National Exams May 2012 08-Mfg-B6, Metrology 3 hours duration NOTE; 1. If doubt exists as to the interpretation of any of any question, the candidate is urged to submit with the answer paper a clear statement of any assumption made. 2. This is an OPEN BOOK EXAM 3. A Casio or Sharp approved calculator is permitted. Note that you must indicate the type of calculator being used. Write the name and model of the calculator on the first inside left hand sheet of the exam work book. 4. The exam has THREE parts: Part A is mandatory and has 50 multiple-choice questions of one mark each. Most of the questions have only one correct answer. Please clearly circle the choice that is your answer. Part B is mandatory and has a drawing of a simple part that is measured using a Coordinate Measuring Machine. Write in your own words the sequence of commands required to measure the dimensions shown on the drawing. These commands are generic and should not be related to particular CMM software. A correct and complete answer has 30 marks. Part C has four essay-type questions, but any two questions, of your choice, will be marked. All four questions in Part C have equal value of 10 marks. Clarity and organization of the answer are important. Front Page08-Mfg -86 Metrology May 2012 Bart There are 60 multiple-choice questions of one mark each. Most of the questions have only one correct answer. Please circle clearly using a pen your choice of a correct answer. Any comments or interpretation should be made in a clear statement on the exam hand sheet withthe corresponding question number. 1. Which of the following feature control frames is incorrect? wv (iJos] w (O05) v Sioaw@Ee| w oA 2. Which of the following symbol indicates total runo v [A] » (Oo) + [CO] « fx 3. Which statement is correct about syrametry and concentricity: a both can be used at MMC ‘b/ symmetry is an orientation tolerance, and concentriity is a position tolerance ef symmetry does not need a datum & they are applied to different types of feature 4. Which of the following definition of accuracy is correct? al accuracy isthe measure of precision by accuracy is the measured o conformity ef accuracy isthe measure of reliability / accuracy is the best synonym for precision 5. __Theability of two inspectors to obtain consistent results when measuring repeatedly the same part using the ‘same instrument, is called: a/ accuracy by reproducibility ef precision systematic error 6 Why do we réund off measurements results with too many decimal places? a to eliminate numbers over or below digit 5 b/ toaverage computational error ¢/ tocliminate meaningless digits to simplify further computation 7. When applied to a surface, perpendicularty also controls: a size bi location ¢ position @ flatness 8. Which of the following are the sources of measurement uncertainty when using a steel rule? a inherent instrument error, temperature error, and manipulative error ‘b/ attachment error, manipulative error, and temperature error cf attachment error, bias, and inherent instrument error inherent instrument error, manipulative error, and observational error 9. What is the primary advantage of the vernier instruments over other hand held measuring instruments? f discrimination W smaller parallax error Page 1 of 808-Mfg -86 Metrology May 2012 10. Whatis the best description of parallax error? al another name for observational error ‘apparent shift of an object witen the position of the observer is changed cf the error caused by the distance between the scale and the measured feature d/ the average of measurements when the object if viewed from the left and from the right. UL. Whatis the main limitation of vernier instruments? al hard to read By high cost ¢/ lack of multiple scales W discrimination may exceed inherent accuracy 12. Which of the following is the main disadvantage of height gages? a/ inherent inaccuracy of the column scale by low amplification of vernier instruments cf wear of the base @ lack of stability 13. __ Whatis the relationship between surface plates and height gages? af no interaction bY the surface plate supports the height gage ¢f surface plate errors are compensated by the height gage errors & any flatness error on the surface plate is multiplied by the height gage 14, __ Whatis the best explanation for considering a micrometer more accurate than a verier caliper? a/ the micrometer is smaller and easier to handle by the standard of a micrometer complies with the Abbe's law, and th ealiper does not, the micrometer as a ratchet to prevent extra pressure. & cylindrical scale is easier to read than flat scale 15. Which ofthe following statements is valid fora height gage? a/ when testing a verier instrument , zero setting repeatability is the most important test b/ accuricy may be checked at any point inthe range by repeatability of successive measurements at that point cf repeated readings of calibrated gage block heights at random points in the range confirm accuracy ‘@/ accuracy may be checked by comparison jaw movement against dial comparator readings 16. __ Whatis the reason to have a clamp ring on the micrometer? af to lock the micrometer when in storage by to prevent temperature changes during measurements cf to minimize parallax error W lock the micrometer so that reading may be remembered 17. Is itmore difficult to calibrate an inside micrometer than an outside micrometer? af Yes, inside micrometers must be calibrated to 0.0005 in (0.0013 mm) whereas outside micrometer are calibrated ‘to 0.0001 in (0.0025 mm) b/ Yes, inside micrometers are more difficult to hold. cf No, both obey Abbe’s law Yes, the outside micrometer is compared directly with the standard, whereas the inside micrometer must use & comparator 18. What is the definition of instrument “resolution”? 2 ability to separate precision from accuracy b/the smallest graduation on the scale or dial c/ visual separation between graduations the difference between the reading and the actual dimension Page 2 of 808-Mfg -86 Metrology May 2012 19. Are gear trains better than levers to achieve amplification in dial comparators? a/ Yes, because they are housed in round cases Dy Yes, because they achieve larger range cf No, because gears are more subjected to mechanical error W No, because lever actions are easier to keep clean 20. What determines the numbers of graduations on the indicator dial? af size of the dial by dial magnifying glass ¢/ precision of the instrument @ maximum length to be measured 21, Are precision and accuracy of dial indicators related ? a/ there is no relationship by accuracy is essential for precision / precision is essential for fulfillment of accuracy / they are essentially the same 22. What error is eliminated or mini a/ parallax error Dy inherent error &/ alignment error / computational error ized by the zero setting adjustment on a dial indicator? 23. What isthe rule ten-to-one as applied to measurement? a/ the instrument value should be 10 times greater than the gauging instrument value Dy the scale range must be at 10 times the required length of the maximum measurement cf itis a customer requirement W the gage error should be 10 times smaller than the tolerance zone of measured feature. 24, Why the rectangular gage blocks are preferred over the square ones? af they cost less DY easier to wring cf easier to clean @ better for use under the sine bar 25. Which of the following best explains the accuracy of gage blocks? a/ surfaces that are plane and parallel ‘by surfuce finish of 0.4 micro inch (1 micron) CLA or better of heat-treated stainless steel that has been stress relieved and resists corrosion & low measuring error traceable to a national standard 26. __ What can contribute in wringing error with properly prepared gage blocks? a variations in thickness of air or ol film between blocks by burrs or solid particles between blocks &/ gage blocks corrosion from the fingerprints of the users blocks of different temperatures 27. The method used to stack different gage block for @ required dimension is known as: al wringing by magnetic resonance of interferometry ultrasonic 28. What is the unique feature for pneumatic metrology? Page 3 of 808-Mfg -B6 Metrology May 2012 a/ no electric supply is required b/ the air blow the dust that could cause errors cf there is a long range of the scales even at high amplifications i there is no metal-to-metal contact 29, Why isthe pneumatic comparator considered to bean analog istrument? a because its capable of very high precision ‘by because the amplification and scale can be changed ef because the change inflow is proportional tothe change in feature size / because a graduated scale is used instead ofa digital scale 30. Pneumatic measurement has the advantage to measure directly diameter, straightness and perpendicularity. ‘What allows this capability? af case insertion of the gauging element b/ differential measurement ‘of wide gap for airflow around the gauging element @/ multiple measurement after averaging 31. Which of the following is usually the largest potential error in calibration? a temperature differences / low frequency vibrations of hysteresis @/ human error 32, What would be the best standard characteristic when calibrating an instrument used for production inspection? a ten time the accuracy by new or never used since last calibration o/ permanently assigned to this particular instrument & using a standard similar in size, shape and material with the part being measured. 33. What is interferometry? a the use of an interferometer to measure length by the highest precision method generally available for length measurement the interpolation of fringe pattems formed when two rays of light interfere with each other W the systematic calibration of tength using a laser instrument 34, Which isthe following best describes the laser light? 2 intense light focused on a small spot without refraction b/ light rays that travel in the same direction cf light that cannot be reflected. coberent with only one wavelength and all waves in phase 35. Why granite is the most poputar material for surface plates? ay resistance to wear Dy flatness cf damage on the granite surface does not alter flatness @ stiffness 36. Which of the following features of a surface plate provides for the plate being a reliable horizontal reference surface? al smoothness by flatness &/ parallelism & length and width Page 4 of 808-Mfg —B6 Metrology May 2012 37. The effect of errors of feel is similar to which of the following? a/ zero settings errors by loose member errors / parallax errors Wf interpolation errors 38. The purpose of calibration schedule isto: af meet customer requirement b/ detect deterioration of accuracy of test quality personnel practice measurement procedure 39. Why light is the best master standard of length? a/ it changes very little with ambieat conditions br it is easy to reproduce ¢ itis convenient to use @/ human sight is the best to discern markings 40, Hows the centerline determined for an irregular profile of surface finish? a/ by averaging between the highest peak and the lowest valley by by separating equal areas above and below the profile within the cutoff limits co by separating equal numbers of peaks and valleys within the cutoff limits W atrandom within the profile range 41. What is the use of roughness comparison specimens? a/ calibration of stylus instruments 1 setup of surface assessment evaluation instruments ce use with non-contact instruments W for comparison by appearance or feel 42. Which ofthe following is the most distinguishing feature of CMM? af ability to measure large parts b/ ability to measure nearly al feature s for most parts in a single setup f ability to both display and print digitally the results W ability to obtain 2 or 3 coordinates of measured points and calculate part features 43, What optical phenomenon makes possible the microscope? ay aberration correction by achromatic lenses Dy the fact that the real image is inverted, whereas the virtual iraage is erect / virtual images can be projected to infinity 4! an optical image may be treated as areal object. 44, Whatis @ universal bevel protractor? a/ any instrument that measure all bevels by aprotractor with a vernier scale and adjustable blades cf a combined protractor and linear measurement instrument an instrument that can use either gage blocks or vernier scale to measure angles 45. Which of the following is the best description of a sine bar? a/ itis steel bar that holds cylinders at an accurate spacing bY it is the hypotenuse in physical form that can set up with various lengths to form angles / itis the combination of a sine instrument, gage blocks and reference surface it isa bar that always holds cylinders at S inch centres Page 5 of 808-Mfg -B6 Metrology May 2012 46. Which of the following is the most common method to check perpendicularity with a square? a/ examination for light gap by direct reading digital comparator ¢/ gage blocks with a sine ber or table feat 47, The most recommended type of CMM recommended for very large parts with large tolerances is the following: gantry type bridge type moving horizontal arm type column type aose ‘What elements need projection on a coordinate system plane? ‘cone, line and circle plane, fine and point point, circle and cylinder Tine and circle rs 9. __ What type of stylus tip is recommended for measuring alurninum parts? stainless steel silicon nitride zirconia industrial iby eeee 50. What type of stylus is recommended for measuring very rough (iregular) surface? long stylus with a large spherical ruby tip short stylus with a dise stainless steel with a silicon nitride ball ceramic hollow ball stylus pose Page 6 of 808-Mfg -B6 Metrology May 2012 Part B This is the drawing of a part that will be measured on a CMM. Dimensions such as countersink and counter bore for holes, as well as the thread of four holes can be measured by conventional instruments faster , but their location must be measured on CMM. Identify the features to be measured on CMM with labels, such as L1, L2... for lines, C1, C2... for circles and P1, P2... for planes, etc. Write in your own words: how to clamp the part on the CMM table, what kind of stylus (styli) to be used, etc, and the sequence of commands that required measuring only the dimensions for a CMM. 30 marks @ 27 THRU @ .40 x 82° csk 2 HOLES 250-20 UNC 4 HOLES EQL SP ON B 2.12 @ 28 THAU © 50 caoRE 25 DEEP 2 HOLES Page 7 of 808-Mfg —86 Metrology May 2012 Part C There are four essay type questions of 10 marks each. Only the first two questions on the answer sheet will be marked. The answer for each question should not exceed approx. one page, including sketches. 10 marks 10 marks 10 marks 10 marks . Explain the necessity of veetor approach/return of a CMM electronic-touch probe ‘when touching the part feature, How does it relate to the probe compensation and what error can bring to the measured point. . Explain the concept of traceability for measuring instruments. Why is needed and how the traceability chain is maintain. |. Explain the advantages and the sequence of tasks for an R & R gage study. How are the results interpreted? . Explain what can happen if you use a Cylinder command on CMM but you measure a conical feature. What happens when you measure a cylindrical feature using the Cone command? Page 8 of 8