Metrology

Metrology is the science of measurement. It includes all theoretical and practical aspects of measurement. It is derived from Greek word metros which means measure. Should not be confused with meteorology which deals with study of the atmosphere that focuses on weather processes and climate forecasting. The subject of metrology has changed since the introduction of concept called Interchangeable parts by Eli Whitney.

Tolerances

Courtesy: ANSI/ISO

Tolerances

Courtesy: ANSI/ISO

Tolerances

Courtesy: ANSI/ISO

Tolerances

Price ? Rs 15 Roundness 25

Rs 200

Roundness 5

Rs 6000 Roundness 0.5

Tolerances

Tolerances

Clearance Fit

Geometric Tolerances

Geometric Tolerances

Geometric Tolerances

Geometric Tolerances

Geometric Tolerances
A

B B as a Datum, Parallelism = 0.05 mm A

B
A as a Datum, Parallelism = 0.02 mm

Geometric Tolerances

Courtesy: ANSI/ISO

Accuracy & Repeatability

100 shafts of diameter 50 mm were manufactured using different manufacturing processes. When manufactured by process A the diameter of shafts were in the range of 49.994 to 50.005 (Accuracy=0.006) When manufactured by process B the diameter of shafts were in the range of 49.978 to 50.024 (Accuracy=0.024) Process A has better accuracy than Process B When manufactured by process C the diameter of shafts were in the range of 49.979 to 49.981 (Accuracy=0.021) Process C has better repeatability than Process A
Accuracy and Repeatability

Accuracy & Repeatability

Accuracy and Repeatability

Accuracy and Resolution

Shafts Y and Z of diameter 50 mm manufactured using a process were measured using three different instruments. Shaft Y Steel Rule 49.5 mm Shaft Z 50.0 mm

Vernier Caliper
Micrometer

49. 41 mm
49.408 mm

49.89 mm
49.892 mm

Resolution of steel rule is 0.5 mm, vernier is 0.01 mm and micrometer is 0.001 mm.
Accuracy and Resolution

Metrology
Shafts of diameter 50 mm were manufactured using a process and needs to be inspected for meeting tolerances.

Micrometer (Option A)

Metrology

Mechanical Comparator (Option B)

Metrology

79.352 =

75 +
1+ 1.3 + 1.05 + 1.002

Slip Gauges

Metrology

Snap Gauge/Go-Nogo Gauge (Option C)

CMM

CMM Coordinate Measuring Machine

CMM

Cylindricity

Flatness

Roundness

CMM Coordinate Measuring Machine

CMM
Flatness 6

Parallelism 3
Squareness 18

CMM

yi

y = a + bx

ei = yi (a + b xi )

a + b xi

CMM Coordinate Measuring Machine

Straightness

Straightness

Straightness

CMM

CMM Coordinate Measuring Machine

Process Capability

Process Capability

Desired 9.25 mm 0.15 mm; Limits 9.1 mm and 9.4 mm Random Variations Result from intrinsic variability in the process, no matter how well designed or well controlled it is (examples: inherent human variability, minor variation in raw material, machine vibrations etc.)

Process Capability
LSL = Lower Specification Limit USL = Upper Specification Limit = Mean (Average)

= Standard Deviation

Process Capability

Process Capability

Rejections

2700 ppm 64 ppm 6 ppm 2 ppb

Process Capability (Cp)

Process Capability

Process Capability

Process Capability

Process Capability (Cpk)

Process Control

Process Control

Process Control
Process Control refers to changing of the process based on the results of process monitoring. Two Approaches

Passive
Monitor process output periodically and act when the process is out of control

Active automated changes to the process that are programmed to correct the out-of-control measurement.

Sampling Inspection
A sample should be picked at random from the lot, and on the basis of information that was yielded by the sample, a decision should be made regarding the disposition of the lot. In general, the decision is either to accept or reject the lot. This process is called Lot Acceptance Sampling or just Acceptance Sampling.

Two important parameters are sample size (n) and defectives (c)

OC Curve

The AQL is that percent defective with a 95% percent chance of acceptance. The LTPD is that percent defective with a 10% chance of acceptance.

Acceptable quality level

Lot tolerance percent defective