates. Valid and reliable results must be acquired in order to make proper decisions on the disposition of parts.
strange looking granite surface plate used in metrology
Surface plates are essential tools in precision engineering and quality control. These flat reference surfaces provide the foundation for accurate measurements and inspections across various industries. Granite surface plates offer exceptional flatness tolerances, long-lasting durability, and resistance to temperature changes, corrosion, and impact damage.
These precision instruments come in different grades and materials to suit various applications. While granite is a popular choice, cast iron plates are also available. The grade of a surface plate determines its level of accuracy, with higher grades offering tighter flatness tolerances. Engineers, machinists, and quality control professionals rely on surface plates for tasks such as layout work, part inspection, and tooling setup.
Proper care and maintenance of surface plates are crucial for preserving their accuracy over time. Regular calibration and protection from environmental factors help ensure consistent performance. As technology advances, surface plates remain indispensable tools for achieving precision in manufacturing and metrology applications.
Surface plates have a rich history spanning centuries. Their evolution has been marked by significant improvements in materials, manufacturing techniques, and applications across various industries.
The concept of using flat surfaces for measurement dates back to ancient civilizations. Early craftsmen used stone slabs to check the flatness of their work. In the 18th century, English engineer Henry Maudslay pioneered the use of surface plates in precision engineering.
He created the first metal surface plate, which greatly improved accuracy in machining and measurement. This innovation laid the foundation for modern manufacturing processes.
The 19th century saw a shift from metal to granite surface plates. Granite offered superior stability and resistance to wear. Its low thermal expansion coefficient made it ideal for precision measurements.
Cast iron plates remained in use but were gradually replaced by granite in high-precision applications. The development of synthetic materials like ceramics in the 20th century provided new options for surface plate construction.
These materials offered unique properties like extreme hardness and chemical resistance.
Today, surface plates are essential in various industries. They serve as the baseline for all measurements in manufacturing, aerospace, and scientific research.
Advanced manufacturing techniques have enabled the production of surface plates with incredible flatness tolerances. Some plates can achieve flatness within microns over their entire surface.
Digital measurement technologies have enhanced the capabilities of surface plates. Coordinate measuring machines (CMMs) and laser scanners now work in conjunction with surface plates for ultra-precise measurements.
Surface plates come in various materials, each with unique properties and applications. The main types are cast iron, granite, glass, and steel. Each material offers different benefits in terms of durability, precision, and cost-effectiveness for metrology and measurement tasks.
Cast iron surface plates provide a durable and economical option for many measurement applications. These plates offer good stability and wear resistance. Their porous structure allows them to absorb vibrations effectively, making them suitable for workshop environments.
Cast iron plates are less prone to warping than steel alternatives. They can be easily resurfaced through scraping or grinding when needed. However, they are susceptible to rust and require regular maintenance to prevent corrosion.
Cast iron surface plates are typically used in machine shops and quality control departments. They work well for layout work, part inspection, and general measuring tasks. While not as precise as granite, cast iron plates offer a good balance of performance and affordability for many industrial applications.
Granite surface plates are considered the gold standard for precision measurement. They offer superior flatness, stability, and wear resistance. Granite's low thermal expansion coefficient ensures minimal distortion due to temperature changes.
These plates are highly resistant to chemicals and corrosion. They do not warp or twist over time, maintaining their accuracy for many years. Granite's natural damping properties make it excellent for reducing vibrations during measurements.
Granite surface plates are ideal for high-precision metrology labs and quality control departments. They excel in applications requiring extreme accuracy, such as calibrating precision instruments and inspecting critical components.
Despite their higher cost, granite plates often prove more cost-effective in the long run due to their longevity and minimal maintenance requirements.
Glass surface plates offer unique advantages for certain applications. They provide exceptional flatness and are optically transparent, allowing for backlit inspection of parts. Glass plates are resistant to chemicals and do not corrode.
These plates are lightweight compared to other materials, making them more portable. They are ideal for clean room environments due to their non-porous nature. Glass plates excel in applications involving optics, electronics, and other industries requiring visual inspection.
However, glass surface plates are more fragile than other types. They require careful handling to prevent chipping or cracking. Glass plates are best suited for light-duty applications and environments where cleanliness and optical properties are crucial.
Steel surface plates offer high durability and resistance to wear. They are often chosen for heavy-duty applications in machine shops and industrial settings. Steel plates can withstand rough handling and heavy loads without damage.
These plates are typically less expensive than granite alternatives. They can be easily machined or ground to restore flatness when needed. Steel plates are often used for layout work, welding setups, and general inspection tasks.
However, steel surface plates are more susceptible to temperature changes and may warp over time. They require more frequent recalibration to maintain accuracy. Steel plates are best suited for applications where durability and load-bearing capacity are prioritized over extreme precision.
The creation of a precision surface plate involves several crucial stages. Each step contributes to the final product's accuracy and reliability.
Surface plates are typically made from granite or cast iron. Granite is preferred for its stability and resistance to wear. Manufacturers select high-quality stone blocks from quarries, ensuring they are free from cracks or imperfections.
The chosen granite undergoes thorough testing for density, hardness, and uniformity. Only blocks meeting strict standards move forward in the process.
Cast iron plates offer an alternative, valued for their durability and lower cost. The iron is carefully formulated to achieve the right balance of strength and machinability.
Large stone blocks are cut to rough dimensions using diamond-tipped saws. Precision machinery ensures accuracy in this initial shaping phase.
The plate is then ground to its final size and shape. This process uses progressively finer abrasives to achieve a smooth surface.
For cast iron plates, the material is poured into molds and allowed to cool slowly. This controlled cooling prevents internal stresses that could lead to warping.
After cooling, cast iron plates undergo machining to achieve their final dimensions.
The flatness of the surface is critical. Plates undergo lapping, a process using abrasive compounds to remove microscopic imperfections.
Granite plates are typically lapped using diamond abrasives. This creates an extremely flat surface with tolerances as tight as 11.5 μm per mm for high-grade plates.
Cast iron plates may be scraped by hand or machine to achieve flatness. This process requires great skill and patience.
Some manufacturers apply special coatings to enhance durability or corrosion resistance.
Quality control is rigorous. Inspectors use precision instruments like autocollimators and electronic levels to verify flatness.
Measurement tools check for parallelism between top and bottom surfaces. Any deviations are carefully documented.
Plates undergo stability testing to ensure they maintain their flatness over time. This may involve temperature cycling and load testing.
Only plates meeting or exceeding industry standards receive certification for use in precision measurement applications.
Surface plates possess several key characteristics that make them essential for precision measurement and inspection tasks. These properties ensure accuracy, durability, and reliability in various industrial applications.
Surface plates provide a flat reference plane for precision measurements. Their flatness is crucial for ensuring accurate results. High-quality surface plates typically have tolerances below 11.5 μm per mm.
Granite surface plates often achieve superior flatness compared to other materials. Manufacturers use specialized grinding and lapping techniques to achieve exceptional flatness.
The accuracy of a surface plate is typically classified into different grades. Grade AA plates offer the highest precision, followed by Grade A and Grade B. Each grade has specific flatness tolerances.
Regular calibration is essential to maintain accuracy. Laser interferometry is commonly used to check and adjust surface plate flatness.
Surface plates must withstand frequent use without losing their flatness. Hardness plays a crucial role in maintaining accuracy over time.
Granite surface plates excel in hardness, making them highly resistant to wear and scratches. This property allows them to maintain their flatness even after prolonged use.
Cast iron plates, while less hard than granite, still offer good wear resistance. They may require more frequent relapping to maintain accuracy.
Surface hardness also affects the plate's ability to resist damage from dropped tools or workpieces. Harder materials provide better protection against accidental impacts.
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Temperature fluctuations can affect the accuracy of measurements. Surface plates must maintain their flatness despite changes in ambient temperature.
Granite exhibits excellent thermal stability. It has a low coefficient of thermal expansion, minimizing distortion due to temperature changes.
Metal surface plates, such as those made from cast iron, are more susceptible to thermal expansion. This can affect their flatness in environments with significant temperature variations.
Some high-end surface plates incorporate temperature control systems to maintain a constant temperature, ensuring consistent measurements.
Surface plates must resist corrosion to maintain their accuracy and appearance over time. Different materials offer varying levels of corrosion resistance.
Granite surface plates are naturally corrosion-resistant. They do not rust or oxidize, making them suitable for use in diverse environments.
Cast iron plates may require special coatings or treatments to prevent rust and corrosion. Regular maintenance is crucial for metal surface plates to prevent degradation.
Glass surface plates offer excellent corrosion resistance but may be more fragile compared to granite or metal options. They are often used in specialized applications where chemical resistance is paramount.
Surface plate calibration ensures accuracy and reliability in precision measurements. Regular calibration maintains flatness tolerances and identifies any deviations that could affect measurement results.
Surface plates are calibrated according to specific standards, such as the ANSI B89.3.7- for granite surface plates. This standard defines tolerance values for different grades of surface plates, including AA, A, and B grades.
Grade AA plates have the tightest tolerances, typically used for high-precision work. Grade A plates are suitable for most inspection tasks, while Grade B plates are used for general-purpose applications.
Calibration standards also specify methods for measuring flatness and repeatability. These methods may involve using precision instruments like autocollimators or electronic levels.
The calibration process begins with a thorough cleaning of the surface plate. Any debris or contaminants can affect measurement accuracy.
Next, technicians use specialized equipment to measure the plate's flatness. This often involves using a laser interferometer to scan the surface and create a detailed topographical map.
Measurements are taken at multiple points across the plate's surface. The number of points depends on the plate's size and grade.
If deviations exceed the specified tolerances, the plate may require re-lapping or resurfacing. This process involves carefully removing material to restore the plate's flatness.
The frequency of surface plate calibration depends on several factors, including usage, environmental conditions, and industry requirements.
Many organizations calibrate their surface plates annually. However, plates used for high-precision work or in harsh environments may require more frequent calibration.
Some manufacturers recommend quarterly or semi-annual checks, especially for plates used in critical applications. Regular interim checks can help identify issues between formal calibrations.
It's important to maintain calibration records. These records track the plate's performance over time and help determine optimal calibration intervals.
Proper care and maintenance are crucial for preserving the accuracy and longevity of surface plates. Regular cleaning, careful handling, and appropriate storage practices help ensure optimal performance and extend the lifespan of these precision tools.
Keeping the surface clean is essential for maintaining accuracy and preventing premature wear. Users should remove dust, dirt, and debris after each use with a soft brush or lint-free cloth.
For stubborn residues, a mild soap solution or specialized surface plate cleaner can be used. It's important to avoid water-based cleaners or volatile solvents, as these can damage the plate.
After cleaning, the surface should be dried thoroughly to prevent moisture accumulation. Regular inspection for scratches, dents, or other damage is also crucial.
To minimize wear, users should rotate the plate's orientation periodically. This practice helps distribute wear evenly across the surface, prolonging the plate's lifespan.
Proper handling is critical to prevent damage. Surface plates should always be lifted using appropriate equipment, never dragged or slid across surfaces.
When not in use, covering the surface plate protects it from dust and accidental damage. A fitted dust cover or plastic sheet works well for this purpose.
The storage area should maintain a consistent temperature and humidity level. Extreme temperature fluctuations can cause warping or expansion of the plate material.
For granite surface plates, it's crucial to ensure the storage surface is level and stable. Uneven support can lead to warping over time.
Regular calibration is essential for long-term preservation. The frequency depends on usage but typically ranges from 6 months to 2 years.
Professional resurfacing may be necessary if significant wear or damage occurs. This process restores the plate's flatness and accuracy.
For granite plates, sealing the surface every few years helps protect against moisture and staining. This process should be performed by a professional to ensure proper application.
Maintaining accurate records of calibration, maintenance, and any repairs helps track the plate's condition over time and predict when replacement may be necessary.
Surface plates serve as essential tools in various industries, enabling precise measurements and quality control. Their flat, stable surfaces provide a reliable reference plane for critical operations.
Surface plates are crucial in precision engineering tasks. Engineers use them for marking out designs and transferring patterns to workpieces with high accuracy.
They provide a stable base for assembling intricate components, ensuring alignment and flatness. Surface plates also support coordinate measuring machines (CMMs), enhancing measurement precision.
In optical assembly, these plates offer a level foundation for aligning lenses and other sensitive components. Their flatness helps maintain the exact positioning required for optimal performance.
Quality control departments rely heavily on surface plates for inspection processes. They provide a consistent reference plane for comparing manufactured parts against specifications.
Inspectors use surface plates to check flatness, parallelism, and squareness of components. This helps identify deviations from design tolerances quickly and accurately.
Surface plates aid in baseline measurements for machined parts, ensuring consistency across production runs. Their stable surface allows for repeatable measurements, critical for maintaining quality standards.
In metrology, surface plates are fundamental reference standards. They provide a known flat surface against which other objects can be measured or calibrated.
Metrology labs use granite surface plates due to their dimensional stability and low thermal expansion. This ensures measurements remain accurate across varying temperatures.
These plates support high-precision measuring instruments, allowing for accurate calibration of gauges and other measurement tools. They also serve as bases for optical comparators and other advanced metrology equipment.
Toolmakers rely on surface plates for creating and checking precision tools. They use the flat surface to ensure cutting edges are properly aligned and ground.
Surface plates provide a stable base for assembling complex tools and fixtures. This helps maintain tight tolerances during the construction process.
Toolmakers also use surface plates for lapping operations, where ultra-fine surface finishes are required. The plate's flatness ensures even material removal across the workpiece.
Surface plates are subject to various standards and specifications that ensure their accuracy and reliability. The Federal Specification GGG-P-463c has long been used to standardize surface plate quality.
International standards like ISO provide guidelines for surface plate grades. These grades typically range from Grade 0 to Grade 2, with Grade 0 being the most precise.
The British Standard BSI 817: also defines surface plate specifications. It outlines flatness tolerances for different grades, similar to ISO .
Grade classifications are based on flatness deviation:
Surface plate accuracy is crucial, with some high-precision plates having tolerances below 11.5 μm per mm.
Manufacturers often provide detailed specifications for their surface plates, including:
These standards ensure that surface plates maintain their critical role as reference surfaces for precision measurements across various industries.
Surface plate accessories enhance functionality, protect the plate, and ensure accurate measurements. Key accessories include support stands, cover plates, and specialized cleaners.
Surface plate stands provide a stable foundation for precision work. Made from welded square steel tubing, these stands offer exceptional strength and durability.
Steel crossbeams are strategically positioned to maintain maximum surface plate accuracy. This design prevents warping or distortion of the plate during use.
Most stands feature an industrial powder-coated finish, resistant to scratches and abrasion. This protective layer extends the life of the stand and maintains a professional appearance.
Adjustable feet allow for precise leveling of the surface plate, crucial for accurate measurements. Some models include built-in storage drawers for tools and accessories.
Cover plates protect granite surface plates from dust, debris, and accidental damage when not in use. Typically made of durable vinyl, these covers have a soft interior to prevent scratching.
Custom-fitted covers ensure a snug fit, preventing dust from settling on the plate surface. Some covers feature reinforced corners for added durability in high-wear areas.
Certain models incorporate handles for easy removal and replacement. UV-resistant materials help prevent degradation from exposure to light, especially important for plates near windows.
Specialized cleaners maintain the accuracy and condition of surface plates. These products remove oils, dirt, and other contaminants without damaging the plate's surface.
Non-abrasive formulas preserve the plate's flatness while effectively cleaning. Some cleaners include anti-static properties to reduce dust attraction after cleaning.
Eco-friendly options are available, using biodegradable ingredients safe for both users and the environment. Regular cleaning with these products extends the life of the surface plate and ensures consistent measurement accuracy.
Application methods vary, with some cleaners designed for spray-on use and others for wipe-on application. Following manufacturer guidelines for cleaning frequency and method is crucial for optimal plate maintenance.
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