Metrology Pre-Requisite Knowledge

Understanding of Basic Measurement Understanding of Basic Drawings (Part )

Program Objective
Each individual working on Shop floor must understand the importance of measurement being carried out in their day to day work.

Basic knowledge of measurement procedure

Awareness about Measurement System Analysis( MSA)

This session is designed to achieve the level of awareness on Measurement System and analysis on the measured data.

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Metrology
Metrology is the science of measurement Dimensional metrology is that branch of Metrology which deals with measurement of dimensions of a part or workpiece (lengths, angles, etc.) Dimensional measurements at the required level of accuracy are the essential link between the designers intent and a delivered product.

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Need for Measurements To Determine the true dimensions of a part. To convert physical parameters into meaningful numbers. To test if the elements that constitute the system function as per the design. For evaluating the performance of a system. To ensure interchangeability with a view to promoting mass production. To establish the validity of design and for finding new data and new designs To ensure that the part conforms to established standard To meet interchangeability of manufacture To maintain customer relations To find shortcomings in manufacture Helps to purchase good quality of raw materials Helps co-ordination of different departments To take decision on defective parts

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METHODS OF MEASUREMENT

1. Direct Comparison 2. Indirect Comparison 3. Comparative Method 4. Coincidence Method 5. Fundamental Method 6. Contact Method 7. Transposition Method 8. Complementary Method 9. Deflection Method

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Metrology Concepts
Uncertainty of Measurement Used internationally to describe the quality of a measurement value. Measurement Uncertainty is the sum of all the variations assigned to the variables that make up the measurement system. The total of those probabilities should be weighed and carry importance in proportion to the seriousness and criticality of the measurements being made.

Measurement Result

Potential Value

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Impact of Uncertainty ERROR identified through Calibration Process

Lower Spec. Limit Upper Spec. Limit

Uncertainty

6 Process Tolerance = T
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Metrology Concepts

Traceability Unbroken chain of comparisons to the SI units, all having stated uncertainties

You, the Consumer

Inaccurate Measurements

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Metrology Concepts

Calibration Set of operations that establish the relationship between value of quantities indicated by a measuring instrument and a Reference Standard

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Engineering Metrology

Measurement Standards Line-graduated Instruments Measuring Straightness, Flatness, Roundness and Profile Coordinate Measuring and layout Machines Gages Optical Instruments Automated Measurement Geometric Dimensioning and Tolerancing

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Engineering Metrology
(1)Measurement of dimensions Length Thickness Diameter Taper Angle Flatness Profiles
(2)Postprocess Inspection (3)In-process, on-line, real-time inspection (4)Dimensional Tolerances
The smaller tolerancehigh cost, but more accurate

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Measurement Standard
Inch, foot; based on human body 4000 B.C. Egypt; Kings Elbow=0.4633 m, 1.5 ft, 2 handspans, 6 hand-widths, 24 finger-thickness AD 1101 King Henry I yard (0.9144 m) from his nose to the tip of his thumb 1528 French physician J. Ferneldistance between Paris and Amiens

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Measurement Standard
1872, Meter (in Greek, metron to measure)- 1/10 of a millionth of the distance between the North Pole and the equator Platinum (90%)-iridium (10%) X-shaped bar kept in controlled condition in Paris39.37 in In 1960, 1,650,763.73 wave length in vacuum of the orange light given off by electrically excited krypton 86.

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Measurement Standard
Sensitivity (Resolution); the smallest difference in dimensions that the instrument can detect or distinguish Precision; the degree to which the instrument gives repeated measurements of the same standard (sometimes called accuracy) Standard measuring temperature 20 0C Instrument, gage

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Line-graduated Instruments
Graduatedmarked to indicate a certain quantity Rules; Steel rule (machinists rule), bar or tape, [1 mm or 1/64 in] Vernier calipers; after P. Vernier 1600s, caliper gages, [25 mm or 0.001 in],With digital readout Micrometers; sensitivity [2.5 mm or 0.0001 in],

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Line-graduated Instruments

Diffraction gratings; with two flat optical glasses, interference fringes with 40 lines/mm (1000 lines/in) gratings. [2.5 mm or 0.0001 in] Indirect-reading; dividers, calipers, telescoping gage for holes and cavities.

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Comparative Length-Measuring Instruments

Also called deviation-type instruments Dial Indicator; using rack-and-pinion and gear-train mechanism, accuracy [1 mm or 40 min] Electronic gage; using sensors (strain gage, inductance or capacitance), LVDT (Linear variable differential transformer) for small displacement Laser Scan micrometer; non-contact measurement; high temperature, too elastic or brittle material, on-line measuring, [0.125 mm or 5 min]

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Other Measurements

Straightness; Knife edge, dial indicator, autocollimator (like a telescope with a light beam that bounces), Optical (transits and laser) Flatness; dial indicator, precision steel square, interferometry (if not flat, light fringes are curved) Roundness; V-block with dial gage, read TIR(total indicator reading) Circular tracing; platform rotates

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Other Measurements

Profile Template, profile gage to check shape conformity Measuring screws and gear teeth Threaded plug gages, screw-pitch gages (similar to radius gages), micrometer with cone shaped points, snap gages Optical contour projector Coordinate measuring machines

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Profile Projector

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Gages
Heat treated, stress-relieved alloy steels or from carbide C.E. Johansson 1900s Gage blocks [0.05 mm or 2 min] Grade 0.5 (AAA)-reference gage, very high precision work Grade 1 (AA)-laboratory grade, for calibration of instruments Grade 2 (A+)-precision grade, tool room and inspection Grade 3 (A)-working grade, use in production Plug gage, GO gage, NOT-GO (NO-GO) Pneumatic (air) gage

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Selection of Measuring Instruments

Accuracy The degree of agreement of the measured dimension with its true magnitude Magnification (amplification) Precision Resolution the smallest dimension that can be read on an instruments Rules of 10 (gage makers rule) At least 10 times accurate than the tolerance Sensitivity Stability (drift); capability to maintain calibrated status
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Precision vs. Accuracy

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Tolerance
Tolerare; put up with, endure Impossible to make perfect parts Too small tolerance, cost is high

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Importance of tolerance

Parts from the same machine can be different Speed of operation Temperature Lubrication Variation of incoming material Other factors ISO system; definitions

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Definitions

Allowance; the specific difference in dimensions between mating parts Basic size; dimension from which limits of size are derived Bilateral tolerance; deviation from the basic size (+ or -) Clearance; the space between mating parts Clearance fit; fit that allows for rotation or sliding between mating parts Datum; theoretically exact axis, point, line or plane

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Definitions
Feature; Physically identifiable portion of a part, e.g. hole, slot, pin, chamfer Fit; the range of looseness or tightness Geometric tolerancing; tolerances that involve shape features of the part Hole-basis system; tolerances based on a zero line on the hole Interference; negative clearance Interference fit International Tolerance grade (IT); a group of tolerances that the same relative level of accuracy within a grade (varies depending on basic size)

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Definition

Limit dimension; Maximum and minimum dimension of a part, MMC(maximum material condition); condition where a feature of size contains the maximum amount of material within the stated limits of size Nominal size; Positional tolerancing; A system of specifying the true position, size, and form of the feature of a part, including allowable variation Shaft-based system; Standard size Transition fit; Fit with small clearance or interference that allows for accurate location of mating parts

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Tolerances
Unilateral tolerancing Zero line; reference line along the basic size from which a range of tolerances and deviations are specified.

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Micrometer
The micrometer is a basic precision measuring tool. To a machinist, this tool is indispensable. The engineer should also realize the importance of being able to use this tool properly. This discussion should help in mastering the use of the common "Mike," whether it is an outside, inside or depth type.

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Thank you

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