Profilometer Uses

Background

A stylus / surface contact profilometer uses a diamond tip

which transverses on a surface with very light pressure to
transfer information about surface topography. The
movement of the tip actuates a extremely sensitive
transducer LVDT (Linear Variable Differential Transducer)
that converts movement in electrical signal. This stylus type
surface profilometer allows measuring a complete range of
surface roughness characteristics. The stylus is commonly
interchanged with the descriptors: tip, probe, detector, pick
up and thingee. The term detector, pick up and probe are
most commonly used term to describe the unit that houses
the LVDT and the actual stylus of the profilometer.
The stylus, tip and needle are the terms used to describe the
actual diamond point on the profilometer that is similar to a
needle on a record turntable. A thingee is a term that people
use when they don't know the correct name for something.

The tip of the profilometer is typically a conical diamond and has a finite rounded shape, which
interacts with the surface being measured. A profilometer stylus is moved vertically in contact with a
sample and then moved laterally across the sample for a specified distance and specified contact
force. A profilometer detector can measure small surface variations in vertical stylus displacement as
a function of position. Typically, a profilometer can measure small vertical features ranging in height
from 10 nanometres to 1 millimetre. The height position of the diamond stylus generates an analog
signal which is converted into a digital signal stored, analyzed and displayed.

The radius of diamond stylus ranges from 20 nanometres to 50 m, and the horizontal resolution is
controlled by the scan speed and data signal sampling rate. The stylus tracking force can range from
less than 1 to 50 milligrams. The vertical sensitivity is in the nanometer range but steep edge profiles
are distorted because of the shape of the tip (see image below). As a result, smaller radius tips
provide better measurements however they are more likely to be damaged by mishandling.

The accuracy of a profilometer scan can only be as good as the mechanical stability of the
detector/probe and stylus. The profilometer tip can be subject to damage by shear forces-- not normal
forces, as a result of misuse on the shop floor. Normal stylus tip force is regulated by the instrument
however very large shear forces can be applied to the stylus if the sample stage is inappropriately
adjusted with the stylus in contact with the surface, or is bumped while in a prone position.
 Advantages of Contact Profilometers
Acceptance: Most of the world's surface finish standards
are written for contact profilometers. To follow the
prescribed methodology, this type of Profilometer is often
required.

Surface Independence: Contacting the surface is often

an advantage in dirty environments where non-contact
methods can end up measuring surface contaminants
instead of the surface itself. However, because the stylus
is in contact with the surface, this method is not sensitive
to surface reflectance or color.

Resolution: The stylus tip radius can be as small as 20

nanometres, significantly better than white-light optical
profiling. Vertical resolution is typically sub-nanometer as
well. Also, this method is a direct technique, mean the
measurement is given as a reading and no modeling is
required.

Types of Detector Tips / Probes

Depending on the model of profilometer you chose there are a number of probes that can be
utilized to to provide a range of useful measurements. Most profilometers are sold with the
standard detector. For small holes and tighter access you can usually purchase a small hole
detector or extra small hole detector. For measuring grooves there is a groove detector and for
specialty work on gears there are gear tooth detectors. See below for illustrations of these detector
tip stylus combinations.
Tips for Measuring Surface Quality

Make sure the part being measured is held securely in place. Any movement could cause
significant errors in the reading.

Take measurements against the grinding / surface finishing pattern. This results in the
measurement being taking perpendicular to the direction of possible scratching / surface
blemishes.

Take multiple measurements at different locations on a part.

Any time theres a process change, its a good practice to check the first, middle and last
parts to get a representative sample.

Use bench top or lab measurement instruments for mirror-like surfaces (> 2in. Ra).

Whether you profilometer is Mitutoyo, Maher Federal or Brown & Sharpe, please
refer to the owner's manual for specific set up and operating procedures.