Chapter 8 - Engineering Metrology and Instrumentation

Introduction to Manufacturing Engineering – Ass.Prof. N.T.
Duong – HUST
CHAPTER 8. ENGINEERING METROLOGY

AND INSTRUMENTATION
 This chapter presents the principle methods of measurement and the characteristics
of the instruments used in manufacturing.
 Engineering metrology is defined as the measurement of dimensions such as length,
thickness, diameter, taper, angle, flatness, profile, and others (Fig. 8.1).
 A important aspect of metrology is the dimensional tolerance. Generally, the smaller
the tolerance, the higher are the production cost.
Figure 8.1 Cross-section of a machine tool slideway. The width, depth, angles, and other
dimensions must be produced and measured accurately for the machine tool to function as expected.
Chapter 8 - 1
Introduction to Manufacturing Engineering – Ass.Prof. N.T. Duong – HUST
8.1. Traditional measuring methods

and instruments
Caliper and Vernier

Figure 8.2 (a) A caliper gage with
a vernier. (b) A vernier, reading
27.00 + 0.42 = 27.42 mm, or 1.000
+ 0.050 + 0.029 = 1.079 in. We
arrive at the last measurement as
follows: First note that the two
lowest scales pertain to the inch
units.
We next note that the 0 (zero) mark on the lower scale has passed the 1-in. mark on the upper scale.
Thus, we first record a distance of 1.000 in. Next we note that the 0 mark has also passed the first
(shorter) mark on the upper scale. Noting that the 1-in. distance on the upper scale is divided into
20 segments, we hve passed a distance of 0.050 in. Finally note that the marks on the two scales
coincide at the number 29. Each of the 50 graduations on the lower scale indicates 0.001 in., so we
also have 0.029 in. Thus the total dimension is 1.000 in. + 0.050 in. + 0.029 in. = 1.079 in.
Chapter 8 - 2
Analog and Digital Micrometers
(a) (b)
Figure 8.3 (a) A micrometer being used to measure the diameter of round rods. Source: L. S.
Starrett Co. Upper one reads 0.200 + 0.075 + 0.010 = 0.285 in.; lower one reads 0.200 + 0.050 +
0.020 + 0.0003 = 0.2703 in. These dimensions are read in a manner similar to that described in the
caption for Fig. 34.2. (b) A digital micrometer with a range of 0-1 in. (0-25 mm) and a resolution
of 0.00005 in. (0.001 mm). Note how much easier it is to read dimensions on this instrument than
on the analog micrometer shown in (a). However, such instruments should be handled carefully.
Source: Mitutoyo Corp.
Chapter 8 - 3
Angle-Measuring Instruments
Figure 8.4 (a) Schematic illustration of

a bevel protractor for measuring
angles. (b) Vernier for angular
measurement, indicating 14° 30´.
Figure 8.5 Setup showing the use of a

sine bar for precision measurement of
workpiece angles.
Chapter 8 - 4
Dial Indicators
Figure 8.6 Setup showing the use of a sine bar for precision measuremnet of workpiece angles.
Chapter 8 - 5
8.2. Modern measuring instruments

and machines
Electronic Gages
Figure 8.7 An electronic gage for measuring bore

diameters. The measuring head is equipped with three
carbide-tipped steel pins for wear resistance. The LED Figure 8.8 An electronic vertical length
display reds 29.158 mm. Courtesy of TESA SA. measuring instrument, with a sensitivity of
1 m (40 in.). Courtesy of TESA SA.
Chapter 8 - 6
Laser Scan Micrometer and Straightness Measurement
Figure 8.9 Two types

of measurement made
with a laser scan
micrometer. Source:
Mitutoyo Corp.
Figure 8.10 Measuring

straightness with (a) a
knife-edge rule and (b) a
dial indicator attached to
a movable stand resting
on a surface plate.
Source: F. T. Farago.
Chapter 8 - 7
Measuring Roundness
Figure 8.11 (a) Schematic illustration of “out of roundness” (exaggerated). Measuring

roundness using (b) V-block and dial indicator, (c) part supported on centers and rotated, and
(d) circular tracing, with part being rotated on a vertical axis. Source: After F. T. Farago.
Chapter 8 - 8
Measuring Profiles
Figure 8.12 Measuring profiles with

(a) radius gages and (b) dial indicators.
Figure 8.13 Measuring profiles

with (a) radius gages and (b) dial
indicators.
Chapter 8 - 9
Horizontal-Beam Contour
Projector
Figure 8.14 A bench model horizontal-beam contour

projector with a 16 in.-diameter screen with 150-W
tungsten halogen illumination. Courtesy of L. S.
Starrett Company, Precision Optical Division.
Chapter 8 - 10
Coordinate Measuring Machine
Figure 8.15 (a) Schematic illustration of one type of coordinate measuring machine. (b)
Components of another type of coordinate measuring machine. These machines are available in
various sizes and levels of automation and with a variety of probes (attached to the probe adapter),
and are capable of measuring several features of a part. Source: Mitutoyo Corp.
Chapter 8 - 11
Coordinate Measuring Machine
Figure 8.16 A coordinate measuring machine.

Brown & Sharpe Manufacturing.
Chapter 8 - 12
Gages
Figure 8.17 (a) Plug gage for holes, with GO-NOT GO on opposite
ends. (b) Plug gage with GO-NOT GO on one end. (c) Plain ring
gages for gagin round rods. Note the difference in knurled surfaces
to identify the two gages. (d) Snap gage with adjustable anvils.
Figure 8.18 Schematic illustration of

one type of pneumatic gage.
Chapter 8 - 13
8.3. Geometric dimensioning and

tolerancing
 Dimension tolerance
 This is defined as the permissible or acceptable variation in the dimensions (height,
width, depth, diameter, and angles) of a part.
 Tolerances are unavoidable, because it is virtually impossible (and unnecessary) to
manufacture two parts that have precisely the same dimensions.
 Close dimensional tolerances can increase the product cost significantly, a narrow
tolerance range is undesirable economically.
 Importance of tolerance control

 Dimensional tolerances become important only when a part is to be assembled or
mated with another part.
 Certain terminology has been established to clearly define these geometric quantities
(ISO system in fig 8.19).
 A proper engineering drawing would specify these parameters with numerical values
(Fig. 8.20).
Chapter 8 - 14
 Importance of tolerance
control
Figure 8.19 Basic size, deviation, and

tolerance on a shaft, according to the
ISO system.
Figure 8.20 Various methods of assigning tolerances on a shaft.

Source: L. E. Doyle.
Chapter 8 - 15
Engineering Symbols
Figure 8.23 Geometric characteristic symbols to be indicated on engineering drawings of parts

to be manufactured. Source: The American Society of Mechanical Engineers.
Chapter 8 - 16

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What are some traditional measuring methods and instruments discussed?

What are some traditional measuring methods and instruments discussed?

What are some modern measuring instruments and machines mentioned?

What are some modern measuring instruments and machines mentioned?

Introduction to Manufacturing Engineering – Ass.Prof. N.T.

CHAPTER 8. ENGINEERING METROLOGY

8.1. Traditional measuring methods

Caliper and Vernier

Analog and Digital Micrometers

Figure 8.4 (a) Schematic illustration of

Figure 8.5 Setup showing the use of a

8.2. Modern measuring instruments

Figure 8.7 An electronic gage for measuring bore

Laser Scan Micrometer and Straightness Measurement

Figure 8.9 Two types

Figure 8.10 Measuring

Figure 8.11 (a) Schematic illustration of “out of roundness” (exaggerated). Measuring

Figure 8.12 Measuring profiles with

Figure 8.13 Measuring profiles

Figure 8.14 A bench model horizontal-beam contour

Coordinate Measuring Machine

Coordinate Measuring Machine

Figure 8.16 A coordinate measuring machine.

Figure 8.18 Schematic illustration of

8.3. Geometric dimensioning and

 Importance of tolerance control

Figure 8.19 Basic size, deviation, and

Figure 8.20 Various methods of assigning tolerances on a shaft.

Figure 8.23 Geometric characteristic symbols to be indicated on engineering drawings of parts

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