Chapter 2 - METROLOGY-Main Notes

MEM560
MANUFACTURING PROCESSES
Introduction
What is metrology?
Science of measurement experimental and theoretical with certain level
of uncertainties.(International Bureau of Weights and Measures)
Aim of metrology
To provide and to maintain precise definition of units measurement
measurement=comparison of unknown dimension to a known standard
Why metrology is important?
Measurement system
1. Imperial/English
2. Metric (SI)
Why metrology is important?
To measure scientifically
Inspect and check measuring parameters
Form standard
Verify specification, to conform the specification of products
Guidelines for measurement to comply with the standard or do
measurement according to standards methods
Find exact dimension
Find and calculate error, avoid discrepancies
To control quality of products
To reduce cost of production
Standards
Common use of the word standard implies that it is a universally
agreed upon set of guidelines for interoperability.
Known set of dimensions or guidelines to evaluate products and
services and identify nonconformity.
Who are the respective parties responsible to maintain standards?
- Local ?
- International?
Example of standards?
Measurement and Inspection
Principle of measurement
-two terms that commonly used and important to describe
the type and quality of an instrument are:
Accuracy
- the degree to which the measured values agrees with the
true value of the quantity of the interest.
Precision
- the degree to which the instrument gives repeated
measurements of the same standard. (degree of repeatability in
the measurements process)
Description of measurement:
Common quantities and geometric features;
Length
Diameter
Roundness
Depth
Straightness
Flatness
Parallelism
Perpendicularity
Angles
Profile
- including all linear dimensions

of parts.
- outside and inside, including
parts with different outside
and inside diameters (steps)
along their length.
- including out-of-roundness,
concentricity, and eccentricity.
- such as drilled or bored holes
and cavities in dies and molds.
- such as shafts, bars, and tubing.
- such as machined and ground
surfaces.
such as two shafts or slideways in machines.
such as a threaded bar
inserted into a flat plate.
including internal & external
angles
- such as curvatures in castings,
forgings, and on car bodies.
The symbols used to

indicate geometric
characteristics
2.1 Tolerance,Limits and Fits

What is allowance?
Specified difference in dimensions between mating part
What is tolerance?
Difference between the two limits
What is limit?
The stated minimum and maximum dimension
What is fit?
Range of looseness and tightness in mating part features
Type of fits
Dimensional tolerance defined as permissible or acceptable

variation in the dimensions (height, width, depth, diameter, and
angles)
Importance of Tolerance Control

Dimensional tolerances is important when a
part is to be assembled or mated with
another part
FIGURE 35.17 Basic size, deviation, and tolerance on a shaft, according to the ISO system.
2.2 Linear Measurement Instruments

Linear Measurement (Direct Reading)
1. Rules: for making linear measurements
2. Calipers: measure inside or outside lengths
3. Micrometers: measuring the thickness and inside or
outside dimensions of parts
Linear Measurement (Indirect Reading)
-They are calipers and dividers without any graduated scales
-Used to transfer the measured size to a direct-reading instrument
Linear Measurement Instruments
2.3 Angular Measurement Instruments

1.
2.
Bevel protractor:
direct-reading of
angles
Sine bar: angle
calculated from trigorelationships
2.4 Straightness, Flatness, and Roundness

Measurement
Straightness
Checked with a straightedge (a) or a dial indicator (b)

Autocollimator accurately measure small angular deviations
on a flat surface
Laser beams used to align individual machine elements in
the assembly of machine components
Flatness
Measured by mechanical means with a surface plate and a

dial indicator
Interferometry uses an optical flat. This is a glass disk or fusedquartz disk with parallel flat surfaces, which is placed on the
surface of the workpiece when surfaces are not flat the fringes are
curved
Roundness
A deviation from true roundness. True roundness is essential

to the proper functioning of rotating shafts, bearing races,
pistons, cylinders, and steel balls in bearings.
1.
2.
Methods of measuring roundness:

of dial indicator with object set on V-block, error in roundness can be directly
V-block - Use
known by comparing the peak height as measured by the dial gauge. (b&c)
Circular tracing - Part is placed on platform, and its roundness is measured by rotating the
platform or alternatively the probe can be rotated around a stationary
part to take the measurement. (d)
2.5 Surface Roughness Measurement

measure of the texture of a surface and related to surface irregularities
resulting from production process.
Surface characteristics includes;
1. Structure : microscopic level effect of processes that the raw material
had gone through
2. Texture : repetitive and/or random deviations from the nominal surface
of an object (roughness, waviness, form, lays and flaws)
3. Roughness : surface profile (peaks and valley)
4. Integrity : subsurface alterations produced due to manufacturing
Surface roughness instruments
2.6 Measurement Using GO and NO GO

Concept.
Using gauge to inspect workpiece/product based on pass test and
fail test.
gives categorical data on one or more dimension of a workpiece is within
specification
Popularly known as GO/NO GO gauges, because one gauge limit allows the
part to be inserted while the other limit does not.
Snap gage (adjustable)
-commonly used to
measure external
dimensions
Plug gage
-commonly used to
measure holes
2.7 Coordinate Measuring Machine (CMM)

-Is an instrument that locates point coordinates on 3-Dimensional structures
while simultaneously integrating both the dimensional and orthogonal
relationships.
-consists basically of a platform on which the workpiece being measured is
placed and then moved linearly or rotated.
-A probe (tactile or non tactile) is attached to a head and records all the
measurements.
Parts are measured and inspected before they are

assembled into products
Parts are measured to ensure that it is
manufactured consistently and within dimensional
tolerances
Measurement of the relevant dimensions and
features of parts is an integral aspect of
interchangeable parts manufacturing
Most important aspects of manufacturing is
product quality

Chapter 2 - METROLOGY-Main Notes

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MEM560

Why metrology is important?

Measurement and Inspection

- including all linear dimensions

The symbols used to

2.1 Tolerance,Limits and Fits

Dimensional tolerance defined as permissible or acceptable

Importance of Tolerance Control

2.2 Linear Measurement Instruments

Linear Measurement Instruments

2.3 Angular Measurement Instruments

2.4 Straightness, Flatness, and Roundness

Checked with a straightedge (a) or a dial indicator (b)

Measured by mechanical means with a surface plate and a

A deviation from true roundness. True roundness is essential

Methods of measuring roundness:

2.5 Surface Roughness Measurement

Surface roughness instruments

2.6 Measurement Using GO and NO GO

2.7 Coordinate Measuring Machine (CMM)

Parts are measured and inspected before they are

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