T.O.

33K6-4-10-1

TECHNICAL MANUAL

CALIBRATION PROCEDURE

FOR

SURFACE PLATES

LASER INTERFEROMETER METHOD

This publication replaces T.O. 33K6-4-10-1 dated 30 June 2015.

Distribution Statement C - Distribution authorized to U. S. Government agencies and their contractors for
official use or for administrative or operational purposes only, 24 May 1990. Requests for this document
shall be referred to AFMETCAL, 813 Irving-Wick Dr W, Heath, OH 43056-1199.

Destruction Notice - For unclassified, limited documents, destroy by any method that will prevent
disclosure of the contents or reconstruction of the document.
Published under Authority of the Secretary of the Air Force

30 JANUARY 2017
T.O. 33K6-4-10-1
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A USAF
 T.O. 33K6-4-10-1

SURFACE PLATES

LASER INTERFEROMETER METHOD

1 CALIBRATION DESCRIPTION:

Table 1.

Test Instrument (TI) Performance Test

Characteristics Specifications Method

Flatness
Maximum Elevation Range: As listed in Table A-1, Appendix A Measured using a
Laser Interferometer
Accuracy: As listed in Table A-1, Appendix A or an Electronic Height
Gage
Closure Error Range: As listed in Table A-1, Appendix A

Accuracy: As listed in Table A-1, Appendix A

2 EQUIPMENT REQUIREMENTS:

Minimum Use Calibration Sub-

Noun Specifications Equipment Item

2.1 LASER Range: N/A Renishaw

INTERFEROMETER ML10-AF
SYSTEM Accuracy: N/A

2.1.1 LASER HEAD Range: Nominal Wavelength Renishaw

632.990577 nm ML10

Accuracy: ±0.3 ppm

(see AFCAV Specifications)

2.1.2 ANGULAR OPTICS Range: ±100 arc-sec Renishaw

SET A-8003-0441
Accuracy: With correction applied
±0.1 arc-sec

2.1.3 ENVIRONMENTAL Range: N/A Renishaw

COMPENSATOR * EC-10
Accuracy: N/A

2.1.4 SOFTWARE Range: N/A T.O. 33K6-4-9011-10

PACKAGE
Accuracy: N/A

2.2 STRAIGHT EDGE Range: As needed to span As Available

Line 1 or 2 (diagonals)

Accuracy: N/A

See footnote at end of Equipment Requirements.

1
T.O. 33K6-4-10-1

Minimum Use Calibration Sub-

Noun Specifications Equipment Item

2.3 ELECTRONIC Range: ±0.0002 in Federal Specifications

HEIGHT GAGE EAS-1226
Accuracy: ±10 µin

TAR: 2.5:1

2.4 SURFACE PLATE Range: 36 × 72 in Brown & Sharpe

701-157
Accuracy: Within 40 µin
over entire measurement area

2.5 LEVELING PLATE Range: N/A AFMETCAL **

8636110
Accuracy: N/A

2.6 C CLAMP Range: N/A As Available

Accuracy: N/A

2.7 ALCOHOL-ETHYL Range: N/A As Required

Accuracy: N/A

2.8 HAND CLEANER Range: N/A As Available

Accuracy: N/A

2.9 REPEAT READING Range: N/A Starrett

GAGE 779
Accuracy: ±20 µin

TAR: 2:1

* Environmental Compensator not required for Calibration Process.

** Contact AFMETCAL if item is not available.

3 PRELIMINARY OPERATIONS:

3.1 Review and become familiar with the entire procedure before beginning the Calibration Process.

WARNING

Unless otherwise designated, and prior to beginning the Calibration Process,

ensure that all test equipment voltage and/or current outputs are set to zero (0) or
turned off, where applicable. Ensure that all equipment switches are set to the
proper position before making connections or applying power. If not strictly
observed, could result in injury to, or death of, personnel or long term health
hazards.

2
 T.O. 33K6-4-10-1

WARNING

The Laser used in this procedure is considered an Air Force Category B Laser.
This category is not considered a radiation hazard provided the blink response of
the eye is normal (0.25 seconds) and personnel do not intentionally stare into the
laser beam. If not strictly observed, could result in injury to, or death of,
personnel or long term health hazards.

WARNING

Alcohol is an eye and skin irritant. Use protective equipment (chemical splash
goggles and gloves) where potential of splash and skin contact may occur.
Failure to do so may result in injury. If eye contact should occur, flush well
with water and seek immediate medical attention. If not strictly observed, could
result in injury to, or death of, personnel or long term health hazards.

WARNING

Alcohol is a flammable liquid and may be ignited by heat, sparks, or flames.

Vapors may travel to a source of ignition and flash back. Alcohol burns with an
almost invisible flame. If not strictly observed, could result in injury to, or death
of, personnel or long term health hazards.

NOTE

Air currents and vibration may affect the indications on the Surface Plate.
Precautions should be taken to minimize these affects.

3.2 Calibration area must be 73 ±6 °F and must not vary more than 2 °F in the four hours prior to and during the
Calibration Process for Grades AA, A and B. For calibration areas outside this range, the TI must be certified to
Grade C. Surface Plates will change at a rate of 3 µin/in/ºF.

3.3 Clean the TI twice with Hand Cleaner, then once with Ethyl Alcohol prior to beginning the Calibration Process.
Wait 4 hours before beginning calibration.

3.4 For small Surface Plates (18 inches and under) proceed to para 4.2 as an alternative if 5 stations cannot be
achieved on shortest line.

3.5 Mark the top surface of the TI with lines as shown in Figure 1. The perimeter lines will be either 3 or 4 inches
from the edge, depending on the size of the Surface Plate. The north side of the TI is the side bearing the
manufacturer name plate and/or Certification Label.

3
T.O. 33K6-4-10-1

TI MFG LABEL OR CERTIFICATION LABEL (North Reference)

Figure 1.

3.6 Whenever possible, move and realign the Laser Interferometer for each line during calibration. If available, use
beam steerer for alignment process.

3.7 Refer to Table B-1, Appendix B. Using a ruler with appropriate graduations, mark the Straight Edge with
increments corresponding to the applicable TI plate size.

3.8 Clamp the Straight Edge parallel to and the appropriate distance from the first TI line to be calibrated, so that
the centerline of the bottom two retroreflector pads, which are closest to the Straight Edge, are centered on the line
being run.

3.9 Connect the test equipment to an appropriate power source and set POWER switches to ON. Allow warm-up as
required by the manufacturer.

3.10 Verify that T.O. 33K6-4-9011-10 is the most recent version per the AF TO Catalog or equivalent.

3.11 Computer displays, selections and menus will appear bold type throughout the Calibration Process text.

3.12 Annotate the Certification Label with the TI Grade and Accuracy, for the corresponding Grade listed in
Appendix A, to which the TI is calibrated. Annotate: See Moody Plot in the Remarks block for PMEL owned TIs
or if requested by user. For TIs calibrated to Grade C add the additional statement: The calibration is only valid for
a temperature range of ## ±6 °F. ## is the average temperature during the Calibration Process.

3.12.1 For PMEL owned Surface Plates only: Email to the AFMETCAL TCM, a copy of the Surface Plate
Isometric Plot, a copy of the Surface Plate Numerical Plot and a copy of the Surface Plate Uniformity Plot. This
information will be used by AFMETCAL to assess the condition of all Surface Plates at all PMEL sites.

3.12.2 If applicable, place a copy of the Surface Plate Isometric, Numerical and Uniformity Plots with the TI.

3.13 UNIFORMITY VERIFICATION: (For PMEL Owned Surface Plate Only)

NOTE

Uniformity verification using the Repeat Reading Gage only needs

accomplished on PMEL owned Surface Plates that have at least one side
dimension longer than 2 feet. Common Surface Plate sizes that require
Uniformity verification include, but are not limited to, 2 X 3, 3 X 6, 4 X 4,
4 X 6, 4 X 5 and 4 X 8 feet, etc.

4
 T.O. 33K6-4-10-1

3.13.1 Refer to Figure 2 and draw an image of the Surface Plate with all 8 lines. Label the drawings as Surface
Plate Uniformity Plot. Number each line accordingly and identify location of the Certification Label. Ensure to
make drawing large enough to annotate measurements approximately every 5 inches ±0.5 inches, beginning at the
center position working outward to the Surface Plate corner or perimeter line. It is acceptable for the last
measurement on each end of the line to be less than 5 inches.

TI MFG LABEL OR CERTIFICATION LABEL (North Reference)

8
5 1
TI

Figure 2.

3.13.2 Identify on the Surface Plate Uniformity Plot, the Surface Plate P/N, S/N, ID#, PMEL Location, Date,
Technician Name, Surface Plate Grade and resolution of the Repeat Reading Gage Indicator. Note that all recorded
measurement results are in microinches.

3.13.3 Place the Repeat Reading Gage in the center of the Surface Plate aligned with line #1. Zero the Repeat
Reading Gage.

3.13.4 Carefully slide the Repeat Reading Gage from the Surface Plate center position outward to each 5 inch
position along line #1 to the last position. Record each measurement onto the Surface Plate Uniformity Plot in
microinches. When the last measurement is recorded, slide the Repeat Reading Gage back to the center position and
re-zero. Repeat this step for the opposite side of Surface Plate line #1. It is acceptable for the last measurement on
each end of the line to be less than 5 inches.

3.13.5 Repeat steps 3.13.3 and 3.13.4 for all Surface Plate lines. Ensure to align the Repeat Reading Gage with the
line being measured when setting zero.

3.13.6 Refer to steps 3.12, 3.12.1 and 3.12.2 for certification and documentation requirements.

3.13.7 If measurement process is complete, secure all equipment.

4 CALIBRATION PROCESS:

NOTE

Unless otherwise specified, verify the results of each test and take corrective
action whenever the test requirement is not met, before proceeding.

5
T.O. 33K6-4-10-1

4.1 FLATNESS CALIBRATION:

4.1.1 Enter the Angular Optics Set correction value into the Renishaw Controller.

4.1.2 Select the Newark Flatness Measurement icon from the computer desktop.

4.1.3 The Renishaw Laser XL Capture screen will be displayed. Ensure measurement units are in inches. Select
the Moody Setup button from the toolbar.

NOTE

Use the mouse or TAB button to transition between fields, pressing ENTER will
abruptly close a dialog box. Number of stations actually measured will be one
less than the number of stations entered in the setup window.

4.1.4 The Newark Flatness Setup screen will be displayed. Refer to Table B-1, Appendix B for the TI plate size
and number of stations. Enter the necessary TI information in inches in the selected fields; ensure Line 4 has the
proper dimension (see Figure 2). Press OK to continue.

4.1.5 The Test Information entry screen will be displayed. Enter the necessary TI information in the selected
fields and press OK.

4.1.6 The TI path plot will be displayed, select path number to be calibrated. The arrow on the path to be calibrated
indicates both the direction in which the Laser Interferometer is to be aimed and the direction the retroreflector is to
be moved. Always move the Laser Interferometer retroreflector in the direction indicated in Figure 2. Click
Capture to continue.

NOTE

Check optics and clean if necessary.

4.1.7 The retroreflector foot spacing to be used will be displayed, click OK. Attach optics to 2 inch footpad. Set
the Laser Interferometer and retroreflector on the TI line to be calibrated as follows or other equivalent method:

a. Clean each line to be calibrated and foot pads of retroreflector with alcohol to
remove any residue. Repeat this process until no residue is observed on
kimwipe. Brush each path being run prior to calibration.

b. Place the retroreflector at the measurement station closest to the tripod. Use
small aperture with target return. Adjust the vertical and horizontal location
of the laser head until the return beam from the retroreflector is centered on
bottom target of aperture.

c. Slide the retroreflector to the station furthest away from the tripod and adjust
the tilt and twist of laser head until the return beam from the retroreflector is
centered on the bottom target of the laser head. (When using beam steerer,
do not adjust the tilt and twist of laser head, but instead use the beam steerer
adjustments.)

d. Slide the retroreflector back to the station closest to the tripod and repeat
steps b and c until the return beam remains centered in the target return.
Once centered, change to two apertures. Place angular interferometer in path
between laser head and retroreflector. To set Laser Interferometer display to
zero, press Datum Device Button. Ensure a satisfactory signal is still visible
over the entire line, adjust Laser Interferometer if necessary to gain signal.

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 T.O. 33K6-4-10-1

4.1.8 Slightly raise the Laser Interferometer retroreflector leading edge. The display will indicate positive; if not
press Toggle Direction Sense button. If the laser must be positioned in the opposite direction to that of what is
displayed on the screen, lift Laser Interferometer retroreflector leading edge. The display will indicate negative; if
not, press Toggle Direction Sense button.

NOTE

Center of footpads may not hit straight edge increments. Adjust each station so
footpads are centered between increments.

4.1.9 The station being calibrated will be displayed. Ensure Laser Interferometer retroreflector is at first station. To
set the Laser Interferometer display to zero, press Datum Device button. Use the remote or Capture button to enter
the first station value. Note the value displayed for the first station. This value will be used to verify a good run.

4.1.10 Slide the Laser Interferometer retroreflector to the next TI station to be calibrated, use the remote or Capture
button to enter the station value, then continue in this manner until the final station.

4.1.11 After the final station has been entered, Data Capture Complete will be displayed, click OK. Slide the
Laser Interferometer retroreflector back to the first station. The displayed value must agree with the value noted in
step 4.1.9 within ±3 µin. If the displayed value and the value noted in step 4.1.9 did not agree within ±3 µin, select
first station on computer and repeat the TI line. Otherwise, click Finish button.

4.1.12 Repeat steps 3.7, 3.8 and 4.1.6 through 4.1.11 for each remaining TI line.

4.1.13 After all the TI lines have been entered, click Save As button.

4.1.14 The Save As screen will be displayed. Enter the filename to be used and location to save it, then press enter.

4.1.15 Click Analyse button.

4.1.16 The Renishaw Laser 10 Analysis screen will be displayed. Click Done on the window. Ensure units are in
microinches, change if necessary. Close all Moody Plot windows. Click Analysis Menu and select Newark
Moody Plot. Use arrow buttons to review data, click Done when completed. (Previewing the plot on the screen
will allow the technician to ensure TI meets the specifications prior to printing plots.)

4.1.17 If closure error exceeds Closure Error Accuracy of Table A-1, check previous contour or iso-plot calibration
chart, if available, for guidance as to which line may need to be rerun. If TI has been resurfaced, then this is not
necessary, because the contour of the TI has been changed.

NOTE

Newark Moody Plot graph is not required unless calibrating a PMEL owned TI
or is requested by the user.

4.1.18 If applicable, ensure Printer Setup is configured correctly. Click Print to print graph. Click Analysis
Menu and select Newark Moody numeric plot. Click Print to print numeric plot.

4.1.19 To exit the Laser Interferometer program, press Exit button on Analysis screen and then on Renishaw Laser
Capture screen. Dialog box will display Exit application, press yes.

4.1.20 Refer to steps 3.12, 3.12.1 and 3.12.2 for certification and documentation requirements.

4.1.21 If calibration is complete, set test equipment POWER switches to OFF, disconnect and secure all equipment.

7
T.O. 33K6-4-10-1

4.2 FLATNESS CALIBRATION: (Alternate Method For Small Surface Plates [18 inches and smaller] only)

4.2.1 Using the calibration numeric plot, locate an area on the Surface Plate (2.4) where the flatness is within
40 µin TIR. Using the Repeat Reading Gage, verify that the Surface Plate (2.4) uniformity does not exceed
40 µin TIR over the selected area.

4.2.2 Place the Leveling Plate on the Surface Plate (2.4). Place the TI on the top of the Leveling Plate.

4.2.3 Place the Electronic Height Gage gagehead on top of the TI near one corner. Level both ends of a diagonal
line near the corners of the TI to within 40 µin or ¼ the Flatness Accuracy listed in Appendix A, whichever is
greater. Repeat for the other diagonal. The two diagonal lines most likely have different numbers in the corners.
For example, Line 1 corner values are 0 and +10 µin and Line 2 values are -10 and -30 µin.

4.2.4 Find the lowest area of the TI and zero the Electronic Height Gage. Scan the entire surface of the TI
excluding roundoff of edges and record the highest indication. This indication will be the Flatness deviation of the
TI and must be within the Accuracy value listed in Appendix A for the corresponding size and grade of the TI.

4.2.5 Refer to steps 3.12, 3.12.1 and 3.12.2 for certification and documentation requirements.

4.2.6 If calibration is complete, set test equipment POWER switches to OFF, disconnect and secure all equipment.

CALIBRATION PERFORMANCE TABLE

Not Required

8
 T.O. 33K6-4-10-1

APPENDIX A

Table A-1.

Grade Accuracies for Common Size TIs

Grade AA Grade A Grade B Grade C

Width Length Flatness Flatness Flatness Flatness Closure Error
(in) (in) Accuracy (in) *1 Accuracy (in) *1 Accuracy (in) *1 Accuracy (in) *1 Accuracy (µin)

12 12 0.000050 0.000100 0.000200 0.000400 40 *2

12 18 0.000050 0.000100 0.000200 0.000400 40 *2

18 18 0.000050 0.000100 0.000200 0.000400 40 *2

18 24 0.000075 0.000150 0.000300 0.000600 40 *2

20 30 0.000100 0.000200 0.000400 0.000800 40 *2

24 24 0.000075 0.000150 0.000300 0.000600 40 *2

24 36 0.000100 0.000200 0.000400 0.000800 40 *2

24 48 0.000150 0.000300 0.000600 0.001200 40 *2

24 60 0.000200 0.000400 0.000800 0.001600 40 *2

30 30 0.000100 0.000200 0.000400 0.000800 40 *2

30 36 0.000125 0.000250 0.000500 0.001000 40 *2

30 48 0.000175 0.000350 0.000700 0.001400 40 *2

30 60 0.000225 0.000450 0.000900 0.001800 40 *2

36 36 0.000150 0.000300 0.000600 0.001200 40 *2

36 48 0.000200 0.000400 0.000800 0.001600 40 *2

36 60 0.000250 0.000500 0.001000 0.002000 40 *2

36 72 0.000300 0.000600 0.001200 0.002400 40 *2

48 48 0.000200 0.000400 0.000800 0.001600 40 *2

48 60 0.000300 0.000600 0.001200 0.002400 40 *2

48 72 0.000350 0.000700 0.001400 0.002800 40 *2

48 84 0.000425 0.000850 0.001700 0.003400 40 *2

48 96 0.000500 0.001000 0.002000 0.004000 40 *2

48 108 0.000600 0.001200 0.002400 0.004800 40 *2

See footnotes at end of Table.

A-1
T.O. 33K6-4-10-1

APPENDIX A (Cont.)

Table A-1. (Cont.)

Grade Accuracies for Common Size TIs

Grade AA Grade A Grade B Grade C

Width Length Flatness Flatness Flatness Flatness Closure Error
(in) (in) Accuracy (in) *1 Accuracy (in) *1 Accuracy (in) *1 Accuracy (in) *1 Accuracy (µin)

48 120 0.000700 0.001400 0.002800 0.005600 40 *2

48 144 0.000950 0.001900 0.003800 0.007600 40 *2

60 60 0.000325 0.000650 0.001300 0.002600 40 *2

60 72 0.000400 0.000800 0.001600 0.003200 40 *2

60 84 0.000475 0.000950 0.001900 0.003800 40 *2

60 96 0.000550 0.001100 0.002200 0.004400 40 *2

60 108 0.000650 0.001300 0.002600 0.005200 40 *2

60 120 0.000750 0.001500 0.003000 0.006000 40 *2

60 144 0.001025 0.002050 0.004100 0.008200 40 *2

72 72 0.000450 0.000900 0.001800 0.003600 40 *2

72 96 0.000600 0.001200 0.002400 0.004800 40 *2

72 120 0.000825 0.001650 0.003300 0.006600 40 *2

72 144 0.001100 0.002200 0.004400 0.008800 40 *2

12 (round diameter) 0.000050 0.000100 0.000200 0.000400 40 *2

18 (round diameter) 0.000050 0.000100 0.000200 0.000400 40 *2

24 (round diameter) 0.000075 0.000150 0.000300 0.000600 40 *2

36 (round diameter) 0.000100 0.000200 0.000400 0.000800 40 *2

48 (round diameter) 0.000125 0.000250 0.000500 0.001000 40 *2

*1 If the Flatness Accuracy for the TI being calibrated is not listed, determine the accuracy using the following
formula. The calculated accuracy for Grade AA will be rounded to the nearest 25 µin, Grade A is 2 times the
Grade AA accuracy, Grade B is 4 times the Grade AA accuracy and Grade C is 8 times the Grade AA
accuracy.

D2
Overall Flatness Accuracy (µin) = 40 +
25
Where: D = diagonal or diameter of TI in inches

*2 Or 10% of the Flatness Accuracy, whichever is greater.

A-2
 T.O. 33K6-4-10-1

APPENDIX B

Table B-1.

Foot Spacing of Common Size TIs

TI TI Measured Width Measured Length Diagonal Diagonal/Side

Width Length TI Number TI Number Number Increments
(in) (in) Width (in) * of Stations * Length (in) * of Stations * of Stations * (in) *

18 18 12 7 12 7 9 2.12/2.00

18 24 12 7 16 9 11 2.00/2.00

20 30 12 7 24 13 15 1.92/2.00

24 24 16 9 16 9 13 1.89/2.00

24 36 16 9 28 15 17 2.02/2.00

24 48 16 9 40 21 23 1.96/2.00

24 60 16 9 52 27 29 1.94/2.00

30 30 24 13 24 13 17 2.12/2.00

30 36 24 13 28 15 19 2.05/2.00

30 48 24 13 40 21 25 1.94/2.00

30 60 24 13 52 27 29 2.05/2.00

36 36 28 15 28 15 21 1.98/2.00

36 48 28 15 40 21 25 2.03/2.00

36 60 28 15 52 27 31 1.97/2.00

36 72 28 15 64 33 35 2.05/2.00

48 48 40 21 40 21 29 2.02/2.00

48 60 40 21 52 27 33 2.05/2.00

48 72 40 21 64 33 39 1.99/2.00

48 84 40 21 76 39 43 2.04/2.00

48 96 40 21 88 45 49 2.01/2.00

48 108 40 21 100 51 55 1.99/2.00

48 120 40 21 112 57 61 1.98/2.00

48 144 40 21 136 69 71 2.03/2.00

See footnote at end of Table.

B-1
T.O. 33K6-4-10-1

APPENDIX B (Cont.)

Table B-1. (Cont.)

Foot Spacing of Common Size TIs

TI TI Measured Width Measured Length Diagonal Diagonal/Side

Width Length TI Number TI Number Number Increments
(in) (in) Width (in) * of Stations * Length (in) * of Stations * of Stations * (in) *

60 60 52 27 52 27 37 2.04/2.00

60 72 52 27 64 33 43 1.96/2.00

60 84 52 27 76 39 47 2.00/2.00

60 96 52 27 88 45 53 1.97/2.00

60 108 52 27 100 51 57 2.01/2.00

60 120 52 27 112 57 63 1.99/2.00

60 144 52 27 136 69 73 2.02/2.00

72 72 64 33 64 33 47 1.97/2.00

72 96 64 33 88 45 55 2.02/2.00

72 120 64 33 112 57 65 2.02/2.00

72 144 64 33 136 69 77 1.98/2.00

* If the TI being calibrated is not listed, determine the number of stations and increments using the following
information: TIs will have perimeter lines offset 3 or 4 inches from edge and require 2 inch increments with
an even amount of stations. The diagonal lines will require about 2 inches and need to have an even amount of
stations to ensure the Laser Interferometer retroreflector contacts the intersecting points at the center and end
of each line. Number of stations to be inputted in software will be 1 more than calculated stations. If
necessary, contact AFPSL for further information regarding foot spacing of a particular size TI.

B-2