Metrology & Quality Control

------------------------------------------------------------------------------------------------------
Quality is never achieved by luck, default or chance. It requires planned, systematic
and consistent efforts.

Section – I Topic 1) Measurements:

Metrology is a science of precision measurements of units like length, weights,
volume, viscosity, illumination etc. And it is applied to every field of
manufacturing. Every measurement has International standard.

The inspection starts with incoming raw material to manufacturing, assembly &
Testing. The reason for inspection is that the parts manufactured vary during
manufacturing process due to ‘Assignable cause & Chance cause’ (see section II).
Engineering metrology deals with high precision measurements & calibration.
Objectives of metrology: Evaluate new product development, analyze accuracy of
measurement, determine process capability, calibration of measuring instruments,
develop new methods, maintain accuracy of inspection, build-up special gauges
and stastical quality control through record.
Atmospheric conditions Metrology lab.
a) Temperature: 20O ± centigrade
b) Relative Humidity: 45 ± 10%. If high-corrosion & sweating. If low, Static charge.
c) Barometer pressure: 10 to 20 N/m2 extra.
d) Air velocity: 0.71 ± 0.28 m3/minute inside the lab...
e) Dust particle count: upto 0.5 μ. & so e Ante-room with glass door is provided.
f) Acoustic noise: 45-60 db (Decibels).
g) Illumination: 450-700—Lux on inspection table with CFL lamp.
h) Vibration: 0.001 gm.
LINE standard END standard WAVE LENGTH Std.
Examples: Imperial Slip gauges, Micrometers, Uses monochromatic
std. yard, Meter, length bars. light of Krypton 86 (or
Laser etc.).
Yard = 36 inch = Set of standard bars. 1 Meter = 1650763.73
0.914400 meter. Gold wavelength of Krypton
inserts in Bronze bar. 86
It is distance between It is distance between 2 Uses Optics, mirror,
2 engraved lines. ends. rays to align with
cross wire,
Can’t give precise value Provides precision Provides very high
of measurement. measurement. precision value.
Quick to measure. Time consuming. Takes time, costly.
Not subjected to wear. Subject to wears. No wear. It is light source.
Parallax error, affected Gives direct reading. There Gives direct reading.
by temperature. can be errors of Not affected by
Requires judgment measurement due to temp. environment.
Simple, but Comparatively more Requires training
inconvenient. complex.
Does not require Calibration & setting Training required
calibration or training required due to wear.
Training reqd.
Not useful for Used in precision Can be used for
interchangability, measurement. measurement &
various type of fit calibration.
 2 MQC (Measurements)

Precision Accuracy
It is repeatability of measuring It is agreement of measurement of job
instrument. with drawing dimension.
Related to instrument or CNC machine Related to job
Expressed as Least count Measured as tolerance on job e.g. ±
/Repeatability/Positional accuracy. Etc 0.10
Precision is constant for instrument or m/c. Accuracy can vary according to fit.
Important to measure accuracy of job Important for interchangability & fit.
Compared with reference standard. Checked by Go No-Go gauges/instrument.
No relation with job accuracy Direct relation with type of fit.
Precision has international standard Choice of designer.
Cost to maintain a precision is Higher the accuracy of job, higher is
constant the cost of manufacture.

Types of Errors in measurements.

An error in measurement is the difference between measured size and actual size
of job. There are many reasons for getting errors as follows:
1) Errors in measuring instrument: defective springs, backlash in gears, wear of
measuring edges.
2) Visual error/ measuring methods: Cosign error; perplex error, setting error,
tiredness of inspector, dirt between job & instrument, person to person variations.
3) Errors due to excessive pressure on instrument, loading error, Fluctuating
pneumatic pressure in pneumatic comparator.
4) Errors due to temperature variation, external vibrations & due to environment.
5) Calibration of instrument not done in time.
6) Errors in product due to geometric tolerances, poor surface finish.
7) Errors due to wrong checking methods e. g. bend of job, misalignment.

How to reduce errors in measurements:

a) Inspect with instruments having magnification facility.
b) Use CNC CMM.
c) Calibrate the instruments periodically.
d) Use sampling methods of inspection ( Statistical method)
e) Inspect at 200 C. temperature. (international standard)
f) Adopt 3 point measurement technique.
g) Provide training to the inspector.
Requirements of instruments: Measuring instruments must be sensitive to show
smallest variations, fast to use without much skill, must have measuring range,
must be calibrated periodically, very high repeatability & minimum response time.
------------------------------------------------------------------------------------------------------
 3 MQC (Measurements)

Geometric errors cannot be checked by ‘LIMIT’ Gauges.

Care while handling slip gauges
1) Remove required slips from slip box slots.
2) Clean mating surfaces by thumb.
3) Hold both mating faces at right angle.
4) Slowly and with light hand pressure rotate one slip to slide over other slip.
5) This will give ‘wringing’ effect i. e. intimate contact. Both slips must stick
together without any external pressure or clamping.
6) Thus total thickness will be equal to addition of sizes of slips.
7) While dismantling slips reverse the procedure.
8) After use, keep the slip in respective slots in the slip box.
9) Apply petroleum jelly to resist corrosion when slips are not in use.
10) Always use slip gauges in 20 degree centigrade temperature.

Measuring instruments
Micrometers
 4 MQC (Measurements)
V block with clamp

Surface plate

Lever type dial indicator Plunger Type Dial indicator

 5 MQC (Measurements)

Types of Venire callipers

Surface plate & Angle plate

Venire height gauge

 6 MQC (Measurements)
Dial stand Use of straight edge
7 MQC (Measurements)
8 MQC (Measurements)