Straight Edges

These are used for checking the straightness and flatness of parts in conjunction with the surface
plates and spirit levels. These may be made of steel or cast iron. Steel straight edges are available
up to 2 m length and may be rectangular in section with bevelled edge. C.l. straight edges, are
made up to 3 m length and widely used for testing machine tool slide ways. They are heavily
ribbed and bow-shaped (camel back construction) to prevent distortion. These are provided with
feet for rest when they are idle to prevent distortion. Feet are placed at points of minimum
deflection.

The straight edges are classified as follows :

(i) Tool-makers straight edge,

(ii) Wide-edge straight edge,

(iii) Angle straight edge,

(iv) Box straight edge.

Tool makers straight edges have the highest accuracy and are available with various cross-
sections, from one to four working edges and length from 75 mm to 175 mm Straight edges with
a single edge are used for checking straightness by sight test. The test consists of applying the
straight edges along the full length of the surface (whose straightness is to be checked) against a
bright background. The absence of light between the straight edges and the surface indicates the
straightness of element. Deviation of 1 or 2 microns from the straightness can be detected by the
eye with some practice.

Flatness of a surface may be tested with single-edged straight edge by applying it in different
directions at different places on the

tested surface. The flatness of the surface is judged by the light showing through. A surface can
also be tested by means of three and four edged type straight edges by applying a light coat of
Prussian blue on the working edges and then drawing the straight edge across the tested surface.
Traces of the marking compound arc rubbed in this way on the tested surface and due to
irregularities in the surface it will be coated in spots with different density. All the high spots are
painted more densely and the low spots are partly painted. The surface is then scraped or ground
until a uniform distribution of spots on the whole surface is obtained after subsequent tests.

Straight edges with a wide working edge are used for testing large surfaces or surfaces with large
intermediate gaps or recesses. Such straight edges may have a length upto 0.6 metre, and have a
form of a rigid beam or frame in order to possess ample of rigidity to maintain the straightness.

Angle straight edges are used for checking surfaces positioned at an angle in relation to each
other. Such straight edges have a triangular or trapezoidal cross-section and are from 250 to 1000
mm in length and usually have handles at their ends to facilitate their application. Surfaces are
usually tested with a marking compound as described above.

The recommended lengths of straight edges for bow shaped and I-section type are as follows.
(.Refer Figs. 2.46 and 2. 47)

Lengths of bow-shap6cLstraight edges (L): 300,500, 1000, 2000, 4000, 6000, and 8000 mm.

Lengths of 1-section straight edge (L) : 300, 5b0, 1000, 2000, 3000, 4000 and 5000 mm

Bow shaped straight edge has two feet of the same width as the working surface and these arc
so located as to allow the

straight edge to be used in 3 positions viz. resting upon the feet ; with the working surface
downward ; and lying on either side. The accuracy requirements specified for straight edge are
applicable for all these three positions.
Usually two grades of accuracy (Grade A and Grade B) are specified. The working surface and
supporting feet of grade A straight edges are finished by scraping, and the working surfaces of
grade B and the side faces of all straight edge, are finished by smooth machining.

The proportion of bearing area of the working surface should not be less than 20% and 10%
respectively for grades A and B : High spots should be uniformly distributed and the percentage
of bearing area should not be so high as to cause wringing. All sharp edges should be removed
and the unmachined parts painted.

The bearing area of the working surfaces should be flat to .001 mm per 100 mm of working
length for grade A and 002 mm per 100 mm of working length for grade B.

When a bow shaped straight edge rests on a flat base, the depths from working surface of the
straight edge to this base, measured immediately over each support foot, shall be equal to each
other to within the tolerances of .0001 mm per 100 mm of working length.

Any 300 mm length of each side face has to be fiat to within 0.025 and 0.050 mm respectively
for grades A and B respectively.

The maximum tolerance on flatness over the whole length of straight edges is 0.05 min for grade
A and 01 mm for grade B for lengths upto 4000 mm, and 0.1 mm and 0.2 mm (grades A and B)
respectively for lengths above 4000 mm.

The working surface and side faces have to be square t within 0.008 mm per 25 mm and 0.015
mm per 25 mm for grades A and B respectively.

Accuracy. According to IS : 22201962, straight edges have been divided into two grades
depending upon the accuracy of straightness (grade A and grade B). Grade A is intended to be
used for inspection purposes, and grade B for workshop purposes during manufacturing. As it is
generally more difficult to machine the ends of the straight edge accurately, it specifies two
lengths, i.e. working length and total length. The total length is greater than the working length
and the inspection is made without using the ends of the straight edge. This standard
recommends rectangular cross-section for total lengths upto 180 mm and I-section beyond total
length of 340 mm. In case of I-section used for bigger lengths, the side face is slightly relieved in
order to reduce the weight. The straight edges beyond 340 mm total length are provided with
drilled holes at uniform intervals in order to reduce the weight still further. Generally the straight
edges are supported on two such points which results in the minimum natural deflection and
these are at distance of 2/9 total length of the straight edge from each end. When the straight
edge is supported at the points of best support, the error in the straightness of the working faces
over its whole length should not exceed (2+10L) microns for grade A and (5+20L) microns for
grade B; where L is the length in metres. In addition, the error over any length of 300 mm should
not exceed five microns for grade A and eight microns for grade B. Further the maximum error
in parallelism should not exceed 15 times the tolerance on their straightness. Further when the
straight edge is supported at its extreme points, then the natural deflection should not exceed 10
microns per metre of length.
It is also essential that the side faces of the straight edge be straight and parallel to each other.
The maximum error that can be tolerated in the straightness of the side faces is ten times the
error in straightness of working faces and the maximum tolerable error in the parallelism of the
two side faces is 15 times the error in straightness of the working faces. Further, the side faces
should be square also with the working faces to within one micron per millimetre of depth for
grade A and two microns per millimetre of depth for grade B straight edges.

The accuracy of straightness of the working faces of a straight edge is tested by direct
comparison with a mastes r surface plate whose accuracy is already known. Two equal slip are
placed on the surface plate just below the points of best Support and v straight edge on its edge
placed over the slip gauges. Then the gap between the lower working face of the straight-edge
and the surface plate is measured at various points by fitting slip gauges of appropriate length,
which gives an indication of the degree of parallelism along the length of straight edge.

Tool Makers Straight Edges. These are intended for very accurate work and are available in
the rage of 15 to 300 mm length for tool room purposes. These have one working edge, which is
bevelled and very slightly rounded off (.commonly known as a knife-edge).

These are made of suitable cast or wrought alloy steel free from defects and hardened, and are
suitably heat treated to remove the internal stresses resulting from the hardening process and to
give stability. The hardness adjacent to working edges is of the order of 650 HV.

The faces adjoining the working edges or the straight edges are ground flat. The working face is
very slightly rounded off to furnish the knife-edge. The working edges are finished by grinding
and lapping and radius on the edge is made uniform from end to end. The sections of the straight
edges for length 15 ar.d 25 mm, 50 to 100 mm and 150 to 300 mm are shown below. The section
of the straight edges for length between 25 and 50 mm can be either

of shape given in Fig. 2.48 or Fig. 2.49. Similarly the sections of the straight edges for lengths
between 100 mm or 150 mm can be either of shapes given in Fig. 2.49 or Fig. 2.50.

Recommended dimensions of straight edges are

Length Width Thickness of flat
 portion
mm Mm mm
15 15 3
25 25 6
50 30 8
75 35 8
100 40 10
150 40 10
o 50 12
250 50 12
300 <0 12

The accuracy of straight edge should be such that when placed against a well-illuminated
background on the tool makers flat or plate no white light should be visible. This applies for
angle upto 10 on either side of the normal.

For checking purposes, usually a flat back glass test plate is also provided with straight edges.

Steel or granite straight edges. These are available in lengths of 300, 500, 1000, 1500 and 2000
mm with corresponding depth and thickness varying from 40 to 125 mm and 6 to 13 mm for
grade A steel straight edges, 30 to 80 mm and 5 to 12mm for grade B steel straight edges, and
from 75 to 150 mm and 25 to 50 mm for granite straight edges.

The handling slots are provided 2/9L away from each end as shown in Fig. 2.51. The side
surfaces can be slightly relieved (F-section) to reduce weight.

Important accuracy requirements for these straight edges are :

(i) straightness tolerance of working face

(ii) tolerance on parallelism of working face

(iii) combined flatness and parallelism of side faces

(iv) squareness of side faces to working faces.

Generation of Straight Edge. A method commonly used for generation of straight edges
requires two blanks clamped together side by side and the edges machined. These edges are then
smeared with a marking compound and while still together, rubbed with a small flat block as
shown in Fig. 2.52 (a). This reveals any high spots, which are removed. The process of marking
and correcting is continued until the edges are accurately matched. The plates are then separated
and placed edge to edge as illustrated in Fig. 2.52 (b). Marking compound is applied to one of
the edges and the high spots located by relative sliding of the two plates The widths of the gaps
between the two edges are equal to twice the error in straightness as shown exaggerated in Fig.
2.52 (c), which helps to locate the high spots more accurately. After matching in this position,
they are again placed side by side and corrected for high spots Testing edge to edge and side by
side is repeated until the required accuracy of straightness is attained. A final check is made by
reversing one of them end for end and subjecting it to be

corrected by scraping. For hardened steel, a small stone or lap must be used, the later being
preferable during the concluding stages, when only small amounts of metal are to be removed.

Box Straight Edge. Fig. 2.53 shows a side view of box type straight edge and the method of
creating a perfect box. The important features of such a straight edge are : rigid cross section
to minimise deflection in all directions, a symmetry and uniformity which minimises distortion
when the straight edge is subjected to uneven temperature distribution ; a 90 form and
straightness which are self-proving both in fabrication and in use.

To scrape the master straight edge, first side 1 is matched to the master surface plate. Side 2 is
also matched and, by means of a thickness check, is scraped parallel to side 1. Inspection is done
using master surface plate as a flat datum and an indicator stand with knife edge. Side 3 is
scraped square to sides 1 and 2. The knife edge on the indicator stand is pressed against the
lower area of side 3. Any out-of-squareness is revealed as half the difference of the indicator
readings when the straight edge is turned over (180), to side 2 and compared again. P highest
accuracy and in order to avoid local flatness errors in the master surface plate, the straight edge
should be turned end-for-end, as well as through 180,

so that the position of the indicator on the surface plate i s not altered.
Once 3 is completed, side 4 is scraped parallel to it, which means that side 4 is automatically
square to side 1 and 2.

Thus both straightness and squareness are developed from the surface plate.

Using a Straight Edge. In fairly coarse measuring situations the deviation of a surface from
the mean true plane can be approximately determined, as shown in Fig. 2.55. The irregular gap
between the straight edge and the surface being tested can be determined by the use of feeler
gauges as shown in Fig. 2.55.

Small components can be tested with a precision straight edge as shown in Fig. 2.56. The light
box provides a means of uniform illumination that is independent of the angle of viewing. Any
error of flatness in the component will leave a gap through which a strip of light will be visible
between the straight edge and the component. With practice the error of straightness can be
estimated by the quality of the light seen.

The colour of light is white for gap greater than 0.002 mm and tinted for gap between 0.001 and
0.002 mm.