Lindsay Epstein

Shirley Lu
2.77 Spring 2019

FPGA 6: Surface Roughness Effect

on Exact Constraint Design
We were interested in seeing how surface roughness affects the
repeatability of an exact constraint design. We varied the surface
roughness of an object by covering two pairs of two adjacent sides with
80 grit (rough) and 320 grit (smooth) sandpaper. We tested the
repeatability of our coupling by mounting a laser to the object we were
placing/constraining and recording the location of the laser point 51 feet
away (using Abbe error) to see the variation.
Deterministic Design Process
Functional Req. Design Parameter Analysis & Ref. Risks & Counter Measures
Demonstrate - Exactly constrained Geometry, surface Changes in position not easily
exact constraint object for roughness and measured Use laser pointer
design repeatable repeatability and abbe error to measure
placement repeatability
FUNdaMENTALs
book
Stay within time - Simple and quick DFM and DFA, Design not highly repeatable
limit fab availability of  use stiff, smooth, press fit
- Few parts machines pins

Close form Measurable with basic Surface roughness Need to be able to stall motor
solution tools (laser pointer and geometry with spring force Choose
and ruler) high running speeds
1
Design Sketches / Concepts

Exact Constrained Design ✔ Combined Elastic and Exact Design ✖

2
MODEL:

3
Analysis
Critical Analysis:
- Geometric impact of surface roughness on object slope, abbe error amplified over
distance

Change in slope: 2δ/W

Abbe Error Amplification:
Δ = 2δ/W * L

4
DETAILED DESIGN
Body – provides plane (3 points)
to constrain the object
Dowel pins – to provide
contacts for the exact
design constraint
Object – to constrain/align
repeatably; sides are taped
with sandpaper (80 grit and
320 grit) to vary surface
roughness
Stand – keep body standing at
an upright angle so that the
nesting force is provided by
(some of) the object’s weight
5
MANUFACTURING
Simple fabrication while effectively
demonstrating FPGA principles
- Parts are laser cut (no post-
processing operations required) or
bandsaw + drill only
- Only 3 parts to fabricate

Most Critical Part: Body

- Accurately laser-cut locations of the
holes for exact constraint design
- Press fit holes for the dowel pins

6
 Testing Results

MEASUREMENTS Expected: 320 grit more repeatable than 80 grit

80 grit
sandpaper

320 grit
sandpaper

10 trials each; measured laser point 51 ft away

7
SUMMARY
- Test results were not as expected, TIME BUDGET

with 80 grit sandpaper performing

more repeatably than 320 grit
sandpaper Category Time [hours]
- Possible sources of error: Design (Individual + Peer Review + Final) 1
- Misalignment in other parts of the CAD 1
system due to: Analysis 2
- Laser pointer taped onto Fabrication + Assembly 2
object – compliance in tape Testing 1
- Variation in applied nesting Documentation 2
force Total 11
- Variation in fabrication of object
(opposite sides of rectangle may
not be straight)
8