Unit Ii MQC

Meterology And Quality
Control
Prof.S.P.Dhavane MECH MIT AOE
Unit II: Design Of Gauges,Interferometers And

Surface Roughness Measurements
Basic definitions
Basic definitions
1. Basic Size: It is the standard size of a
part , with reference to which all the limits
of variations of size are determined.
2. Zero Line: the line corresponding to basic
size is called as zero line.
3. Shaft And Hole: These terms are used to
designate all the external and
internal
features of any shape and not necessarily

cylindrical.
Basic definitions
4.Hole Designation: By upper case letters
from A, B, ... Z, Za, Zb, Zc (excluding I, L,
O, Q, W and adding Js, Za, Zb, Zc) - 25
nos. Indian Stds.
5.Shaft Designation: By lower case letters
from a, b, ... z, za, zb, zc (excluding i, l,
o, q, w and adding js, za, zb, zc) - 25 nos
Deviation
Upper Deviation:
The Algebraic Difference Between The Maximum
Limit Of Size (Of Either Hole Or Shaft) And The
Corresponding Basic Size
LOWER Deviation:
The Algebraic Difference Between The Minimum
Limit Of Size (Of Either Hole Or Shaft) And The
Corresponding Basic Size
FUNDAMENTAL Deviation:
It Is One Of The Two Deviations Which Is Chosen
To Define The Position Of The Tolerance Zone
Tolerance
Need: Never Possible to make a component of
actual given size

How to decide tolerance?
Functional requirements of mating parts
Cost of production
Available manufacturing process
Choose
tolerance
as
possible
without
compromising functional requirements
Proper balance between cost and quality of parts
Tolerance:
The algebraic difference between upper
and lower deviations. It is an absolute value.
Types of Tolerances
Unilateral tolerance : If the tolerance is
allowed on one side of the basic size, the
system of tolerance is said to be
unilateral.
Types of Tolerances
Bilateral tolerance : if the tolerance is
allowed on both side of the basic
size, the system of tolerance is said
to be bilateral.
10
Limits
The limits are two extreme permissible sizes of a
part between which, the actual size of that part is
contained. They are fixed with reference to the basic
size of that dimension.
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Basic Shaft: it is the shaft, whose upper
deviation is zero or whose max. limit of size

is equal to basic size .
Basic Hole: it is the hole, whose lower deviation is
zero or whose min. limit of size is equal to basic size
.
12
Allowances
Allowance is the prescribed difference between the
hole dimension and shaft dimension for any type of
fit.
It is the intentional difference between the lower
limit of the hole and higher limit of the shaft.
13
Fits
The relation between the two parts, where one
is inserted into the other with a certain degree
of tightness or looseness is known as fit.
Fit is the degree of tightness or looseness
between two mating parts to perform a
definite function .
fit is the relation between dimensions of two
mating parts before their assembly.
14
Types of Fits
15
Clearance fit
In this type of fit, the largest permitted shaft
diameter is smaller than the Diameter of the smallest
hole, so that, the shaft can rotate or slide through,
with Different degrees of freedom according to the
purpose of the mating members
16
Interference fit
In this type of fit, diameter of minimum allowable

shaft is greater than that of Maximum allowable
hole.
In this type of fit, the sizes of the mating parts are
so
selected
that,
interference
Or
negative
allowance will always occur.
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Transition fit
In a fit of this type, the diameter of the largest allowable
hole is greater than that of the smallest shaft, but the

smallest hole is smaller than the largest shaft, so that,
small positive or negative allowance between the shaft
and hole members are employable.
In this type of fit, the size limits of mating (shaft and hole)
parts are so selected that, either clearance or interference

may occur depending upon the actual size of the parts.
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Transition fit
19
Fits Applications
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Fits Applications
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Hole Basis System

In this system, the design size of hole,
whose lower deviation is zero, is assumed
as basic size and different class of fits are
obtained by varying the limits of the shaft
only.
In other words, the limits of the hole are
kept constant and those of the shaft are
varied so as to obtain the necessary fit.
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Hole Basis System
23
Hole Basis System
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Shaft Basis System

In this system, the design size of a shaft,
whose upper deviation is zero, is assumed
as basic size and different class of fits
obtained by varying the limits of the hole
only.
In other words, the limits of shaft are kept
constant and limits of holes are varied to
obtain the necessary type of fit.
25
Shaft Basis System
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Shaft Basis System
27
Designations
To describe completely a hole or a shaft, its basic
size followed by appropriate letter and the number
of tolerance grade is given.
Holes are designated by capital letter
Shafts are designated by small letter.
Example:
20 mm hole H' with tolerance
grade IT7 is
designated as 20H7.
20. mm 'f' shaft with tolerance grade IT8 is
designated as 20f8.
28
Grades of Tolerance
Grade of Tolerance: It is an indication of the
level of accuracy.
There are 18 grades of tolerances IT01,
IT0, IT1 to IT16
for Eg; IT01 to IT4 - For production of
gauges, plug gauges, measuring instruments
IT5 to IT 7 - For fits in precision engineering
applications
29
Designation of fits
Example:
50 H7g7 : is a fit indicated by its basic size 50mm,
followed by symbols representing the limits of hole (H7

i.e hole having basic size 50mm and tolerance grade IT7)
and shaft (g7
i.e
shaft having basic size 50mm and
tolerance grade IT7)

the type of fit system is hole basis and obtained type of
fit is clearance fit.
30
Designations
31
Limit Gauges
Gauges are inspection tool of rigid design,
without a scale, which serves to check the
dimensions of manufacturing parts.
Gauge do not indicate the actual value of
the inspected part of the component.
They are used to determine whether the
part is made within the specified limit.
32
Limit Gauges
33
Types of Limit Gauges

The classification is principally according
to the shape or purpose for which each is
used.
1.Snap Gauges
2. Plug Gauges
3. Radius Gauges
4. Feeler Gauge
5. Pitch Gauge
34
Plug Gauges
35
Snap Gauges
36
Pitch Gauges
37
Feeler Gauges
38
Radius Gauges
39
Basic Of Interferometry
1. Interference Interaction of light
2. Monochromatic lights (having only a single
wavelength)
is
wavelength
that
is
composed of one color but it is confined to

an extremely narrow range .
40
Interference Of Light
41
Interference Of Light
42
Interference Of Light-flatness Testing By Inferometry
43
Optical Flat
Cylindrical pieces 25 to 300 mm diameter with a
thickness of about 1/6 th of the diameter.
Transparent MaterialQuartz, glass, sapphire
Quartz
Hardness,
Low coefficient of expansion,
Resistance to corrosion
44
Optical Flat
45
Interference Patterns
46
Interferometers
Limitation Of Optical Flat
It is difficult to orient the fringes patern as it is
difficult to control the lay of the optical flat.

The fringe pattern is not viewed from directly
above and resulting obliquity can cause distortion
and errors in viewing.
47
Interferometers
The extension of the application of
optical flat
Use for measuring flatness
Overcomes
the
disadvantages
of
optical flat
48
NPL Flatness Interferometers
49
NPL Interferometer Setup
50
51
Laser Interferometer
1. Optical technique and
digital electronics
2. High Repeatability and
resolution
of
displacement
measurement
(0.1
micron)
3.
High
accuracy,
long
range optical path

52
Laser
Interferometer
53
Laser
Interferometer
54
55
Surface Finish
Measurement
56
Surfaces
1. Nominal
surface
Designers
intended
surface contour of part, defined by lines in

the engineering drawing.
2. Nominal surfaces appear as absolutely straight
lines, ideal circles, round holes, and other edges
and surfaces that are geometrically perfect.
3. Actual surfaces of a part are determined by the
manufacturing processes used to make them .
4. Variety of processes result in wide variations in
Prof.S.P.Dhavane .MECH MIT AOE
surface characteristics
57
Why Surfaces are Important..??

Aesthetic reasons.
Surfaces affect safety.
Friction and wear depend on surface
characteristics.
Surfaces
affect
mechanical
and
physical properties.
Assembly of parts is affected by their
surfaces.
58
Metallic Part Surface
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Terminology on Surface Texture
60
Terminology on Surface
Surface Texture
:
Texture
Defined as local deviations of a surface
from its ideal shape which tends to form a pattern
on the surface. It includes following type of
irregularities :
A)Surface Roughness(Primary Texture):
) It is defined as the irregularities in the surface
texture with short wavelength .
) It appears due to the production process employed to
create surface.
61
Terminology on Surface
Texture
B) Surface
Waviness (Secondary Texture):
It is defined as the irregularities in the
surface texture which are spaced more
widely.
It appears due to spindle or cutter deflection
, machine vibrations , heat treatments.
C) Errors of form : The deviations of surface
from desired form.
D) Lay : It is the direction of surface pattern.
62
Surface Texture- Parameters
63
Terminology on Surface Texture

Flaw (Defect) Random irregularities such as
scratches, cracks, holes, tears, inclusions, etc.
Lay
(directionality)
Direction
of
the
predominant surface pattern.

Waviness Recurrent deviation from a flat
surface.
Roughness
Closely
spaced
irregular
deviations on a scale smaller than that of

waviness.
64
Surface Texture Parameters
65
Surface Texture
Parameters
A) Waviness
Width (Spacing): Linear distance
between any one point of a wave to the same
point on adjacent wave .
B)
Waviness
height:
Distance
between
the
highest point of peak to the deepest point of

valley of waviness profile.
c) Roughness Width : Distance between two
adjacent peaks or two adjacent valleys.
d) Roughness height: defined as the surface
irregularities of Prof.S.P.Dhavane
a wavelength.
MECH MIT AOE
66
Analysis of Surface Traces
67
68
69
Surface Roughness Representation
70
Surface Roughness Representation
71
Surface Lay Indication
72
73
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75
Methods of Measuring Surface Finish

There are two methods used for measuring the
finish of machined part :
1. Surface Inspection by Comparison Methods.
(i)Touch Inspection, (ii) Visual Inspection, (iii) Scratch
Inspection, (iv) Microscopic Inspection, (v) Surface
Photographs.
2.Direct Instrument Measurements :
These methods enable to determine a numerical value
of the surface finish of any surface.
(i) Profilometer
(ii)Tomlinson surface meter
76
77
Touch Inspection :
This method can simply tell which surface is more
rough.
In this method, the finger-tip is moved along the
surface at a speed of about 25 mm per second and the

irregularities as small as 0.01 mm can be easily
Visual Inspection :
detected.
Visual inspection by naked eye is always likely to
be misleading particularly when surfaces having
high degree of finish are inspected.
The method is, therefore, limited to rougher
surfaces and results vary from person to person..
78
Microscopic Inspection :
In this method, a master finished surface is placed

under the microscope and compared with the surface
under inspection.
Scratch Inspection:
In this method, a softer material like lead babbit or
plastic is rubbed over the surface to be inspected.
By doing so it carries the impression of the
scratches on the surfaces which can be easily
visualised.
79
Surface Photographs :
In this method magnified photographs of the
surface are taken with different types of illumination.
In case we use vertical illumination, then defects
like irregularities and scratches appear as dark spots
and flat portion of the surface appears as bright area.
In case of oblique illumination, reverse is the case.
Photographs
with
different
illumination
are
compared and the results assessed.
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Tomlinson Surface Recorder
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Profilometer
82
Insem MQC QP
83
End sem MQC Questions
84

Unit Ii MQC

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Meterology And Quality

Prof.S.P.Dhavane MECH MIT AOE

Unit II: Design Of Gauges,Interferometers And

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

features of any shape and not necessarily

Prof.S.P.Dhavane MECH MIT AOE

actual given size

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Basic Shaft: it is the shaft, whose upper

deviation is zero or whose max. limit of size

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

In this type of fit, diameter of minimum allowable

allowance will always occur.

Prof.S.P.Dhavane MECH MIT AOE

hole is greater than that of the smallest shaft, but the

parts are so selected that, either clearance or interference

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Hole Basis System

Hole Basis System

Prof.S.P.Dhavane MECH MIT AOE

Hole Basis System

Prof.S.P.Dhavane MECH MIT AOE

Shaft Basis System

Shaft Basis System

Prof.S.P.Dhavane MECH MIT AOE

Shaft Basis System

Prof.S.P.Dhavane MECH MIT AOE

50 H7g7 : is a fit indicated by its basic size 50mm,

followed by symbols representing the limits of hole (H7

shaft having basic size 50mm and

tolerance grade IT7)

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Types of Limit Gauges

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

composed of one color but it is confined to

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Interference Of Light-flatness Testing By Inferometry

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

Prof.S.P.Dhavane MECH MIT AOE

It is difficult to orient the fringes patern as it is

difficult to control the lay of the optical flat.

Prof.S.P.Dhavane MECH MIT AOE

NPL Flatness Interferometers

Prof.S.P.Dhavane MECH MIT AOE

NPL Interferometer Setup