What Is a Level Set?
A level set is a jig or tool used to secure a workpiece in a predetermined position for machining. There are many types of level sets, each designed according to the specific requirements of the workpiece.
The positioning of the workpiece in 3D space is based on the “3-2-1 rule,” which allows for precise positioning. This rule involves assigning three coordinate points to one plane as the reference plane, and two and one points to the other planes, respectively, in a three-dimensional XYZ coordinate system.
Level sets are installed following this “3-2-1 rule” as needed.
Uses of Level Sets
Level sets, named for their function, come in various shapes and materials to suit different applications. In machining, L-shaped workpieces and blocks are often made of metal or resin. On production lines, many workpieces are made of resin to prevent product damage.
The selection of shape and material for a level set depends on the required precision for positioning and the durability needed for production line applications.
Features of Level Sets
Since level sets are crucial for positioning accuracy, the materials used in their construction are carefully selected and crafted.
For example, a common specification for level sets is SS400 material with electroless nickel plating, featuring a plating thickness of 5 to 10 μm. “SS400” refers to a type of rolled steel sheet commonly used in general structural applications, characterized by a low carbon content (typically 0.15~0.20%). This low carbon steel cannot be strengthened by heat treatment, reducing the risk of heat-related issues.
Electroless nickel plating, known for its excellent corrosion and wear resistance, is often used for machine parts. The plating’s film hardness is highly beneficial if the thickness and other factors are properly controlled. It usually contains phosphorus, with three types available based on phosphorus content: low, medium, and high. Each type has distinct physical properties, and the medium phosphorus type typically contains 7 to 9% phosphorus.