This paper presents a comprehensive study of three different materials used
for surface roughness replication on five different types of machined surf
aces. Steel sheets (electron beam texturing and shot blasted texturing), a
cylinder liner, a crankshaft and a face-ground surface. The three different
replica materials used were Araldite, Microset and Technovit. The surfaces
were measured with the non-contact WYKO interference instrument, zoomed to
relocate the same area on the original and on the replicas. Finally, three
-dimensional surface parameters were calculated to compare each replica wit
h the original surface.
The results show that all materials are possible to use in order to measure
and calculate three-dimensional surface parameters, but they have some pec
uliarities. The three replicas all show good accuracy on all surfaces, with
deviations <10%, except for the crankshaft. Only Araldite and Technovit oc
casionally show Sz values that are >10% too high due to a small number of p
ores in these materials. Replicas in the Microset material in general show
somewhat lower parameter values than the original surface. All replicas sho
wed some problems on the fine-ground crankshaft with an enlargement of the
fine structure, resulting in parameters ca 20% too large. The deviation of
surface parameters on repeated measuring on replicas is considerably larger
than on repeated measuring of the original surfaces. (C) 2001 Elsevier Sci
ence Ltd. All rights reserved.