Metrology and Measurements
Metrology and Measurements
Metrology and Measurements
CONCERNEDWITH:
ESTABLISHING UNITS OF MEASUREMENT
TO FORM STANDARDS
DEVELOPING METHODS OF MEASUREMENT
ANALYSING ACCURACY
FIND CAUSES OF MEASURING ERRORS &
ELIMINATE
ObjectivesofMetrology:
1. To provide accuracy at minimum cost.
2. Thorough evaluation of newly developed products, and to ensure that
components are within the specified dimensions.
3. To determine the process capabilities.
4. To assess the measuring instrument capabilities and ensure that they
are adequate for their specific measurements.
5. To reduce the cost of inspection & rejections and rework.
6. To standardize measuring methods.
7. To maintain the accuracy of measurements through periodical
calibration of the instruments.
8. To prepare designs for gauges and special inspection fixtures.
Typesofmetrology
Scientific Metrology :-
LegalMetrology:-
part of metrology which treats units of measurements, methods of
measurements and the measuring instruments, in relation to the
technical and legal requirements
Activities:
Control testing,verification,standardization of measuring
instruments
Testing of prototypes/models of measuring instruments
Examination- verify its conformity to the statutory requirements
Engineering Metrology:
Measurement of dimensions such as length, thickness,
diameter, taper, angle, flatness, profile and others
Post-Process Inspection:
Measurements taken after the part is produced
In-process, On-line or Real-Time Inspection:
Checking part characteristics while part is being produced
Sensitivity:
Is the smallest difference in dimensions that the instrument
can detect
Accuracy:
The ability of a measurement to match the actual value of the
quantity being measured
Precision:
The degree to which the instrument gives repeated
measurements of the same standard
MethodsofMeasurements
In precision measurement various methods of measurement
are adopted depending upon the accuracy required and the
amount of permissible error.
Themethodsofmeasurementcanbeclassifiedas:
l. Direct method
2. Indirect method
6. Coincidence method
DefinitionofStandards:
A standard is defined as something that is set up and established by an
authority as rule of the measure of quantity, weight, extent, value or
quality
RoleofStandards:
The role of standards is to achieve uniform, consistent and repeatable
measurements throughout the world
entire industrial economy is based on the interchangeability of parts
the method of manufacture
To achieve this, a measuring system adequate to define the features
to the accuracy required & the standards of sufficient accuracy to
support the measuring system are necessary
StandardsofMeasurements
The different types of standards of length are
1.Material Standards
(i)Line Standard When length is measured as the distance
between centers of two engraved lines.
(ii)End Standard When length is measured as the distance
between to flat parallel faces.
2.Wavelength Standard
The wavelength of a selected orange radiation of Krtypton-86 isotope
was measured and used as the basic unit of length
DefinitionofStandards:
A standard is defined as something that is set up and established by an
authority as rule of the measure of quantity, weight, extent, value or
quality
RoleofStandards:
The role of standards is to achieve uniform, consistent and repeatable
measurements throughout the world
entire industrial economy is based on the interchangeability of parts
the method of manufacture
To achieve this, a measuring system adequate to define the features
to the accuracy required & the standards of sufficient accuracy to
support the measuring system are necessary
Line Standards When length is measured as the distance between centers of two
engraved lines, it is called Line Standards. Both material Standards, yard and metre are
line standards
E.g.Scale,Rulers,ImperialStandardYard.
CharacteristicsofLineStandards:
Scale can be accurately emblemed, but the engraved lines posses thickness and it is not
possible to accurately measure
Scale is used over a wide range
Scale markings are subjected to wear. However the ends are subjected to wear and this
leads to undersize measurements
Scale does not posses built in datum. Therefore it is not possible to align the scale with
the axis of measurement
Scales are subjected to parallax errors
Assistance of magnifying glass or microscope is required.
DifferentiatebetweenLineandEndStandards
Sl no
1
2
3
4
5
6
7
Characteristi
Line Standard
cs
Principle
Length
is
expressed as
distance between
2 lines
Accuracy
Ltd. To
0.2mm.
End Standard
Length
is
expressed
as
distance between 2
ends
Highly accurate of
closed
tolerances
to 0.001mm
Ease
Quick and easy Time
consuming
and requires skill
Effect
of Wear at only the wear at measuring
wear
ends
surfaces
Allignment
Cannot be easily easily aligned
aligned
Cost
low cost
high
cost
Parallax
Effect
Subjected
parallax effect
to not subjected
parallax effect
to
Mediumresolutiondevices
Micrometer
Micrometer with assistance of
Telescoping
Extendable ball gauges
Vernier calipers
Dial indicators
Microscope
Highresolutiondevices
Gauge blocks
Gauge block with assistance of
Mechanical comparator
Electronic comparator
Pneumatic comparator
Optical flats
Measuring Instruments:
1) Length measuring Instruments.
1.1) Direct measuring.
1.2) Indirect measuring.
2) Angle measuring Instruments.
3) Instruments for surface finish.
4) Instruments for deviations.
24
LinearMeasuringInstruments
Vernier caliper
Micrometer
Slip gauge or gauge blocks
Optical flats
Interferometer
Comparators
1)Lengthmeasuring
Instruments:
1.1) Rules and tapes:
(Direct measuring)
26
1)Lengthmeasuring
Instruments:
1.1)Rulesandtapes:
(Direct measuring)
Measuring lengths.
Measuring the outside diameter of pipe.
Measuring the inside diameter of pipe.
Measuring the circumference of pipe.
Measuring inside dimensions.
Measuring the thickness of stock through a hole.
Measuring outside dimension with a tape
27
1)Lengthmeasuring
Instruments:
Verniercaliper:
(Direct measuring)
28
1)Lengthmeasuring
Instruments:
1.2)Verniercaliper:
(Direct measuring)
31
VERNIER CALIPER
Vernier calipers are available in size of 150 mm,
225 mm, 900 mm and 1200 mm.
The selection of the size depends on the
measurements to be taken.
LeastCountofVernierCalipers
Least Count refers to the smallest distance that can be measured
using an instrument. It indicates the degree of precision of an
instrument. Most of the vernier Calipers have a least count of
0.1mm.
DIGITAL CALIPER
VERNIER HEIGHTGAUGE
VERNIER DEPTH
GAUGE
1)Lengthmeasuring
Instruments:
1.3)TheMicrometer:
(Direct measuring)
41
MEASUREMENT
OPENING
BARREL
SCALE
55
THIMBLE
SCALE
5
0
10
15
RATCHET
20
25
45
ANVIL
SPINDLE
BARREL
0.01 mm
FRAME
THIMBLE
THIMBLE
SCALE
HORIZONTAL
READING
LINE
BARREL
SCALE
0
55
10
0.01 mm
DIVISION
15
0.5 mm DIVISION
(distance moved by
1 revolution of thimble)
20
25
55
10
15
20 30 25
25
Comparators:
are employed to find out, by how much the dimensions of the given
component differ from that of a known datum.
CharacteristicsofGoodComparators:
1. It should be compact.
2. It should be easy to handle.
3. It should give quick response or quick result.
4. It should be reliable, while in use.
5. There should be no effects of environment on the comparator.
6. Its weight must be less.
7. It should be sensitive as per the requirement.
8. The design should be robust.
9. It should have less maintenance.
10. It should have hard contact point, with long life.
11. It should be free from backlash and wear.
MechanicalComparator:
1.It is self controlled and no power or any other form of energy is required.
2.It employs mechanical means for magnifying the small movement of the measuring
stylus.
3.The movement is due to the difference between the standard and the actual dimension
being checked .
4.The method for magnifying the small stylus movement in all the mechanical
comparators is by means of levers, gear trains or combination of these. They are
available of different make and each has it's own characteristic.
5.The various types of mechanical comparators are dial indicator, rack and pinion,
sigma comparator, Johansson mikrokator.
Dial Indicators :
RequirementsofGoodDialIndicator:
1. It should give trouble free and dependable readings over a long period.
2. The pressure required on measuring head to obtain zero reading must remain
constant
over the whole range.
3. The pointer should indicate the direction of movement of the measuring plunger.
4. The accuracy of the readings should be within close limits of the various sizes and
ranges
5. The movement of the measuring plunger should be in either direction without
affecting the accuracy.
6. The pointer movement should be damped, so that it will not oscillate when the
readings are being taken.
Applications:
1. Comparing two heights or distances between narrow limits.
2. To determine the errors in geometrical form such as ovality, roundness and taper.
3. For taking accurate measurement of deformation such as intension and compression.
4. To determine positional errors of surfaces such as parallelism, squareness and
alignment.
5. To check the alignment of lathe centers by using suitable accurate bar between the
centers.
6. To check trueness of milling machine arbours and to check the parallelism of shaper
arm with table surface or vice.
Optical Comparators
Projects enlarged shadow onto screen where it is compared to
lines or to master form that indicates limits of dimensions or
contour of part being checked
Fast, accurate means of measuring workpiece with master
Suited to checking extremely small or odd-shaped parts
Available in bench and floor models
Principle of the
Optical Comparator
Advantages:
1. These Comparators are almost weightless and have less number of moving parts, due tothis
there I s less wear and hence lessfriction.70
2. Higher range even at high magnification is possible as the scale moves past the index.
3. The scale can be made to move past a datum line and without having any parallax errors.
4. They are used to magnify parts of very small size and of complex configuration such as
intricate grooves, radii or steps.
Disadvantages:
1. The accuracy of measurement is limited to 0.001 mm
2. They have their own built in illuminating device which tends to heat the instrument.
3. Electrical supply is required.
4. Eyepiece type instrument may cause strain on the operator.
5. Projection type instruments occupy large space and they are expensive.
6. When the scale is projected on a screen, then it is essential to take the instrument to a dark
room in order to take the readings easily.
MECHANICAL
COMPARATORS
JOHANSSON MIKRAKATOR
This comparator was made by C.F.
Johansson
and therefore named so.
It uses the simplest and most
ingenious method for obtaining the
mechanical magnification designed
by H. Abramson which is called
Abramson Movement.
It works on the principle of a button
spinning on a loop of string.
CONSTRUCTION
A twisted thin metal strip carries at the
centre of its length a very light pointer made
of thin glass.
One end of the strip is fixed to the adjustable
cantilever strip and the other end is
anchored to the spring elbow, one arm of
which is carried on the measuring plunger.
The spring elbow acts as a bell crank lever
and causes twisted strip to change its length
thus making it further twist or untwist.
The length of cantilever can be varied to
adjust magnification.
REED
COMPARATO
R
REED COMPARATOR
The reed mechanism is frictionless device
for magnifying small motions of spindle.
It consists of a fixed block A which is rigidly
fastened to the gauge head case, and
floating
block
B, which carries the gauging spindle and is
connected horizontally to the fixed block by
reeds
C.
A vertical reed is attached to each block
with upper ends joined together. Beyond
this joint extends a pointer or target.
SIGMA COMPARATOR
Optical
Comparat
or
In
mechanical
optical
comparators,
magnification is done in two stages.
First by mechanical pivot and then by single
optical system involving projection of an
image.
The light rays from source are condensed by
condensing lens and are converted into
parallel beams by objective lens which fall on
mirror.
The pivot tilts the mirror about its hinge and
mirror reflects light rays on the screen (semi
transparent glass).
The projected image is compared with
magnified master drawing.
(needles, cam
profiles, saw teeth)
ELECTRICAL COMPARATOR
Consists of three major parts
Transducer, Display Device, Amplifier.
An iron armature, provided between two
coils is supported by plunger at one end
and fixed at other end.
The two coils act as two arms of A.C
wheat Stone Bridge circuit.
Amplifier amplifies given input signal and
display device used as meter.
LVDT
ELECTRONIC COMPARATOR.
VERNIER BEVEL
PROTRACTOR
the simplest angle measuring
It is
instrument.
Consists of main body, base plate stock,
adjustable
blade,
circular
plate
containing vernier scale, acute angle
attachment.
Length of blade can be about 150-300m
long,13mm wide and ends are bevelled
at angles of 45o and 60o.
Generally
tested
for
Flatness,
Squareness, Parallelism, Straightness.....
SOME
APPLICATIONS
Precision angles
to within 5'
(0.083)
Consist of base
Vernier scale
Protractor dial
Sliding blade
Dial clamp nut
ACUTE ANGLE
OBTUSE ANGLE
OPTICAL BEVEL
PROTRACTOR
SINE BAR
ACCURACY REQUIREMENTS OF
A SINE BAR
The rollers must have equal diameter
and length, should be parallel to each
other and also parallel to upper surface.
The accurate centre of rollers must be
known.
The top surface of bar must have high
degree of flatness and should be
parallel to a plane connecting axes of
rollers.
CLASSIFICATION
SOURCES OF ERRORS IN
SINE BAR
ANGLE GAUGE
Developed by Dr.Tomlinson in 1941 to measure
angles with accuracy to 3.
Made up of hardened and stabilized steel.
Measuring surfaces are lapped and polished to
a high degree of accuracy and flatness.
Approximately 75mm long and 16mm wide and
available in set of 13 to 16 pieces along with
square block.
AUTO COLLIMATOR
It is an optical instrument used for
measurement
of
small
angular
differences, changes or deflection,
plane surface inspection etc.
It is a combination of a collimator and
a telescope.
- collimator: takes diverging light and
focuses it into a non-diverging column.
- telescope: takes light from a source
at infinity and focuses it onto a point.
PRINCIPLE OF AUTOCOLLIMATOR:
The autocollimator projects a beam
of collimated light.
An external reflector (object)
reflects the beam which is focussed
and detected by a photo-detector.
The autocollimator measures the
deviation between the emitted
beam and the reflected beam.
Since the autocollimator uses light
to measure angles, it never comes
into contact with the test surface.
CONSTRUCTION
It consists of three parts: micrometer
microscope,
lighting
unit
and
collimating lens.
A 45o
transparent beam splitter
reflects the light from graticule
towards the collimating lens.
The angular variations of the
reflected image are picked up and
measured by microscope.
APPLICATIONS
Measurement of Straightness and
Flatness of surfaces.
Assessment of Squareness and
Parallelism of components.
Comparative angle measurement
using master angles.
Measurement
of
small
linear
dimensions, machine too adjustment
setting etc
Projector
Toolmakers Microscope
A toolmakers microscope is a
measuring device that can be
used to measure up to 1/100th
of an mm.
It works on the principle of a
screw gauge, but a few changes
were added to it to make its
operation more easier.
of
the
object,
which
the
measurement
accuracy
of
123
Construction
Construction
construction
Two scales are meant for measuring in X and Y
directions and the movement of table the respective
direction.
The other scale is meant for measuring rotation as well
as rotation of table.
Working
Object to be measured is
placed on glass table,
illuminator is turned on.
Let the object be a
rectangle.
It may look as shown if
seen through lens
Result
Difference in micrometer reading of X
movement gives us the length of the rectangle
Similarly, the difference in micrometer reading
of Y movement gives us the breadth of the
rectangle
Applications
The large tool makers microscope is suitable for the following
fields of applications;
Length measurement in Cartesian and polar co-ordinates.
Angle measurements of tools; threading tools punches and
gauges, templates etc.
Thread measurements i.e., profile major and minor diameters,
height of lead, thread angle, profile position with respect to the
thread axis and the shape of thread. (rounding, flattering,
straightness of flanks)
Comparison between centers and drawn patterns and drawing
of projected profiles.
STYLUS PROBE
INSTRUMENT
TAYLOR-HOBSON TALYSURF