Hi Thomas,
I'm nervous when you say you have 0.01 degree accuracy. Your screw mechanism cannot be perfectly accurate, and any setup cannot be perfectly rigid. So how accurate and repeatable is a given machine? Does it have accuracy and repeatability of a few microns? I don't even think watchmakers have gears that accurate.
If the error of a machine is bigger than 0.01 degrees, then it cannot claim to have an accuracy of 0.01 degrees. For a machine to have an accuracy of 0.01 degrees, it's error must be less that 0.01 degrees (actually less than 0.005 degrees). Otherwise it makes no sense to claim an accuracy of 0.01 degrees.
(1) Error can come from looseness of moving parts (this is also called slack, hysteresis, or back-lash error).
(2) Error can come from non-rigidity (flexing of parts under load).
(3) Error can even come from things like thermal expansion.
If someone is claiming an accuracy of 0.01 degrees, then then need to show that the errors from (1),(2), and (3) cause a total error of less than 0.01 degrees.
I'm asking because a right-triangle which is one centimeter wide, and two microns tall represents 0.011 degrees.
So if your sharpening rig is about 1 cm long, you need it to be precise and rigid to 2 microns. That is a tall order.
If your set-up is about 10 cm long, then you need to be precise and accurate to 20 microns. Now, 20 microns is 0.00079 inches, or 0.79 mils. That is more accurate that many imperial calipers. In other words, even if you measure your machine with imperial calipers, that is not accurate enough to guarantee 0.01 degree accuracy.
So if a machine is accurate to 0.01 degrees, its errors due to slack or gaps in moving parts, and also rigidty, must be smaller than 20 microns (say your machine is about 10 cm). I think 20 microns is very small; it's less than 0.8 mils. How often in machine shop, do you make a part with your own hands, that has accuracy of 0.8 mils (20 microns) ?
And how are you sure your rod, or base does not flex by more than 0.8 mils (20 microns) ? Personally, I doubt my own sharpening rig is anywhere near this rigid. I also doubt anything except a precision threaded rod, like that used in a micrometer, has this level of accuracy/repeatibility. Remember, this is more accurate than a standard imperial caliper (which are typically accurate to 0.0016 inches, or 1.6 mils).
http://www.amazon.com/Mitutoyo-500-..._1?s=industrial&ie=UTF8&qid=1336680461&sr=1-1
To be clear, I am talking about accuracy, not resolution. Even though those Mitutoyo calipers have a finer _resolution_ of 0.0005" inches, notice that their _accuracy_ is 0.001" inches. It's worth introducing or reviewing the difference between accuracy, precision, repeatibility, and false precision.
https://en.wikipedia.org/wiki/Accuracy_and_precision
https://en.wikipedia.org/wiki/Repeatability
https://en.wikipedia.org/wiki/False_precision
If the slack and/or flexing is more than 20 microns for your 10 cm machine, then you cannot claim an accuracy of 0.01 degrees. So if one is claiming 0.01 degree accuracy, then one has to demonstrate it by measurement, or at least by showing the system has a rigidity and slack better than 20 microns. At worst, you need to show a calculation that under expected loads, that the steel you are using has enough rigidity to avoid deflections of 20 microns. This can be done either by hand, or as a computer simulation. At best, you can measure the play and flexibility of a set-up using a dial indicator, a test dial indicator, a micrometer, or other high precision measuring device.
If you disagree, then let me ask: How much does your guide-rod bend when sharpening? From physics, we know it must bend; it is just a question of how much. And if you don't know much, how can you be sure it is less than 20 microns? With your own eyes and hansd, can you feel or see something as small a 20 microns difference? Maybe you can; the thickness of aluminum foil is 16 microns. But are you sure you can see or feel it? I am not sure I could see or feel such a small difference.
Similarly, how accurate and repeatable are the adjustment screws? And if you don't know, how can you be sure they are good to 20 microns? I'm sure that most regular bolts and nuts have a slack (backlash error) which is bigger than 20 microns.
A difference of 20 microns is not like the difference between 0.0095 degrees and 0.01 degrees (ie: a 5% error). It is the difference between 0.02 degrees and 0.01 degrees. That's a 100% error.
Don't take the 20 micron part too literally; just scale it to your setup. It's all similar triangles, so you can scale it linearly. ie: a 2x larger setup has a 2x larger allowed slack to achieve the same angular accuracy. If your setup is 30 cm long, then the allowed inaccuracy is 60 microns (which is about 0.002 inches, or 2 mils).
The point is very small errors (flexing, slack in moving parts) easily cause deviations bigger than 0.01 degrees. At this level of accuracy, the ideal geometry is nice, but not sufficient. Not only do you need accurate and rigid parts, but we can calculate how accurate and rigid the parts need to be.
Sincerely,
--Lagrangian
P.S. When I have time, I will actually go measure the slack and flexibility of my sharpening rig. I'll measure that with dial indicators, one which is from Mitutoyo and is accurate to 10 microns (about 0.0005 inches) , the other dial indicator claims to accurate to 2.54 microns (about 0.0001 inches) but it's a cheapo made in China, so I won't trust it without testing. I also have a micrometer from Mitutoyo that is accurate to 2.54 microns. I'll be testing the parts as well (rigidity of 1/4" inch diameter steel rod over 16 inches, etc.). As I mentioned, I can feel, by hand, some play (looseness) in the spherical rod ends. If I can feel it, it must be fairly signfificant.
So, who wants to _place bets_ on how un-accurate, non-repeatable, and non-rigid my sharpening rig is?