Metrology Exercise

1State the effects of standardization and reasons to have primary standard and secondary
. standard.

2State two reasons for adopting toleranced dimensions.

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3State the benefits of interchangeability of components and state the procedure to
. manufacturing the quality slip gauges.
4Define the following dimensioning conditions:
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(i) tolerance
(ii) allowance
5Estimate the error in the measurement of bar length due to difference temperatures. (see
. pg 16 on section A )
6Name four types of Limit Gauges and describe the use of gap gauge.
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7A hole and shaft assembly of nominal size 40 mm for an average clearance fit to H8 f7.
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Nominal size H8 f7

30 – 50 mm ＋39 －25
＋0 －50
(Tolerance unit 0.001 mm)
Find:
(i) the hole tolerance
(ii) the shaft tolerance
(iii) the maximum clearance of the assembly
(iv) the minimum clearance of the assembly
8On assessment of Surface Texture, explain the following qualities:
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(i) Waviness
(ii) Roughness
9Describe Taylor’s Principle of Gauging and CMM machine.
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1Calculate the workpiece taper by the optical flats principle. (see exercise of optical
0fringes)
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1Using p ± 3σ as the control for acceptance, calculate the upper control limit (UCL)
1
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and lower control limit(LCL) for the product acceptance (see Section E page14)
1State the surface roughness of peaks to valleys heights index (Rz). and work out the Rz as
2in the assignment.
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 1Outline the working principle of the Michelson Interferometer.
3
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Solution

1 Through standardization, we can eliminate the waste of time and materials involved
in the producing unnecessary varieties of patterns and sizes of articles for the same
purpose.

A standard that is designated or widely acknowledged as having the highest

metrological qualities and whose value is accepted without reference to other
standards of the same quantity..

A standard whose value is assigned by comparison with a primary standard of the

same quantity.
2 (i) It is impossible to make anything to an exact size. besides more exactness
means more cost.

(ii) The amount of error that can be tolerated is stated by placing the limits on
the drawing.

3 Interchangeability leads to reduced assembly costs and facilitates maintenance

by ensuring an adequate and readily available supply of replacement parts.

Procedure:
1. First approximate the size of slip gauges.
2. Special heat treatment process to hardened and increase wear resistant.
3. To stabilize the whole life of blocks by seasoning process.
4. Grinding the gauge to required dimension..

4 Tolerance － This is the difference between the upper limit and lower limit of the
dimension. The choice of tolerance depends on the functional needs of the
component and the production cost. The method of tolerancing can be unilateral or
bilateral.
 Allowance － This is the difference between the maximum metal limits on the
hole and the shaft and it determines the quality of the fit. The allowance gives the
minimum clearance between the hole and the shaft or the maximum amount of
interference, i.e. the largest shaft and the smallest hole giving the “tightest” fit that
will function correctlyTolerance

6 Limit Gauges

i) Go & Not Go Gauging

ii) Ring Gauge
iii) Taper plug gauge
iv) Caliper Type Gauges (Gap Gauges)

Caliper Type Gauges (Gap Gauges) － They are suitable for checking
diameters, lengths or widths. The Go end must pass over the feature under test to
show that the dimension is not oversize; the Not Go end must not pass over to show
that the dimension is not undersize.
7 Hole tolerance＝40.04－40.00＝0.04 mm
Shaft tolerance＝39.98－39.95＝0.03 mm
Maximum clearance (＝largest hole－smallest shaft)＝40.04－39.95＝0.09 mm
Minimum clearance (＝smallest hole－largest shaft)＝40.00－39.98＝0.02 mm
Reason: For cost saving,
8 Assessment of Surface Texture
There are two qualities to be taken into consideration:

i) Waviness refers to the deviation which results from such factors as machine or
work deflections, vibrations, chatter, heat treatment or warping strains.
i) iRoughness refers to the irregularities in the surface texture superimposed on
waviness which are inherent in the production processes such as: traverse feed,
scratches and tool marks.

9 A Taylor’s principle states a gauge should check the geometrical accuracy in

addition to the dimensional accuracy of a component. ”

CMM
It is a three dimensional measurements for various components. These machines
have precise movement is x,y,z coordinates which can be easily controlled and
measured. Each slide in three directions is equipped with a precision linear
measurment transducer which gives digital display and senses positive and negative
direction.

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12 Average peak to valley height index (Rz)－An arbitrary datum line is

drawn parallel (but below) the mean centre line. The five highest peaks and the
five deepest valleys within the sample length L measured from the arbitrary datum
are taken.
Then
(P1 + P2 + P3 + P4 + P5 ) − (V1 + V2 + V3 + V4 + V5 )
Rz =
5

13

A schematic representation of the Michelson Interferometer. Light originates from the laser, is split by the beam-splitter, and travels

down two separate paths. The two beams are then reflected by mirrors and recombine to form an interference pattern at the beam-

splitter. This interference pattern can be detected by any suitable optical detector.
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