CASE STUDY - An Analysis of the Relationship

between Surface Roughness and distribution of

diameter measurements of the large cylindrical
feature of an Automobile Connecting Rod.
Abstract
The automobile industry currently operates in

a highly competitive

environment where innovation and performance are critical to enhanced

market share and competitiveness. Thus system design and optimal
performance of the automobile parts are crucial elements that enable a
particular automobile brand to achieve sustainable competitive advantage.
This research examines performance parameters for the connecting rods of
automobiles. Here the surface roughness in relation to the diameter of the
large cylindrical feature of the connecting rod is examined. It is desirable
that for optimum performance and low fuel consumption, the surface
roughness is as low as possible. This research also examines how Faro Arm
and Vernier callipers may be used to measure the diameter of the connecting
rod and the methods for evaluating surface roughness as well.
Keywords: Surface roughness; Surface texture; Surface roughness
tolerance.

Introduction
The Connecting Rod is a very important part of internal combustion engines
that propel automobiles. The connecting rod is fixed to the crankshaft of the
automobile by a crank pin and the other end of the rod gets connected to the
piston through a piston pin. As the piston within the internal combustion
engine moves up and down, it is the connecting rod that transmits the power
thrusts so generated to the crank pin which in turn is transferred to the
piston shaft in the form of rotary motion (Walishaw, 2011). It is this motion

that turns the wheels of the vehicle generating movement. It may be inferred
here that the efficiency of the engine is dependent on how effectively or
completely the connecting rod converts reciprocating motion into rotary
motion.
According to (Tlusty, Smith, & Winfough, 2013), it is very important that the
connecting rod be dimensionally correct in terms of weight and size so that
no energy is lost due to vibrations in the connecting rod. This specification
assumes great significance given that the connecting rod is invariably the
most stressed out part of internal combustion engines (Smith, Winfough, &
Halley, 2012). These stresses are generated by the pressures exerted on the
piston on the crankshaft and can lead to failure of the connecting rod. In
addition, the reciprocating load generates its own set of pressures leading to
alternate stretching and compression which can lead to connecting rod
failure called throwing the rod (Davies, Dutterer, & Pratt, 2014). (Pai, 2013)
says that this failure is often catastrophic and irreparable. In recognition of
this reality much research has been conducted on how to design and
manufacture connecting rods that are light yet strong.
However an area that has been overlooked is the relationship between
surface roughness of the connecting rod and its dimensions. Surface
roughness is a most important parameter that impacts the productivity of
machine parts such as connecting rods. This is because low levels of surface
roughness ensures optimal tribological properties, increases resistance to
fatigue and possible failure, creates corrosion resistance surfaces and
increases the aesthetic appeal of the end product (Jeppsson, 2013). Surface
roughness impacts precision of fits, the strength of fastenings and friction
between connecting rods and the crankshaft pins (Smith, S; Tlusty, J, 2013).
Various parameters impact surface roughness including the speed of cutting
and machining, the feed rates of cutting spindles, the density of the metal in
the work piece and the rigidity of the machine tools (Serag, Sevien, Sheha, &
El-Beshtawi, 2014). However it may be noted here that these are processes

that impact surface roughness at the end stage which is machining. What is
also important is the beginning or the design stage to understand those
optimal dimensional measurements that impact surface roughness. One of
these dimensional measurements is the diameter of the small end of the
connecting rod that interfaces with the piston and the other is the diameter
of the big end that connects with the crankshaft. However, the study of
relationship between the dimensional distribution and surface roughness is
carried out on the large cylindrical feature of the connecting rod.
This study is important because of the competitive business environment in
which the automobile industry operates today where the demand is for light
weight, fuel efficient and long lasting vehicles. This puts great pressure on
research and development to develop critical components such as
connecting

rods

that

function

efficiently.

On

the

basis

of

the

aforementioned introduction the following research questions and aims &

objectives may be formulated.

Research Question
What is the relationship between distribution of large cylindrical diameter
measurements and the corresponding surface roughness of an automobile
connecting rod?

Aims & Objectives

To conduct an experiment using both Vernier scales and Faro Gage to

measure diameter of the large cylinder feature of automotive
connecting rods and their corresponding surface roughness.

To analyse the correlation of the surface roughness versus the

diameter measurements using statistical methods for each sample.

To understand whether the surface roughness characteristics have

direct impact on the distribution of measurement result for the cylinder
diameter measurement.

To draw conclusions explaining issues related to feature dimensions

and surface characteristics at design, manufacturing and service
stages.

Working Methodology
The method employed to analyse impact of dimensional measurement
distribution on surface roughness of connecting rods is shown below. This
included the Define, Measurement, Analysis, Understanding the correlations
and results and conclusions.

Figure 1.Flow Chart of Methodology followed to Evaluate Surface Roughness

Parameters and Dimensional Measurements.

Define
This stage defines the nature of the experiment performed. The experiment
is conducted on five different connecting rods of varying geometry and
surface roughness. These include low carbon steel, aluminum silicate alloy
(AlS) and MV 9 alloy. These represent the standard materials used in the

automobile industry for connecting rod manufacture. The below figure shows
the connecting rods used to conduct the experiment arranged in the order
(a) Low carbon steel connecting rod (b) MV9 alloy connecting rod (c)
Aluminium silicate connecting rod (d) Low carbon steel connecting rod and
(e) MV9 alloy connecting rod.

i.

Surface Roughness Parameter Measurement

Many surface roughness parameters can be used to define and analyze the
surface of a mechanically manufactured object which includes Average
surface roughness (Ra), Maximum height of the profile (Rt), Root mean square
(Rq) etc. Out of this, the most common roughness parameter employed to
define a surface in many of the manufacturing industries is the average
surface roughness or Ra.
The average surface roughness is given by,

Where,

n is the number of evaluated points.

Yi is the absolute deviation of the profile line from the mean line.
The Ra value is measured using Taylor Hobson Surtonic-25 instrument.
ii.

Dimensional Measurement

The dimensional measurement used in the experiment is the diameter of the

large cylindrical feature of the automobile connecting rod. The dimension
measurement is initially observed using a Mitutuyo Vernier Caliper and then
measured using a FARO articulated arm CMM. The later readings were
observed with the aid of CAM2 Measure 10.2 software platform in a computer
system.

Measurement
This stage explains the experimental procedure employed to measure the
required surface roughness parameter and the dimensional measurement of
the connecting rod.
i.

Surface Roughness Measurement

Prior taking the diameter dimensional measurements of the large cylindrical

feature of the connecting rods marked (a), (b) and (c), the Taylor Hobson
Surtonic-25 equipment is calibrated against a specimen of known surface
roughness value of 6m. On calibration an error of 0.02m is found. Also,
prior taking the diameter measurements of the large cylindrical feature of
the connecting rods marked (c) and (d), the Taylor Hobson equipment is
calibrated against the same specimen but an error of 0.26 m is shown.
For the experiment all the connecting rods are individually held firmly on a
working bench using a mechanical G-clamp so that error due to vibration or
misalignment of the connecting rod while measuring can be avoided. The
surface roughness values were taken at random points from the periphery of
the large cylindrical feature of the connecting rods marked (a), (b) and (c)
whereas in case of connecting rods marked (c) and (d), the roughness values
of fixed marked points were recorded. The observed surface roughness
readings are as follows:
Marked

Observed Surface

Calibration

Actual Surface

Connecting

Roughness value

Error (m)

Roughness (m)

Rods
a

(m)
0.38

0.26

0.38

0.66

0.26

0.66

0.26

1.26

0.16

0.02

0.18

0.28

0.02

0.30

The surface roughness value of connecting rod marked (c) could not be
measured using Taylor Hobson Surtonic-25 as its roughness value is beyond
the measuring range of the instrument. Due to the non-availability of other
surface measuring instrument in the metrology laboratory a roughness value
above 1m based on visual experience is assumed for the connecting rod (c).
ii.

Dimensional Measurement

The dimensional measurement of the large cylindrical feature of the

connecting rods marked (a), (b), (c), (d) and (e) were initially measured using
a Mitutuyo Vernier caliper. Before making the diameter readings all the
connecting rods were individually clamped to a work bench using a
mechanical G-clamp to avoid misalignment of the rod while measuring. The
diameter readings of the connecting rods marked (a), (b) and (c) are
observed from random points on the periphery of the large cylindrical part
where as in case of connecting rods marked (d) and (e), the diameter
readings were taken corresponding to marked points on the periphery of the
cylindrical portion.
This was deliberately done to analyze how different measuring procedures
can alter the accuracy of the measurement readings.
Similarly for all the connecting rod specimens diameter measurements were
taken using FARO arm CMM machine. As explained in the previous chapter,
the FARO arm CMM gives much more accurate measurements than Vernier
caliper and this can be interpreted by following the below procedure of
diameter measuring.
(a) Before making the readings the FARO gauge arm CMM must be
calibrated and verified to avoid uncertainty in readings and to obtain
precise and accurate readings. The FARO gauge CMM is calibrated by

placing the hard ball probe at the measuring arm of the device in to a
kinematic socket. The calibration process is achieved by making
several readings for different orientations of gauge arms and wrists
without altering the position of the probe from the socket. The device
can be defined as accurate if all the calibration readings are the same.
One can easily assess the size of the sphere that embodies all the
points and utilize that at an indicator of the impact of the intensifying
errors of the angular encoders. The FARO arm CMM was calibrated,
verified and certified by the manufactures according to National
Physical Standards before the instrument was purchased (Laboratory,
2014).
(b)Measuring Procedure 1: The diameter readings of the connecting
rods (a), (b) and (c) were observed at random points on the top and
bottom of periphery of the large cylindrical portion of each connecting
rods and random orientation of the articulated arms of the FARO arm
CMM with respect to each arm joints. The coordinates of the origin was
kept constant by placing the FARO CMM at fixed station.
(c) Measuring procedure 2: The diameter readings of the connecting
rods (d) and (e) were observed from marked points of the planes on
the periphery of the large cylindrical part. The appropriate number of
uniformly spaced planes orthogonal to the cylinder axis were obtained
by the following equation (Flack, 2014).
Where,
nc is the appropriate number of planes orthogonal to the
cylinder axis.
N is the number of observations.
h is the height of the cylindrical feature.
r is the radius of the cylindrical feature.
The appropriate number of points to be marked on the planes is
obtained by,
(Flack, 2014).
Where,

nc is the appropriate number of planes orthogonal to the

cylinder axis.
N is the number of observations.

Figure 2. Distribution of measuring planes and points on the cylindrical feature of the
connecting rod (Flack, 2014).

Table 1 - the required number of planes and points for the successful measurement

Marked

Diameter of

Radius of the

Appropriate

Appropriate

connecting

the

cylindrical

number of

number of

rods

cylindrical

feature, r

planes, nc

points on

feature, D

(mm)

(mm)
39
36
41
48
18

19.5
18
20.5
24
18

A
B
C
D
E

the planes,
2.7
2.8
2.6
2.4
2.8

np
11
10.7
11.3
12.2
10.7

Also, the readings were observed from the FARO gauge instrument by
keeping the following angle of orientations for the instrument:

Angle of orientation at Wrist (1) at below 15 with respect to the fixed

station.
Angle of orientation of the gauge arm 1 and gauge arm 2 at 30.

Varying angle of orientation of the gauge arm 2 and gauge arm 3 since

the orientation will change according to the marked points.

The lengths of the gauge arms are fixed and the detailed specifications
of the instrument are described in the brochure of FARO arm CMM

given by the manufacturer. (See Appendix).

The working temperature is the room temperature (20C). For the
maximum

accuracy

and

portability,

the

temperature

sensors

incorporated in the instrument allows the measuring arm to react to

the thermal variations as described in the methodology of the project.

Figure 3. Description of position and angle of orientation of FARO gauge arm.

The all the diameter readings and other measurement related details were
assessed using CAM2 Measure 10.2 software platform (See appendix).

Analysis
Descriptive statistics tool is employed to conduct the analysis of diameter
and surface roughness datas of the large cylindrical feature of the selected
connecting rods under investigation. The statistical analysis is performed in
Microsoft

Excel

to

achieve

accurate

analysis

results.

The

statistical

parameters considered in descriptive statistics included Mean, Standard

deviation, Maximum, Minimum and Range. The range between the maximum
and minimum numbers represents the Gaussian or normal distribution within
which the average values of diameters of the large cylindrical feature
corresponding to varying surface roughness and is diagrammatically
represented in the form of a histogram. In the histogram, the x axis
represents the diameters of large cylinder feature of the connecting rods
under examination while the y axis represents the corresponding frequency
values.
The descriptive statistical analysis is initially done for the diameter
measurements obtained from the two defined measuring strategies of the
FARO arm CMM. The statistical analysis of diameter measurements from
Vernier calliper is also done to verify the results of the analysis.

Statistical Analysis of FARO arm measurements.

For each of the analysis, the band width of the bin of the histogram is
theoretically calculated for the optimum bin size and is given by the formula
(Jenkinson, 2014),

h=

3.5
n1 /3
Where,
h is the band width of the bin.
is the standard deviation.
n is the number of readings.

(a)

Low Carbon Steel Connecting Rod

The table shows the descriptive statistical values for 30 sets of diameter
readings of the large cylindrical feature of the connecting rod made of low
carbon steel and the surface roughness value, Ra=0.38m.

Mean
Standard Error
Median
Mode
Standard

39.0084
0.005129271
38.999
38.989

Deviation
Sample

0.028094177

Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum
Count

0.000789283
-0.020582247
0.800724163
0.11
38.974
39.084
1170.252
30

Table 2. Descriptive statistical analysis of diameter readings of the low carbon steel
connecting rod.

From the descriptive statistical analysis, the maximum and minimum

diameter

reading

of

the

observation

is

39.084mm

and

38.974mm

respectively. The difference between the maximum and the minimum value
is the range and is observed as 0.11mm. The mean diameter values is
approximately 39 and the standard deviation across the range from the
mean value is 0.028.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 1. Histogram of diameter readings of the low carbon steel connecting rod.

The greatest range of diameter reading occurrence is between the values

38.974mm and 39.005mm followed by 39.005mm and 39.036mm. By
employing the statistical equations,
Upper value=Mean+ ( Standard errorZ ) , and
Lower value=Mean( Standard errorZ)

We can predict that 68% of observed diameter readings lies between the
range 39.0033mm and 39.0135mm, 95% of the diameter readings lies
between the range 38.9982mm and 39.0186mm and 99.7% of the diameter
readings lies between the range 38.9931mm and 39.0237mm.

(b)

MV9 Alloy Connecting Rod

The table shows the descriptive statistical values for 30 sets of diameter
readings of the large cylindrical feature of the connecting rod made of MV9
alloy and the surface roughness value, Ra=0.66m.

Mean
Standard Error
Median
Mode
Standard

36.07006667
0.004645585
36.063
36.059

Deviation

0.025444915

Sample
Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum
Count

0.000647444
-0.168587878
0.60776998
0.103
36.029
36.132
1082.102
30

Table 3. Descriptive statistical analysis of diameter readings of the MV9 alloy connecting
rod.

From the descriptive statistical analysis, the diameter readings fluctuates

between 36.029mm and 36.132mm with in a range of 0.103mm. The mean
diameter values is 36.07 and the standard deviation across the range from
the mean value is 0.025.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 2.Histogram of diameter readings of the MV9 alloy connecting rod.

From the Histogram, most of the observed diameter readings falls between
36.057mm and 36.085mm. The statistical analysis reveals that 68% of the
observed diameter readings of the connecting rod lies in the range
36.0649mm and 36.0751mm while 99.7% of the diameter readings lies in
the range 36.0547mm and 36.0853mm.

(c)

Aluminium Silicate Connecting Rod

The table shows the descriptive statistical values for 30 sets of diameter
readings of the large cylindrical feature of the connecting rod made of
Aluminium Silicate and the surface roughness value, Ra=1.26m.
41.1248333
Mean

3
0.03400811

Standard Error
Median
Mode
Standard

5
41.1315
41.146

Deviation

0.18627012
0.03469655

Sample Variance

7
6.58377521

Kurtosis
Skewness
Range
Minimum
Maximum
Sum
Count

2
-1.82601957
1.063
40.421
41.484
1233.745
30

Table 4.Descriptive statistical analysis of diameter readings of the Aluminium silicate

connecting rod.

From the descriptive statistical analysis, the minimum diameter reading is

40.421mm and the maximum diameter reading is 41.484mm. The difference
between the maximum and the minimum value is the range and is observed
as 1.063mm. The mean diameter values is 41.124mm and the standard
deviation across the range from the mean value is 0.186.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 3. Histogram of diameter readings of the Aluminium silicate connecting rod.

From the Histogram, most of the observed diameter readings falls between
41.0588mm and 41.2714mm. The statistical analysis reveals that 99.7% of
the observed diameter readings of the connecting rod falls in the range
41.022mm and 41.226mm while 68% of the diameter readings lies in the
range 41.09mm and 41.158mm. 41.056mm to 41.192mm constitutes 95% of
the observed diameter readings.
(d)

Low Carbon Steel Connecting Rod

The table shows the descriptive statistical values for 30 sets of diameter
readings of the large cylindrical feature of the connecting rod made of Low
carbon steel and the surface roughness value, Ra=0.18m.

Mean
Standard Error
Median
Mode
Standard

48.1828
0.002472562
48.1845
48.187

Deviation
Sample Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum

0.01354278
0.000183407
0.547812479
-0.96958511
0.05
48.15
48.2
1445.484

Count

30

Table 5. Descriptive statistical analysis of diameter readings of the Low carbon steel
connecting rod.

From the descriptive statistical analysis, the minimum diameter reading and
the maximum diameter reading achieved is 48.15mm and 48.2mm
respectively. The difference between the maximum and the minimum value
is the range and is observed as 0.05mm. The mean diameter values is
48.1828mm and the standard deviation across the range from the mean
value is 0.0135.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 4.Histogram of diameter readings of the low carbon steel connecting rod.

From the Histogram, the highest frequency range of number of observations

is 15 and it corresponds to the range of diameter readings between
48.182mm and 48.198mm. The statistical analysis reveals that 68% of the
observed diameter readings of the connecting rod falls in the range
48.1804mm and 48.1852mm while 99.7% of the diameter readings lies in
the range 48.1756mm and 48.1876mm. 95% of the diameter readings of the
corresponding connecting rod were observed between the range 48.178mm
and 48.1876mm.

(e)

MV9 Alloy Connecting Rod

The table shows the descriptive statistical values for 30 sets of diameter
readings of the large cylindrical feature of the connecting rod made of MV9
alloy and the surface roughness value, Ra=0.30m.
36.015466
Mean

67
0.0029613

Standard Error

34

Median
Mode
Standard

36.0115
36.008
0.0162198

Deviation
Sample

97
0.0002630

Variance

85
14.814631

Kurtosis

13
3.4177694

Skewness
Range
Minimum
Maximum
Sum
Count

12
0.088
36.001
36.089
1080.464
30

Table 6. Descriptive statistical analysis of diameter readings of the MV9 alloy connecting
rod.

From the descriptive statistical analysis, the observed diameter readings of

the large cylindrical feature varies from 36.089mm to 36.001mm. The
average diameter is found as 36.015mm and the dispersion of the readings
or standard deviation is 0.0162. The range over which the diameter readings
falls is 0.088.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 5.Histogram of diameter readings of the MV9 alloy connecting rod.

From the Histogram, the most of the observed diameters lies in the range
36.001mm and 36.0186mm. From the statistical analysis we can predict that
68% of the observed diameter readings of the connecting rod falls in the
range 36.0121 and 36.0179 while 99.7% of the diameter readings lies in the
range 36.0063mm and 36.0208mm. 95% of the diameter readings of the
corresponding connecting rod were observed between the range 36.0092mm
and 36.0208mm.
Statistical Analysis of Vernier Calliper Measurements
The statistical analysis of the diameter measurements from the Vernier
calliper is performed to assess whether the statistical analysis of FARO arm
CMM reading for the same follows any similar trend. For each of the analysis
as of FARO arm, the band width of the bin of the histogram is theoretically
calculated for the optimum bin size and is given by the formula (Jenkinson,
2014),

h=

3.5
n1 /3
Where,
h is the band width of the bin.
is the standard deviation.
n is the number of readings.

(a)

Low Carbon Steel Connecting Rod

The table establish the descriptive statistical analysis of the 30 sets of

diameter readings of the large cylindrical feature of the low carbon steel
connecting rod with surface roughness, Ra as 0.38m.

Mean
Standard Error
Median
Mode
Standard

38.83333333
0.031114669
38.92
38.97

Deviation
Sample

0.170422059

Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum
Count

0.029043678
-0.679136819
-0.879469425
0.52
38.48
39
1165
30

Table 7. Descriptive statistical analysis of diameter readings of the low carbon steel
connecting rod.

The descriptive analysis reveals that observed diameter readings falls in the
range from 38.48mm to 39mm. The mean readings about which a standard
deviation of 0.1704 occurs is 38.83mm. The range over which the 30 counts
of readings fall is 0.52mm.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 6. Histogram of diameter readings of the low carbon steel connecting rod

From the histogram we can anticipate that 68% of the observed diameter
readings lies between 38.79 and 38.86 while 99.7% of the observed readings
falls between 38.73 and 38.92. The maximum frequency value is in the
range 38.86mm and 39.05mm. From the shape of the histogram it can be
inferred that the diameter readings does not follow normal distribution like
FARO arm readings for the same connecting rod.
(b)

MV9 Alloy Connecting Rod

The table establish the descriptive statistical analysis of the 30 sets of

diameter readings of the large cylindrical feature of the MV9 alloy connecting
rod with surface roughness, Ra as 0.66m.

Mean
Standard Error
Median
Mode
Standard
Deviation
Sample Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum

35.78433333
0.033701473
35.81
35.53
0.184590569
0.034073678
-1.212139894
-0.343955533
0.6
35.42
36.02
1073.53

Count

30

Table 8. Descriptive statistical analysis of diameter readings of the MV9 alloy connecting
rod.

From the descriptive analysis, the maximum and minimum diameter reading
is 36.02mm and 35.42mm respectively. The difference between the
maximum and the minimum gives the range and is found as 0.6. The mean
of the observations is 35.78mm and the standard deviation is 0.184.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 7. Histogram of diameter readings of the MV9 alloy connecting rod.

From the Histogram, the most of the observed diameters lies in the range
35.82mm and 36.02mm. From the statistical analysis we can predict that
68% of the observed diameter readings of the connecting rod falls in the
range 35.67mm and 35.81 while 99.7% of the diameter readings lies in the
range 35.67mm and 35.88mm. 95% of the diameter readings of the
corresponding connecting rod were observed between the range 35.57mm
and 35.84mm.
(c)

Aluminium Silicate Connecting Rod

The table establish the descriptive statistical analysis of the 30 sets of

diameter readings of the large cylindrical feature of the low carbon steel
connecting rod with surface roughness, Ra as 1.26m.

Mean
Standard Error
Median
Mode
Standard

40.74866667
0.07343577
40.705
40.63

Deviation
Sample

0.402224276

Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum
Count

0.161784368
-0.260166927
0.341361706
1.6
40.09
41.69
1222.46
30

Table 9. Descriptive statistical analysis of diameter readings of Aluminium silicate

connecting rod.

From the descriptive statistical analysis, the mean diameter reading for the
range of observations from a minimum of 40.09mm and maximum of
41.69mm is 40.74mm. The range size is 1.6 and the corresponding standard
deviation of the readings is 0.402.
The histogram depicting the frequency of occurrence of the diameter with in
each range of standard deviation is shown

Graph 8.Histogram of diameter readings of the Aluminium silicate connecting rod.

From the Histogram, most of the observed diameter readings falls between
40.54mm and 40.99mm followed by 40.9mm and 40.54mm. The statistical
analysis reveals that 68% of the observed diameter readings of the
connecting rod lies in the range 40.66mm and 40.82mm while 99.7% of the
diameter readings lies in the range 40.52mm and 40.96mm. The shape of
the histogram depicts the shape of a flattened bell curve.
(d)

Low Carbon Steel Connecting Rod

The table establish the descriptive statistical analysis of the 30 sets of

diameter readings of the large cylindrical feature of the low carbon steel
connecting rod with surface roughness, Ra as 0.18m.

Mean
Standard Error
Median
Mode
Standard

48.03666667
0.02433168
48.08
48.1

Deviation
Sample Variance

0.1332701
0.01776092
-

Kurtosis

0.572953373
-

Skewness
Range
Minimum
Maximum
Sum
Count

0.392874739
0.53
47.75
48.28
1441.1
30

Table 10.Descriptive statistical analysis of diameter readings of low carbon steel connecting
rod.

From the descriptive analysis, the maximum and minimum diameter of the
observations is 48.28mm and 47.75mm with mean value of 48.036mm. The
difference between the maximum and the minimum values gives the range
of

the diameter distribution

and is

observed

corresponding standard deviation is found as 0.133.

as

0.53mm and the

The histogram depicting the frequency of occurrence of the diameter with in

each range of standard deviation is shown

Graph 9. Histogram of diameter readings of the low carbon steel connecting rod.

From the Histogram, the most of the observed diameters lies in the range
48.03mm and 48.17mm. From the statistical analysis we can predict that
68% of the observed diameter readings of the connecting rod falls in the
range 47.78mm and 48.27mm while 99.7% of the diameter readings lies in
the range 47.30mm and 48.75mm.

95% of the diameter readings of the

corresponding connecting rod were observed between the range 47.54mm

and 48.52mm. The shape of the histogram reveals a uniform probability
distribution of diameter readings.
(e)

MV9 Alloy Connecting Rod

The table establish the descriptive statistical analysis of the 30 sets of

diameter readings of the large cylindrical feature of the low carbon steel
connecting rod with surface roughness, Ra as 0.30m.

Mean
Standard Error

36.052
0.025508
169

Median
Mode
Standard

36.08
36.08
0.139713

Deviation
Sample

994
0.01952

Variance
0.791917
Kurtosis

666
0.133231

Skewness
Range
Minimum
Maximum
Sum
Count

68
0.5
35.8
36.3
1081.56
30

Table 11. Descriptive statistical analysis of diameter readings of MV9 alloy connecting rod.

The descriptive statistical analysis reveals that the diameter of the MV9
connecting rod is distributed over a range of 0.5mm with maximum and
minimum observations 36.3mm and 35.8mm respectively. The mean across
which the observations lie is 36.052mm and the standard deviation is
0.139mm.
The histogram depicting the frequency of occurrence of the diameter with
in each range of standard deviation is shown

Graph 10. Histogram of diameter readings of the MV9 alloy connecting rod.

From the Histogram, most of the observed diameter readings falls between
35.95mm and 36.1mm. The statistical analysis reveals that 68% of the
observed diameter readings of the connecting rod lies in the range 36.02mm
and 36.07 while 99.7% of the diameter readings lies in the range 35.98mm

and 36.13mm. The shape of the histogram depicts a perfect bell curve
graph.

Results and Discussions

The major objective of the investigation was to analyse the correlation of
distribution

of

dimensional

measurements

and

surface

roughness

parameters. The descriptive statistical analysis is the most suitable tool to

quantitavely define the important features of collection of informations.
Therefore,

for

the

investigation

the

measurements

of

five

different

automobile connecting rods of varying surface textures were statistically

examined.

Results of correlation of the surface roughness and the

dimensional measurements
The correlation signifies how a particular quantity is depended on other
parameters. With a perfect relationship between two quantities helps to
define one quantity in terms of the other. From the analysis it is clear that
surface roughness characteristics has an impact on the distribution of
measurement result for the large cylindrical feature diameter measurement
of the automobile connecting rod. This correlation can be revealed by
plotting a graph of surface roughness of the different connecting rod under
investigation and the corresponding standard deviation of the diameter
measurements.

Graph 11. Surface roughness vs. Standard deviation of diameter measurements from FARO
arm CMM.

The graph 11. Shows the correlation of surface roughness and the standard
deviation of diameter measurements of FARO arm CMM.

Graph 12.Surface roughness vs. Standard deviation of diameter measurements from

Mitutuyo Vernier Calliper.

The graph 12. Shows the correlation of surface roughness and the standard
deviation of diameter measurements of Mitutuyo Vernier Calliper.
The nature of relationship between the surface roughness and dimensional
distribution could not be well established from the investigation since the
graph showed a scattered output. But the scattered graph revealed a strong

correlation as the value of rate of dispersion of observed dimensional

measurements

projected

up

with

corresponding

surface

roughness

parameter. Plotting an imaginary line through the maximum points as shown

in figure 11 and figure 12 would help to identify an improved correlation. The
line obtained showed a direct relationship between the variables for both the
graphs. Hence, the investigation shows a linear relationship of distribution of
dimensional measurement and the surface roughness parameter. An
improved correlation data could be produced if more similar components
were examined.
Also, the defined experimental methodology showed following results:
1. The Mitutuyo Vernier calliper observations showed a wide range of
dispersion of diameter readings of the large cylindrical feature of the
automobile connecting rod compared to FARO arm CMM. Also, the
observations made from FARO gauge arm produced a Gaussian bell
curve which reveals that all the readings were uniformly distributed
across the mean reading. This may be due to high precision and
accuracy of FARO gauge instrument as defined in the methodology.
2. The methodology defined two different procedures for the dimensional
measurement of the connecting rods. This was deliberately done to
verify the accuracy and uncertainties in following different measuring
procedures. Out of the two experimental procedures, the experimental
procedure followed to measure the diameter of the large cylindrical
feature of the connecting rods marked (c) and (d) as suggested by the
National

Physical

Laboratory-

good

practise

guideline

for

CMM

measurements gave an healthy output for the analysis of the

investigation.
3. A fluctuating histogram shape was noted during the analysis of
dimensional measurements. This may be due to varying profile of the
surface roughness of the examined cylindrical feature.

Conclusions
The paper looks at the relationship between distribution of large cylindrical
diameter measurements and the corresponding surface roughness of an
automobile connecting rod. An experiment was conducted experiment using
both Vernier scales and Faro Gage to measure diameter of the large cylinder
feature of automotive connecting rods and their corresponding surface
roughness. We have analysed the correlation of the surface roughness versus
the diameter measurements using statistical methods for each sample and
attempted to understand whether the surface roughness characteristics have
direct impact on the distribution of measurement result for the cylinder
diameter measurement.
We find that the relationship means how a specific quantity is relied on upon
different

parameters.

With

an

impeccable

relationship

between

two

quantities, it serves to characterize one quantity regarding the other. From

the investigation it is clear that surface roughness qualities has an effect on
the appropriation of estimation result for the large cylindrical feature
diameter width estimation of the auto associating pole. This connection can
be uncovered by plotting a chart of surface roughness of the distinctive
interfacing bar under scrutiny and the relating standard deviation of the
measurement estimations.
The way of relationship between the surface roughness and dimensional
dissemination couldn't be settled from the examination since the chart
demonstrated a scattered yield. However the scattered diagram uncovered a
solid connection as the estimation of rate of scattering of watched
dimensional estimations anticipated up with relating surface roughness

parameter. Plotting a graph through the greatest focuses as demonstrated in

figure 11 and figure 12 would help to recognize an enhanced connection. The
line acquired demonstrated an immediate relationship between the variables
for both the diagrams. Henceforth, the examination demonstrates a straight
relationship of circulation of dimensional estimation and the surface
roughness parameter. Enhanced relationship information could be delivered
if more comparable parts were inspected. Additionally, the characterized
exploratory strategy indicated after results The Mitutuyo Vernier caliper
perceptions demonstrated an extensive variety of scattering of distance
across readings of the huge tube shaped gimmick of the vehicles associating
bar contrasted with FARO arm CMM. Likewise, the perceptions produced
using FARO gage arm created a Gaussian chime bend which uncovers that all
the readings were consistently appropriated over the mean perusing. This
may be because of high exactness and precision of FARO gage instrument as
characterized in the philosophy. The approach characterized two separate
methodologies for the dimensional estimation of the uniting bars. This was
deliberately done to confirm the exactness and instabilities in after diverse
measuring systems. Out of the two test methodology, the exploratory
method took after to gauge the width of the vast tube shaped diameter of
the interfacing bars checked (c) and (d) as proposed by the National Physical
Laboratory- great practice rule for CMM estimations gave a sound yield for
the investigation of the examination. A fluctuating histogram shape was
noted amid the investigation of dimensional estimations. This may be
because of fluctuating profile of the surface roughness of the analyzed
cylindrical diameter.

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References