Metrology

by

P.Venkateswara Rao
Professor in Mechanical Engg.
IIT Delhi
 Course Content

 Introduction to Metrology
 Standards of Length
 Line & End Standards
 Limits, Fits & Tolerances
 Interchangeability & Selective assembly
 Standard Specifications
 Application of Tolerances
 Course content contd..

 Inspection by Gauging & by Measurement

 Limit Gauging
 Taylor’s Principles of Limit Gauging
 Design of Limit Gauges
 Classification of Gauges
 Measuring Instruments
 Course content contd..
 Direct & Indirect
 Linear Measuring Instruments & Gauge
blocks
 Comparators, their design considerations,
types of comparators-Mechanical, optical,
pneumatic, electric & electronic
comparators
 Course content contd..
 Angular Measurements- Sine bar, angle
gauges, precision levels, autocollimator,
interferometers, etc.
 Applications of Dimensional inspection
 Gear Inspection
 Thread inspection
 Course content contd..
 Surface Quality Inspection
 Quantification of Surface Roughness
 Various parameters for assessment of
Surface Roughness
 Roughness nomenclature
 Measurement of Surface Roughness
 Course content contd..
 Feature Inspection
 Positional & Geometrical Tolerances
 Straightness & Flatness
 Parallelism & Squareness
 Circularity & roundness
 Course content contd..
 Study of advanced measuring Machines
 Coordinate Measuring Machines, types,
probes, accessories, measurement
 Optical 3D measuring instruments
 In-Process gauging
 Post Process Inspection, etc.
 Reference Books
 Francis T. Farago & Mark A. Curtis, “Hand
Book of Dimensional Measurement”, 1994,
Industrial Press Inc., New York.

 Clifford W. Kennedy, Edward G. Hoffman &

Steven D.Bond, “Inspection and Gaging”, 1987
Industrial Press Inc., New York.
 Reference Books Contd..

 Galyer, J.F.W. & Shotbolt, C.R., “Metrology for

Engineers”, 1980, Cassell & Co. Ltd., London.

 ASTME, “Hand Book of Industrial Metrology”,

1972, PHI Pvt. Ltd., New Delhi.
 Importance of Inspection

 What is the role of inspection in the

Manufacturing ? & what is the use of
Metrology in Inspection?
 Manufacturing activity can be divided into
three important activities:
 Product Engineering
 Process Engineering
 Manufacturing (shop floor activity)
 Product Engineering
 To design the product for function
 Build models for testing
 Provide part prints
 Physical dimensions
 Material
 Special processes required such as painting, plating, heat treatment
 Provide tool design and construction aids
 Master layouts
 Templates
 Master Models
 Product Engineering Contd..
 Provide specification or standard manuals
 Material specifications-chemical analysis and physical properties

 Specifications for special processes -chemical and physical

properties for plating, painting, heat treatment
 Procedures for testing and inspection
 Procedures and specifications for joining processes such as
welding, brazing, soldering, riveting, cementing and so on
 Specifications for threads, gears, splines, keys and so on
 Product Engineering Contd..
 To design the product for customer satisfaction
 Sales appeal
 a.Appearance- color and styling
 b.Improvements- changes and additions over the model
 c.Designs to meet the needs of the customer

 Durability and life expectancy of product-Parts

are designed to satisfy customer by giving the
durability expected in relation to cost
Product Engineering Contd..
 To design the product for cost
 Cost of product must be low enough to compete
with similar parts
 Cost must be high enough to provide a profit
desired by owners of company
 Cost must be in correct relationship with durability
and life expectancy.
Product Engineering Contd..
 To design the product to ease of
Maintenance and assembly
 Accessibility for ease of part repair and replacement
 Design for ease in assembly and disassembly
 Provide drawings for maintenance and method of assembly
 Process Engineering
 To determine the basic manufacturing processes to
be used
 To determine the order or sequence of operations
necessary to manufacturing the part
 Operation routing or lineup
 Process pictures
 To determine and order the tooling and gages
needed to manufacture the part
 Orders to design
 Orders to build
 Orders to buy
 Process Engineering Contd..
 To determine, select and order the equipment
needed to manufacture the part
 To determine the need for and originate orders for
all process revisions necessary when part print
changes occur
 To follow up the tooling and equipment to
determine if all is functioning as planned and if not,
make the necessary revisions
 Process Engineering Contd..
 To provide estimates of the cost of tooling and
equipment needed to manufacture new products for
the purpose of quotations or bids
 To determine part changes necessary to ease
manufacture or reduce cost and request part print
changes
 To take part in product study groups to assist the
product engineer in the design of a product that will
be feasible and economical to make
 International Prototype: Meter
____________________________
 Sub division of Standards
 Primary Standards
 Secondary Standards
 Tertiary Standards
 Working Standards
Line Standards
End Standards
 Line & End Standards
 Line Standards have limited
accuracy
 Line Standards are quick in
operation
 End standards have built in datum
 End standards are not subjected
to parallax error
 No wear & tear for line standards
 Wavelength Standards
 1 metre = 1650763.73 wavelengths of the
red-orange radiation of the isotope
Krypton-86

 Also equal to the length of the path

travelled by light in vacuum during a time
interval of 1/299792458 of a second.
 Standard Terminology
 Basic Size: Designer’s dimension
and is same for both shaft & hole
 Limits of Size: Maximum &
Minimum permissible sizes of the
part
 Upper Limit: Maximum size
 Lower Limit: Minimum size
(BIS:919)
 Standard Terminology contd..
 Deviation: Algebraic difference between
a size & the corresponding basic size
 Upper Deviation: Algebraic difference
between the upper limit & the basic size
 Lower Deviation: Algebraic difference
between the lower limit & the basic size
(BIS:919)
 Standard Terminology contd..
 Fundamental Deviation: Either of the
upper or lower deviation which is the
nearest to the basic size. It fixes the
position of the tolerance zone with
respect to the basic size
(BIS:919)
 Standard Terminology contd..
 Tolerance: Difference between the
upper & the lower limit
 Fits: The relationship existing between
the two mating parts which are to be
assembled with regard to the difference
in their sizes
(BIS:919)
Types of Fits
 Clearance Fit: Ensures clearance between
the hole & shaft
 Interference Fit: Ensures material
interference between the hole and shaft
 Transition Fit: A small interference or
clearance can result in
Details of Fits
 Clearance Fits
 Interference Fits
◦ Press Fits
◦ Shrink Fits
◦ Expansion Fits
◦ Thermal Fits
Standard designation of Fit
 Basic size followed by an alphabet
(capital letter representing “hole” &
small letter representing : “ shaft ”
and quality numbers
For example: 40 H7 g9
Alphabets represent the position of the
tolerance zone w.r.t. the basic dimension
Position of fundamental
deviation
Standard designation of Fit
 Numbers represent the tolerance grade
(quality): 18 grades of tolerances are
provided i.e. 01, 0, 1, 2, 3, 4, 5, 6, 7, 8, -------
--------------,16. The actual tolerances 5 to
16 are production grade and are multiples
of “Fundamental Tolerance Unit (FTU)”
Standard designation of Fit
FTU (i) = (0.45 D1/3 + 0.001 D) in mm
and D is in mm where D is the geometric
mean of the lower & upper of a particular
diameter step in which the diameter lies
 The diameter steps are 0-3, 3-6, 6-10, 10-
18, 18-30, 30-50, 50-80, 80-120, 120-180,
180-250, 250-315, 315-400, 400-500.
 Standard designation of Fit
 The tolerance value of the each of the
grades are listed below:

Grade 5 6 7 8 9 10 11 12 13 14 15 16

Values 7 i 10 i 16 i 25 i 40 i 64 i 100 i 160 i 250 i 400 i 640 i 1000 i

 Types of Inspection

 Inspection by Measurement
◦ Direct
◦ Indirect
 Inspection
by Gauging
(Limit Gauging)
 Limit Gauging

 No attempt is made to determine

the size of the workpiece
 To see whether the component
size lies within the specified limits
 The inspection is carried out by
GO & NOGO gauges
 Limit Gauging Contd..
 GO Gauge: Always made to the Maximum
Material condition of the Component
 NOGO Gauge: Always made to the
Minimum Material condition of the
Component
 It is not always that simple as the Gauges
can not be manufactured to the exact size
and hence gauge makers tolerance needs
to given
Plug Gauges (BIS:3484)

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 Plain Ring/Snap gauges
(BIS:3485)
Go' plain ring gauge for dimension
'Go' plain ring gauge for dimension from
from 3 to 70 mm
70 to 250 mm

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