METEOROLOGY AND QUALITY ASSURANCE 1

Introduction to Meteorology:
❖ Metrology means science of measurement.
❖ Metrology is concerned with the establishment, reproduction, conservation and transfer of
units of measurement & their standards.
❖ Engineering metrology is the measurement of dimensions: length, thickness, diameter, taper
angle, flatness, profiles, etc.
❖ In engineering, there are various stages during which inspection and measurement is
required. Metrology becomes useful while raw material inspection, during production and
after the parts are manufactured i.e. final inspections of parts.
❖ Measurand is the physical quantity or property like length, angle, diameter, thickness etc to
be measured.
❖ The various precision linear measuring instruments are:
➢ vernier caliper
➢ outside micrometer
➢ vernier height gauges
➢ vernier depth gauge
➢ inside micrometer
➢ micrometer depth gauge etc.
❖ Such linear measuring instruments measure linear measurements such as length, height,
depth, diameter and thickness.

Objectives of Metrology:
The basic objectives of metrology are;
❖ To provide accuracy at minimum cost.
❖ Thorough evaluation of newly developed products, and to ensure that components are within
the specified dimensions.
❖ To determine the process capabilities.
❖ To assess the measuring instrument capabilities and ensure that they are adequate for their
specific measurements.
❖ To reduce the cost of inspection & rejections and rework.
❖ To standardize measuring methods.
❖ To maintain the accuracy of measurements through periodical calibration of the instruments.
❖ To prepare designs for gauges and special inspection fixtures.

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Experiment # 01
To measure the length and diameter of simple pins with the help of Vernier
caliper.
Objective:
The objective of this experiment is to measure the length and diameter of simple pins with the help
of Vernier caliper.

Apparatus:
❖ Vernier Caliper
❖ Pins of different diameters

Theory:
Vernier calipers are used to measure inner and outer diameters of cylindrical rods and spheres and
thickness of any kind of object. The Vernier caliper can also be used to measure depths of holes
and objects which can be very difficult to do with any other scale. This is done through the depth rod
which is attached at the end of the Vernier caliper.

Labelled diagram:

Parts
❖ Upper Jaws of Vernier caliper are smaller in size as compared to lower jaws. One of
these jaws is fixed and the other is movable. These are employed to measure the inner
dimensions of hollow objects such as boxes, pipes, etc.
❖ In Lower Jaws one of the lower jaws is attached to the main scale and is fixed. The
other is attached to the Vernier scale and is movable. These jaws help in measuring the
outer dimensions of the objects. .com

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❖ Main Scale runs along the Vernier caliper’s body and is stationary. It is either in
centimeters, millimeters or inches.
❖ Vernier Scale attached to the main scale, this is smaller in size. It can move along the
main scale when the jaws of Vernier scale are opened or closed. It offers accurateness
to the reading of the main scale by dividing its tiniest reading into increments.
❖ Depth Rod is attached to this instrument to gauge the depth of holes and other deep
places or objects. It is a thin rod placed at the end of the main scale. It slides with the
main scale when the jaws open. It is extended till it reaches the bottom and then the
reading is taken.
❖ Lock Screw is used for fixing the position of the jaws after the object is appropriately
positioned. This is done to ensure accurate reading.
❖ Thumb Screw is positioned at the bottom of the Vernier scale. It offers grip so that the
jaws can slide and adjust with ease.

Least count
The smallest value that can be measured by the instrument is known as Least count of Vernier
Caliper.
This can be calculated by using relation;

𝑽𝒂𝒍𝒖𝒆 𝒐𝒇 𝒔𝒎𝒂𝒍𝒍𝒆𝒔𝒕 𝒅𝒊𝒗𝒊𝒔𝒊𝒐𝒏 𝒐𝒏 𝑴𝒂𝒊𝒏 𝑺𝒄𝒂𝒍𝒆

Least Count =
𝑻𝒐𝒕𝒂𝒍 𝒏𝒐.𝒐𝒇 𝒅𝒊𝒗𝒊𝒔𝒊𝒐𝒏𝒔 𝒐𝒏 𝑽𝒆𝒓𝒏𝒊𝒆𝒓 𝑺𝒄𝒂𝒍𝒆
The least count of imperial Vernier calipers is usually 0.001 in, whereas the resolution/least
count of metric calipers is either 0.05mm or 0.02mm.

Working principle
First determine the least count of Vernier caliper. Bring the moveable jaw close the fixed jaw to
check zero error. Do it three times to get accurate zero error. Open the jaws and place the
workpiece between jaws. And tight the jaws with screws attached the Vernier scale. Mark the
zero and note main scale reading and Vernier scale divisions coincides with main scale
divisions. Now use relations to get final reading.
Formulae for calculating total reading with the help of Vernier caliper

Total reading = 𝒎𝒂𝒊𝒏 𝒔𝒄𝒂𝒍𝒆 𝒓𝒆𝒂𝒅𝒊𝒏𝒈 + (𝒍𝒆𝒂𝒔𝒕 𝒄𝒐𝒖𝒏𝒕 𝒐𝒇 𝒗𝒆𝒓𝒏𝒊𝒆𝒓) (𝒗𝒆𝒓𝒏𝒊𝒆𝒓 𝒅𝒊𝒗𝒊𝒔𝒊𝒐𝒏𝒔
𝒄𝒐𝒊𝒏𝒄𝒊𝒅𝒆𝒔 𝒘𝒊𝒕𝒉 𝑴𝒂𝒊𝒏 𝑺𝒄𝒂𝒍𝒆 𝒅𝒊𝒗𝒊𝒔𝒊𝒐𝒏𝒔)

Procedure:
❖ Got the pins which have a varying diameter.
❖ Measured the diameter of each pin at its one point in mm as well as in inches.
❖ Change in diameters of pins.
❖ Construct the table which contains the diameter of some point of different pins.

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Observations and Calculations:

No of Main scale Vernier scale Y=VSR * L.C Total=MSR +Y
obs reading reading
1 25 5 0.25 25.25
2 25 5 0.25 25.25
3 25 5 0.25 25.25
4 25 7 0.35 25.35
5 25 3 0.30 25.30
6 25 4 0.20 25.20
7 25 5 0.25 25.25
8 25 5 0.25 25.25
9 25 4 0.20 25.20
10 25 5 0.25 25.25

Comments:
The change in the diameter of pins was observed during the experiment, it was mainly due to

❖ Some personal errors while measuring diameter.

❖ Error may be occurring due to zero error of the calipers.
❖ Poor Calibration of calipers.

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Experiment # 02
To develop the given dimensions with the help of Gauge blocks/Slip Gauges.
Objective:
The objective of this experiment is to develop the given dimensions with the help of Gauge
blocks/Slip gauges.

Apparatus:
❖ Set of Gauges
❖ Tray (Petrol + Tissue Paper + Petroleum Jelly)

Theory:

❖ Slip gauges were first developed by Johnson, and sometimes also called as ‘Johnson Gauge

Blocks’.
❖ Gauge block is a length standard having flat and parallel opposing surfaces. The standard
does give suggested dimensions for rectangular, square and circular cross sections.
Gauge blocks have nominal lengths defined in either the metric system (millimeters) or in
the English system.
❖ Slip gauges are the universally accepted ‘standard of length’ in industries. These are the simplest
possible means of measuring linear dimensions very accurately.

Need of Slip Gauges:

For tool-room and other precision work, the ordinary methods of measurement are not always

accurate. Micrometer and vernier caliper can be used to check tolerance fine within 0.002 to 0.02

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mm, but for fine tolerance they are not effective. Thus there is a need of instrument which can

measure fine tolerance limit.

Grades of Accuracy of Slip Gauges:
Slip gauges are made in five grades of accuracy. Calibration grade, grade 00, grade 0, grade I, and

grade II, in the decreasing order of accuracy.

Grade 0, grade I, grade II are used for general workshop purpose and are known as working gauge

blocks, whereas, calibration grade (master gauge blocks) and grade 00 (Inspection gauge blocks)

are used only for checking other types of blocks.

Wringing Process:
If two blocks are twisted together under certain pressure, it will be found that due to molecular

attraction and atmospheric pressure they will adhere to each other quite firmly. This process is

known as wringing. This Process is very useful to produce a required size by assemble several

gauge blocks.

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Procedure:
❖ First, check the measurements and then choose accordingly the slip gauges to combine.
❖ For wringing Effect, clean the slip gauges before joining with tissue soaked with petrol in a
tray.
❖ After this, join the two slip gauges while rotating one slip gauge on the other for just one
time.
❖ By using this technique, make all the required sizes.

Observations and Calculations:

Gauges Used

Sr. Req. G1 G2 G3 G4
Dimensions
1 20.87 1.007 1.08 18 0
2 25.005 1.005 24 0 0
3 28.09 1.09 25 2 0
4 22 22 0 0 0
5 31.002 1.002 20 10 0
6 31.079 1.009 1.07 20 9
7 11.134 1.004 1.03 1.1 8
8 3.781 1.001 1.08 1.7 0
9 5.341 1.001 1.04 1.3 2
10 7.412 1.4 1.002 1.01 4

Comments:
❖ Block gauges should pressed Sufficient so as to make strong bond between
gauges.
❖ Always put smaller gauge on larger, So that they can be easily pressed

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Experiment # 03
To measure the internal and external angle of workpiece with the help of Bevel
Protractor.
Objective:
The objective of this experiment is to measure the internal and external angle of workpiece with the
help of bevel Protractor.

Apparatus:
❖ Universal Bevel Protractor
❖ Workpieces

Theory:
Bevel protractor is also called universal bevel protractor. It is one of the simplest instruments for
angular measurement. It is a direct type of angular measuring instrument. The range of this
instrument is 0 to 360 degrees i.e. it can measure angles up to 3600 which any other angular
metrological instrument cannot measure.

Labelled diagram:

Main parts:
Main parts of bevel protractor are:

❖ Fixed Base blade and a circular body is attached to it.

❖ Adjustable blade.
❖ Blade clamp/lock.
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❖ Scale magnifier lens.

❖ Acute angle attachment.
❖ Vernier and main scales
Construction:
It has two arms (Fixed blade and Adjustable Blade), which can be set along the faces and a circular
scale to indicate the angle between them. Workpiece is set in between these two arms (two blades,
fixed blade and adjustable blade), and the difference of two scale (main scale and Vernier scale)
readings gives accurate measurement.

Working:
Magnifying lens has been provided for easy reading of the instrument. Main scale is circular and is
graduated in degrees on the circular body. Main scale graduations are all around the circular body
which is attached to fixed base blade. Fixed base blade also called as stock is attached to circular
body of bevel protractor as shown in figure. Once the reading is fixed, blade clamp fixes the reading.
Blades are about 150 mm long or 300mm long, 13mm wide and 2mm thick. Its ends are beveled at
angles of 45 degree and 60 degree. Vernier scale is also marked on turret which can rotate all over
the fixed body. Adjustable blade can pass through the slot provided in turret. So as the turret rotates,
adjustable blade also rotates full 360 degrees. There are 12 graduations of Vernier scale starting
from 0 to 60o on both sides of zero of Vernier scale as shown in fig below.

Least count:
Least count can be determined by relation as:
Least Count = 𝑠𝑚𝑎𝑙𝑙𝑒𝑠𝑡
𝑑𝑖𝑣𝑖𝑠𝑖𝑜𝑛 𝑜𝑛 𝑀𝑎𝑖𝑛 𝑆𝑐𝑎𝑙𝑒
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜.𝑜𝑓 𝑑𝑖𝑣𝑖𝑠𝑖𝑜𝑛𝑠 𝑜𝑛 𝑉𝑒𝑟𝑛𝑖𝑒𝑟 𝑆𝑐𝑎𝑙𝑒
Applications:
1.For measuring acute angle of shapes 2. For checking ‘V’ block

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Procedure:
❖ Unscrew the large clamp on the front protector. This loosens the blade, so that you can swivel
it.
❖ Align the base of the protector on one side of the angle, and then swivel the blade to form
the other side of the angle. Tighten the large clamp.
❖ Find the zero on the Vernier scale. The Vernier scale is the smaller on the inside of the
protector.
❖ Read the number on the degrees on the main scale, directly above the zero on the Vernier
scale. Say, for example, the zero on the Vernier scale lines up with the 85-degree mark.
❖ Read the minutes on the Vernier scale. The minutes are found by looking counterclockwise
on the Vernier scale, and noting the first place where the line on the Vernier scale lines up
exactly with the line on the main scale. For example, the first line to match up with a main
scale line is 30. This is measured in minutes, so the measurement is 30.

Observations and Calculations:

No of Shape Corne Main VSR L.C MSR+VCR Internal External
obs s r Scale *L.C=Tot angle angle
reading
1 1 122 10 5 120.5 239.5 120.5
2 2 120 5 5 120.25 239.75 120.25
3 3 118 20 5 118.1 241.9 118.1
4 4 119 30 5 119.15 240.89 119.15
5 5 120 20 5 120.1 239.9 120.1
6 6 120 0 5 120 240 120

1 1 93 0 5 93 267 93
2 2 53 15 5 53.75 305.25 54.75
3 3 34 30 5 34.15 325.85 34.15

Comments:
❖ Easy to use.
❖ End and line standards are affected by temperature difference.
❖ Angle gauges are made of high grade cast steel.

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