Unit 1: Metrology and Inspection

• Course Content
• Introduction to measuring instruments, Measurement standards,
Types and sources of errors, Accuracy and Precision, Limits, fits
and tolerances; linear and angular measurements; comparators,
form and finish measurement; tolerance analysis in
manufacturing and assembly.
 References
• Chapter 35: Engineering
Metrology and Instrumentation:
Book ‘MANUFACTURING
Engineering and Technology’ by
Serope Kalpakjian and Steven R.
Schmid
• Book, ‘Engineering metrology
and measurements’ by N. V.
Raghavendra and L.
Krishnamurthy
Introduction
• Engineering metrology is defined as the measurement of dimensions,
such as length, thickness, diameter, taper, angle, flatness, and profile.
• Geometrical Measures only, not mechanical and physical properties
• Inspection
• postprocess inspection
• in-process, online, or real-time inspection
• Dimensional tolerance
• The permissible variation in the dimensions of a part.
 Measurement Standard
• History

photo credit: Andrew Robinson

Standardized weights from the

Indus river valley

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 Measurement Standard
• History of meter
3,000 BC in Ancient Egypt : Cubit
2500 BC: More standardised ‘royal master cubit’, represented as a black
marble piece, resembling a rule

photo credit: Andrew Robinson

Standardized weights from the Indus river valley

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 Measurement Standard
• History of Yard
Yard

It was the distance from his nose to the tip of his

thumb.
(0.9144m)

Every King start to define his own standrd

In 1101

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Measurement Standard
• History of meter
1790, in France, with the concept of a mètre (from the Greek word metron, meaning “measure”) is
introduced.

A copy of the "provisional" metre installed 1796–1797,

located in the wall of a building, 36 rue de Vaugirard, Paris.
These metres were based on the "provisional" metre,
because the expedition to re-determine the metre wasn't
completed until 1798.[39]

Until 1960, the SI standard of length was

disseminated using platinum-iridium meter bars
such as these from the NIST Museum.
 Measurement Standard
• Present meter
based on the speed of light in a vacuum, which is calculated by multiplying the
wavelength of the standardized infrared beam of a laser by its frequency.

Definitions of the metre since 1795[121]

Absolute Relative
Basis of definition Date
uncertainty uncertainty

1/10 000 000 part of the quadrant along the meridian, measurement by Delambre and
1795 500–100 μm 10−4
Méchain (443.296 lines)

First prototype Mètre des Archives platinum bar standard 1799 50–10 μm 10−5

Platinum-iridium bar at melting point of ice (1st CGPM) 1889 0.2–0.1 μm (200–100 nm) 10−7

Platinum-iridium bar at melting point of ice, atmospheric pressure, supported by two

1927 n.a. n.a.
rollers (7th CGPM)

Hyperfine atomic transition; 1650763.73 wavelengths of light from a specified transition

1960 4 nm 4×10−9[122]
in krypton-86 (11th CGPM)

Length of the path travelled by light in a vacuum in 1/299 792 458 second (17th CGPM) 1983 0.1 nm 10−10
 Measurement Standard
• Resolution
• The smallest difference in dimensions that the measuring instrument can
detect or distinguish
• Precision
• Sometimes incorrectly called accuracy, it is the degree to which the
instrument gives repeated measurements of the same standard

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Errors
• Errors
• Difference between the true value and the mean value of the set of readings
on the same component
E = Vm - Vt
where E is the error, Vm the measured value, and Vt
the true value.

% error

• Error and Accuracy

• The instrument is more accurate if the magnitude of error is low.
Errors
• Accuracy • Accuracy & Cost
• Sensitivity
• Consistency

• Sensitivity
• It is the ability of the
measuring equipment
to detect small
variations in the
quantity being
measured.
General Measurement Concepts

1. Measurand, a physical quantity such as length, weight, and angle to be measured

2. Comparator, to compare the measurand (physical quantity) with a known standard (reference)
for evaluation
3. Reference, the physical quantity or property to which quantitative comparisons are to be
made, which is internationally accepted
ERRORS IN MEASUREMENTS
• Systematic or Controllable Errors
1. Calibration errors
2. Ambient conditions
3. Deformation of workpiece
4. Avoidable errors

• Random Errors
ERRORS IN MEASUREMENTS
Traditional Measuring Methods and Instruments

• Line-graduated Instruments
• Linear Measurement (Direct Reading)
• Rules
• Caliper
• Micrometer
Traditional Measuring Methods and Instruments

• Line-graduated Instruments
• Linear Measurement (Indirect Reading)
Traditional Measuring Methods and Instruments

• Line-graduated Instruments
• Angle Measurement
• Bevel protractor
• Sine Bar
Traditional Measuring Methods and Instruments

• Line-graduated Instruments
• Comparative Length Measurement
Traditional Measuring Methods and Instruments

• Measuring Geometric Features

• Straightness
• Flatness
Traditional Measuring Methods and Instruments

• Measuring Geometric Features

• Straightness
• Flatness
Traditional Measuring Methods and Instruments

• Measuring Geometric Features

• Roundness
Traditional Measuring Methods and Instruments

• Measuring Geometric Features

• Screw Threads and Gear Teeth. Optical Contour Projectors
Traditional Measuring Methods and Instruments

• Gages
 Traditional Measuring Methods and Instruments

• Air Gages
Modern Measuring Instruments and Machines
• Coordinate-measuring Machines
Modern Measuring Instruments and Machines
• Coordinate-measuring Machines
 General Characteristics and Selection of Measuring Instruments

• Accuracy: The degree of agreement of the measured dimension with its true magnitude
• Amplification, also called magnification: The ratio of instrument output to the input
dimension
• Calibration: The adjustment or setting of an instrument, to give readings that are accurate
within a reference standard
• Drift, also called stability: An instrument’s capability to maintain its calibration over time
• Linearity: The accuracy of the readings of an instrument over its full working range
• Precision: Degree to which an instrument gives repeated measurement of the same
standard
• Repeat accuracy: The same as accuracy, but repeated several times
• Resolution: Smallest dimension that can be read on an instrument
• Sensitivity: Smallest difference in dimension that an instrument can distinguish or detect
• Speed of response: How rapidly an instrument indicates a measurement, particularly when a
number of parts are measured in rapid succession
 Geometric Dimensioning and
Tolerances

GDandT-Drawing-Plunger-Relief-Valve2.png (1025×462) (solidworks.com)

Geometric Dimensioning and
Tolerances
• Dimensional Tolerance
• Dimensional tolerance, from the Latin tolerare, meaning to “endure,” is
defined as the permissible or acceptable variation in the dimensions

• Tolerances are unavoidable

• Process inaccuracies
• Cost of Production
• Time Requirement
Geometric Dimensioning and
Tolerances
• Cost of Production

• Close dimensional
tolerances can
significantly increase
the product cost
Geometric Dimensioning and
Tolerances
• Time Requirement

• Tighter tolerances and

smoother surfaces
being the most time
consuming
Geometric Dimensioning and
Tolerances
• Importance of Tolerance Control
Geometric Dimensioning and
Tolerances
• Importance of Tolerance Control
Geometric Dimensioning and
Tolerances
Geometric Dimensioning and
Tolerances
Geometric Dimensioning and
Tolerances
Geometric Dimensioning and
Tolerances
• Importance of
Tolerance Control
Geometric Dimensioning and
Tolerances
• Importance of
Tolerance Control
Geometric Dimensioning and
Tolerances
• Definitions
• Refer pdf file. Page No. 1025
Geometric Dimensioning and
Tolerances
Geometric Dimensioning and
Tolerances
Geometric Dimensioning and
Tolerances
References
• Chapter 35: Engineering Metrology and Instrumentation: Book
‘MANUFACTURING Engineering and Technology’ by Serope Kalpakjian
and Steven R. Schmid
• Book, ‘Engineering metrology and measurements’ by N. V.
Raghavendra and L. Krishnamurthy