Unit I Qa PDF

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Prof S P Dhavane/ Prof V P Kulkarni MIT AOE

Prof S P Dhavane/ Prof V P Kulkarni MIT
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Reference Books

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Unit I:Introduction to Metrology
Syllabus
 Metrology
 Accuracy and Precision
 Errors
 Measuring Instruments & Calibration
 Types of Geometric Form & measurements
(GD&T)

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Science is Dependent on Measurements..!!

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Meterology…??
• Metrology is a Science of Measurement.
• Metrology is derived from Greek words.
Metro Measurement
Logy Science
• Metrology is concerned with the establishment,

reproduction and conservation and transfer of
units of measurements and their standards
• E.g. Measurement of length, angles, width, depth,

diameter and straightness with high accuracy
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Basic Elements of Measurement System

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Measurement
Measurement – It is a process of comparison with
standard measuring instruments or numerical
evaluation of a dimension.
Measuring system includes the instrumentation,
calibration standards, environmental influence, human
operator limitations and features of the workpieces for
Industries.
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Objectives of Metrology
 Ensure the Material, parts and components conform
to the established standards.
 Meet The interchangeability of Manufacture
 Provide the means of finding the problem area for not
meeting the established standards.
 Produce the Part having Acceptable Quality Levels
with reduced scrap and wastages.

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Objectives of Metrology
 Taking necessary efforts to measure and Reduce The
Rejection Percentage for the forthcoming production
batches by matching the tech specification of the
product with the process capabilities.
 Judge the possibility of rework of defective parts and
re-engineer the process.
 To Have Good Accuracy and Precision.

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Standards of Measurement
 Types of Standards :
(universally accepted specification for A quantity )
• International Standards
• National Standards(Primary)-weight and measures standard
• Calibration Standards(Secondary)-working standards
• Metrology Standards-Reference standards
 Classification of standards for Linear Measurement :
1. Line Standard
2. End Standard
3. Wave length Standard
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Line Standard (Material Standards)
 The measurement of distance made between two parallel lines.

 e.g. meter is the Line standard
 Meter- It is the distance between the center portion of two lines
etched on a polished surface of a bar of pure platinum (90%) and
iridium alloy (10%).

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End Standard
 The measurement of distance made between two surfaces.
 Length bars and slip gauges are in the form of End
standards.
 End standards are highly accurate and very small
dimensions can also be measured with it.
e.g. Slip Gauges.

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Wavelength Standard
 The working standards are derived from the physical standards
and comparison with these standards may leads to errors.
 Use of wavelength of monochromatic light as the working
standard reduces the dependency on physical standards. This
standard has no effect of variation in the temperature, pressure or
overall environment.
International standard measures the meter in terms of wavelength
of Krypton 86 (Kr86).
1meter= 1650763.73 x wavelength of radiation
= 999.999652 mm

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True Value…..??
Measured Value (Indicated Value) …??

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Precision And Accuracy
 Accuracy : The Closeness of the Measured Value with the True Value
 Precision :
The repeatability of the Measuring Devices OR
It is the degree to which an instrument gives repeated measurements.

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• Precision –
 It is the nearness of the reading with other readings of the same
dimension.
It is repeatability of a measuring process.
A Precise measurement need not to be necessarily be accurate.
• Accuracy –
 It is the nearness of the reading with the true value of the
dimension.
 It is agreement of the result of a measurement with the true
value of the dimensioned being measured.
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Repeatability & Reproducibility
• Repeatability is ability of a measuring instrument to give
same value of a quantity when the measurements are made
under same conditions.
• Reproducibility is the quantitative measure of the
Closeness Of The Agreement Between The Results Of
Measurements Of The Same Parameter carried out by
changing the method of measurement, operator, instrument,
operating condition ,time ..etc

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Errors
•Types Of Errors: (True Value – Measured Values)
1.Gross Errors :
 Human mistakes that occur due the causes like
i) Using a wrong instrument
ii) Mistake in recording the reading
iii) Faulty setting of instrument
iv) Wrong calculation and procedure.
 Impossible to correct these errors since they cannot
be estimated mathematically.
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2.Systematic Errors:(Bias Error/ Controllable Error)
 These errors have definite magnitude and direction and are
repeated consistently every time a reading is repeated.
 Types:
i) Instrument errors
ii) Environmental errors-pressure ,temp, humidity, magnetic
field.
iii) Observational errors
iv) Operational errors-eg. Bulb of thermometer for reading
v) System interaction errors eg change in dimensions due to
pressure.
 These errors can be detected by repeated readings at different
times with different instruments and under different
conditions. Prof S P Dhavane/ Prof V P Kulkarni MIT
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2.Systematic Errors
i) Alignment errors
ii) Environmental errors-pressure
,temp, humidity, magnetic field.
iii) Parallox errors
iv) Contact errors
v) Support Error
vi) Dirt Error

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3.Random Errors:
 These are small accidental errors that vary in
magnitude and direction in an unpredictable manner.
 Caused by:
1.Friction and stickiness of surfaces
2.Vibrations
3.Variation in power supply
4.Elasto deformation of parts.

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Sources of Errors
1.Instrument Errors
2.Environmental effect
3.Flexure (bend or curve) at contact surfaces-
deformation at contact surfaces
4.Alignment Method
5.Parallox Error or error of reading
6.Support error
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Examples of
Failed Measurements

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Examples of
Failed Measurements

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Examples of Failed Measurements

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Linear and Angular Measurement
 Linear measurements :
• Non-precision type – Steel rule, Caliper, depth
gauge
• Precision Type – Vernier Caliper, Vernier Height
Gauge, Micrometer, Slip Gauges
Angular measurements :
• Angle gauges, sine bar, sine center

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Linear Measurements

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Linear Measurements
• It applies to measurement of lengths, diameters, heights and
thicknesses including external and internal measurement
Direct Contact Indirect Contact
Precision
Non-Precision Type
Graduated Non-graduated
Rulers,Vernier
Calipers,Micrometer,Dial Calipers,Sine Bar,Gauges
Gauage,Protectors

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Linear Measuring Instruments
1. Micrometers
2. Vernier Calipers
3. Dial Indicators
4. Telescopic Gauges
5. Small Hole Gauges
6. Thickness Gauges
7. Straight Edge

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Micrometers

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Where To Find Range

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Readings

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Digital Micrometers

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Using Inside Micrometer

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Standard Vernier Caliper

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Vernier Height Guage

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Vernier Depth Guage

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Telescopic Gauges
Spring loaded
Measure large inside dia.

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Using Telescopic Gauges

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Slip Gauges (Gauge Blocks/Johannsen
Gauges:
These are the working standards of linear
measurements
i)To form the size of Gauge Blocks in
Comparators
ii)For direct and precise measurements when
the accuracy of the Work piece is required.

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Angular
Measurements

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Try Square

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Dial Indicator with Stand

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Bevel Protractor

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Bevel Protractor
Readings

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Geometric Forms and Measurements

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Checking All Geometric Forms

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Outline
• What is GD & T ?
• History
• Symbols and characteristics
• Modifiers
• Feature control frame
• All 14 Characteristics

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What is GD & T ?
• Geometric Dimensioning and Tolerancing (GD&T) is a Language Used On
Mechanical Engineering Drawings composed of symbols that are used to
efficiently and accurately communicate geometry requirements for
associated features on component and assemblies.
• A method to Specify The Shape Of A Piece Of Hardware On An Engineering
Drawing.
• A set of fourteen symbols used in the language of GD&T.
• It consists of well defined symbols, rules, definitions and conventions, used
on engineering drawings to accurately describe a part.
• GD&T is a Precise Mathematical Language That Can Be Used To Describe The
Size, Form, Orientation, And Location Of Part Features.
• GD&T is also a design philosophy on how to design and dimension parts.
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Dimension:
• A numerical value expressed in appropriate units of measure and used to
define the size, location geometric characteristics or surface texture of a part.
• It is a measurable extent, as length, breadth and depth
Tolerance
• It is a Allowable Variation In Any Measurable Property.
• The total amount that features of the part are permitted to vary from the
specified dimension.
• The tolerance is the difference between the maximum and minimum limits.
• Two common methods to specify tolerances
– limit tolerances
– plus-minus tolerances

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Torpedo..??
Prof S P Dhavane / Prof V P Kulkarni MIT AOE

History of GD & T
 Stanley Parker from Royal Torpedo Factory in Alexandria developed the

concept of position or “True Position” in year 1938
 He found parts for torpedoes that were rejected when inspected using
traditional tolerances.
 However, he found that many were functional parts and were being sent to
production even though they were technically out of specification tolerance.
 His system increase the acceptance to 57% of rejected parts.
Benefits of GD & T
• It is international language.
• It comprises of symbols, rules and definitions for defining geometry of a
part.
• Uniformity in drawings, better designs, No assumptions, large tolerances.

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Symbols And Its Characteristics
14 characteristic
symbols with Individual
geometric type (No Datum Reference)
control:
• Form – 4 Individual Or Related
• Profile – 2 Feature
• Orientation – 3
• Location – 3
• Run out – 2
Related Feature
(Datum Reference
Required)

Modifiers And Its Symbols
Modifiers are symbols which defines conditions for the tolerance zone of a geometric
tolerance.
Additional symbols

Feature Control Frame

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Form Tolerances : Straightness
Surface straightness Axial straightness with MMC
Plunger dial or Lever dial attached to height gauge
Tolerance zone : Axis of cylinder to

which the tolerance frame is
Tolerance zone is defined connected, shall be contained in
by two parallel line cylindrical tolerance zone of diameter
distance apart 0.030 0.030 Prof S P Dhavane/ Prof V P Kulkarni MIT
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Form Tolerances : Flatness
Plunger dial or Lever dial attached to height gauge
Tolerance zone: surface shall be contained Feeler gauge (not more accurate)
between two parallel planes 0.030 apart.
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Form Tolerances : Circularity
Circularity symbol is used to describe how close an object should be a true circle.
Fix Plunger dial and by rotating

the part to be measured.
Tolerance zone : Circumference of each cross section shall be

contained between two coplanar concentric circles 0.030 apart
Form Tolerances : Cylindricity
• Circularity symbol is used to describe how close an object should be a true cylinder.
• It is two dimensional tolerance that controls overall form of cylindrical feature to ensure
it is round enough and straight enough along its axis.
Moving Plunger dial along straight line and

by rotating the part to be measured.
Tolerance zone :
considered surface
shall be contained
between two coaxial
cylinders 0.030 apart.
Profile Tolerances : Line and Surface
Profile of a line Profile of a surface
Tolerance zone : considered surface

Tolerance zone : considered profile shall be contained between two CMM is better for profile
shall be contained between two lines surfaces enveloping spheres of measurements.
enveloping circle of diameter 0.030, diameter 0.030, centers of which are
situated on a surface having true
centers of which are situated on a line geometrical form.
having true geometrical profile. Prof S P Dhavane / Prof V P Kulkarni MIT AOE
Orientation Tolerances ∶ Parallelism
Tolerance zone : the tolerance

axis shall be contained in
cylindrical zone of diameter 0.03
parallel to datum axis A.
Tolerance zone : between two

parallel planes 0.003 apart which
are parallel to datum A.
Orientation Tolerances ∶ Perpendicularity
Axis Perpendicularity
Surface Perpendicularity
Height gauge
Tolerance zone :
Axis should between two
Tolerance zone : between parallel planes 0.03 apart which
two parallel planes 0.03 are perpendicular to datum A.
apart which are
perpendicular to datum A. AOE
Orientation Tolerances ∶ Angularity
Tolerance zone : between

two parallel planes 0.03
apart which are inclined at
60 degree to datum plane A
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Location tolerances – Position, Concentricity and Symmetry
Position
Tolerance zone : Axis of hole shall be contained within a cylinder of diameter of 0.030

Concentricity
Tolerance zone : Axis of hole shall be

contained within a cylinder of diameter of
0.030, coaxial with A-B

Symmetry
Tolerance zone : Median plane of the slot shall be

contained between two parallel planes which are
0.030 apart and symmetrically disposed about
median plane with respect to datum plane A

Run Out Tolerances ∶ Run out and Total Run out
Run out
Tolerance zone : The radial run out should not be greater than 0.030 in any plane of
measurement during one revolution about the datum axis A.
Run Out Tolerances ∶ Run out and Total Run out
Total Run Out
Tolerance zone : The total radial run out should not be greater than 0.030 in at any
point on specified surface during several revolutions about datum axis A and with
relative axial movement between part and measuring instrument.
Calibration
 Calibration: Process of checking the accuracy of the Measuring
Instruments or the dimensions & Tolerances of a gauge by comparing
it with same or standard instrument/Guaooge which has been
certified as per standards
 Need of Calibration
 Requirement of Calibration Systems
(Accuracy , Precison and reliability)
 Procedure Of Calibration
 Calibration of General Metrological Instruments (Vernier, Micrometer

Etc) AOE
Straightness-Testing Methods
A) Straight Edge Method

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B) Wedge Method

B) Wedge Method
C ) Spirit level method

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Flatness-Testing Methods
A) Surface Plate Method

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B) Dial Guage Method

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C) Straight Edge Method

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Parallelism-Testing Methods
A) Parallelism of two Axis

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B) Parallelism of two Planes

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C) Parallelism of an axis to the plane

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Squareness-Testing Methods
A)Try Square and Combination Square

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Squareness-Testing Methods
C) Indicator method

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Quality Assurance

Prof S P Dhavane/ Prof V P Kulkarni MIT AOE

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

• Metrology is derived from Greek words.

• Metrology is concerned with the establishment,

• E.g. Measurement of length, angles, width, depth,

Prof S P Dhavane/ Prof V P Kulkarni MIT

standard measuring instruments or numerical

Measuring system includes the instrumentation,

calibration standards, environmental influence, human

operator limitations and features of the workpieces for

to the established standards.

 Meet The interchangeability of Manufacture

 Provide the means of finding the problem area for not

meeting the established standards.

 Produce the Part having Acceptable Quality Levels

with reduced scrap and wastages.

Rejection Percentage for the forthcoming production

batches by matching the tech specification of the

product with the process capabilities.

 Judge the possibility of rework of defective parts and

re-engineer the process.

 To Have Good Accuracy and Precision.

 The measurement of distance made between two parallel lines.

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Measured Value (Indicated Value) …??

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

same value of a quantity when the measurements are made

under same conditions.

• Reproducibility is the quantitative measure of the

Closeness Of The Agreement Between The Results Of

Measurements Of The Same Parameter carried out by

changing the method of measurement, operator, instrument,

operating condition ,time ..etc

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

3.Flexure (bend or curve) at contact surfaces-

deformation at contact surfaces

5.Parallox Error or error of reading

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

• Non-precision type – Steel rule, Caliper, depth

• Precision Type – Vernier Caliper, Vernier Height

Gauge, Micrometer, Slip Gauges

• Angle gauges, sine bar, sine center

Prof S P Dhavane/ Prof V P Kulkarni MIT

Direct Contact Indirect Contact

Prof S P Dhavane/ Prof V P Kulkarni MIT

5. Small Hole Gauges

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT

Prof S P Dhavane/ Prof V P Kulkarni MIT