nswers Metrology and Measurements - Questions and A\ a QUESTIONS WITHOUT ANSWERS: 4. Write down the differences between Precision &Accuracy, 2. Differentiate random errors from systematic errors. 3. Explain the types of errors with examples. 4. Explain the causes of errors with suitable examples. 5. Explain the classification of measuring methods. 6.Draw the block diagram of generalized measurement system and explain different stages with examples. 7.Distinguish between Repeatability and reproducibility. 8. inguish between Systematic and random errors. 9.List various types of measuring instruments and explain each one of them. 10.List the various measurement methods and explain. 11.Briefly discuss on the applications of measuring instruments. 12.What are the Fundamental Methods of measurements? 14.What are the Classification Methods of measurement instruments? 16.Explain the working principle of mechanical comparator with a neat sketch. 20.Explain the construction and working of floating carriage micrometer. 21.What is measurement? Give its types. 22.Define Resolution. 23.Define Sensitivity. 24.Define Threshold. 25.Define Drift. 26.Define measurement. 27.What are the elements of generalized measurement system? 28.Define ‘precision and ‘accuracy’ 5071 = Question Bank of Prof. Dr, AHMED M.EASAyetrology and Measurements - Questions and Paracrerat 2014 29.What is hysteresis? 30.Define systematic errors, 31.Define random errors, 32.Draw the biock diagram of generalized measurement system and explain different Stages with examples. 33.Distinguish between Repeatabili 'y and reproducibility 34.Distinguish between Systematic and random errors. 35.Distinguish between Static and dynamic response. 36.Describe the different types of errors in measurements and the causes. 37.List the various linear measurements. 38.What is the Range of measurement? 39.Differentiate between sensitivity and range with suitable example. 40.Define system error and correction. 41.State and explain the “Taylor’s principle of gauge design’. 42.Explain the following in connection with gauge design: (1) Gauge maker’s tolerance (2) Wear allowance. 43.Shafts of ¢ 75+ 0.02 mm diameter are to be checked by the help of a Go, Not Go snap gauges. Design the gauge, sketch it and show its Go size and Not Go size dimensions. Assume normal wear allowance and gauge maker’s tolerance. 44.Determine the dimensions of hole and shaft for a fit 30H7 h8. 30mm lies between 18 and 30mm. What is the type of fit? 45.Define: Measurements. 48.Define True size. 47.Give any four methods of length measurement. 48.Give classification of measuring instruments. 49.Define Actual size. 50.Define the span.Metrology and Measurements - Quest ae 51.Differentiate accuracy and Uncertainty with example, 52.Differentiate between precision and accuracy. 53.What is Scale interval? 54.Define Repeatability. 55.Explain the term of magnification. 56.Classify the Absolute error. 57.What is Relative error? 58.Classify the errors. 59.What is the basic Principle of measurement? 60.What is the need of inspection? 61.What are the important elements of measurements? 62.What is LEGAL METROLOGY? 63.List the various linear measurements? 64.What are the various types of linear measuring instruments? (Draw and explain one type). 65.Mention any two disadvantages of reed type mechanical comparator. 66.Write short notes on: (i) Sensitivity. (ii) Calibration. Precision. (iv) Interchangeal 'y. 67.With neat diagram explain the construction and working principle of depth micrometer? 68.What types of measuring systems are used for linear distance? 69.Determine the dimensions of hole and shaft for a fit ° 50H7- h8. 70.What is the type of fit? - What is the Rang® ol measurement?: 71.Give classification of measuring instruments. ere S509Page EDjeasurements - Questi 09) and Mi luestions and Answers 2014 fe 1 out any four angular measuring instrum tr 0109" —_ ent used in 13. What IS foeuuaunlalference between linear measurement. and angular hat is the advantage of i 4. Wi of using |, . interferometry? moo bean 75. State “Taylor’s principle of gauge design”. 76, State any two limitations of sine bar. 77.4100 mm sine bar was used to measure the taper angle ofthe specimen and the gauge block was 5.055mm. What is the taper angle? 78.What is the need of calibration? Explain the classification of various measuring methods. 79.State and explain the “Taylor’s principle of gauge design’. 80.Differentiate accuracy and Uncertainty with example. 81.Define: Actual size and True size. ity and range with suitable 82.Differentiate between sensiti example. 83.Differentiate between precision and accuracy. 84.Explain the magnification term. What is Scale interval. %6.What are the important elements of measurement What is the need of inspection ? '8.What is the comparators? Draw one type © ts? | | £ mechanical ; Comparators. 9.Classity pneumatic comparators. of micrometer. “Explain a method for determine zero or. interference fit- “.Wefine the following: loose fit - slide ft - PUSh Fit, it the basic size of the fii a push, AHMED M.EASAMetrology and Measurements Questions and Answers aera If the tolerances quoted are 62, 0 for the hole i 10--mm. cone Le eo Find the upper limit and lowe, and -80, -180 for the shaft. limit of the shaft and minimum clearance. 93.Determine and sketch the limits of tolerance and allowance for a 25 mm shaft and hole pair designated Hg _ d9. The basic size lies in the range of 18-30mm. a. State the working principle of an electronic comparator. 94.Mention the important parts of an electronic comparator, 95.Classify pneumatic comparators. 96.What are the advantages of electrical and electronic comparator. 97.What are the disadvantages of electrical and electronic comparator? 98.List the various parts of an optical comparator. 99.What are the advantages of pneumatic comparator? 100.What are elements of a measuring system? How they affect accuracy and precision? How error due to these elements are eliminated. 101.With neat sketch explain the construction and working principle of differential pneumatic comparator. 102.Describe the working principle, advantages and disadvantages of optical comparators. 103.0n what basis the transducer works? 104.How is the accuracy of an electrical comparator checked? 105.Classify pneumatic comparators. 106.What are the advantages of electrical and electronic comparator? 107.What are the disadvantages of electrical and electronic comparator? 511Page _ Bank of Prof. AHMED M.EASAology and Measurements - Questions and Answers eS 2014 ,96.tist the various parts of an optical comparator. 4o9.What are the advantages of pneumatic ,10.Describe the working Principle, disadvantages of optical comparators, comparator? advantages and 111.What is the constructional difference between an autocollimator and an angle dekkor? 112.How the displacements are measurement using laser interferometer. 113.Explain with the help of neat sketches, the principle and construction of an auto-collimator. 114.Explain the working principle of oto-mechanical comparator with a neat sketch. 115.Explain the working principle of Electrical comparator with a neat sketch. 116.Explain the working principle of pneumatic comparator with a neat sketch. 117.Explain with the help of neat sketches, the principle and construction of an Angle dekkor. 118.Classify the comparator according to the principles Used for obtaining magnification. 119.Explain the working principle of Electrical comparator with a neat sketch. 120.Explain the working principle of pneumatic comparator with a neat sketch. 121.What is the comparator? a 122.classity the comparator according to the principles “Sed for obtaining magnification. : 123.How the mechanical comparator works in 124.State the best example of a mechanical comparator. HMED M.EASAMetrology and Measurements - Questions and Answers: Ta 125.How the mechanical comparator is used? State with Cy one example. 426.State some advantages of reed type mechanica| comparator. a 127.Define : Precision and Interchangeability. 128.Explain with the help of neat sketches, the Principle and construction of an Angle dekkor. 129.Explain with the help of neat sketches, the principle ang construction of an auto-collimator. 430.What are the considerations while manufacturing the slip gauges? 131.How do you calibrate the slip gauges? 132.Name the various types of pitch errors found in screw. 133.Define Drunken thread. 134.What is the effect of flank angle error? 135.What is the effect of helix angle error? 136.Define periodic error. 137.The outside diameter of a gear is 100mm and the number of teeth is 50, what is the module of gear? 138.Define lead angle. 139.Name four gear errors. 140.Define concentricity. 141.What is the use of Stylus Probe? 142.Explain the construction and working of floating Carriage micrometer. 143.How are the major and minor diameters of thread measured? 144.Define various terminologies related with screw threa”srology and Measurement westi i jons and Answers 2014 445.Define various terminologies related with screw geai 446.Explain any two taper measurements method ant 447.Explain the construction and i F working of ie 9 of Gear tooth 448.Briefly explain various terminologies used in a screw thread. 149.Name different types of Interferometers. 150.What is crust and trough? 151.What is CMM? 152.Mention four types of CMM. 153.Mention advantages of CMM. 154.State applications of Reverse Engineering. 155.What is the advantage of using Laser Interferometry? 156.Define Straightness. 157.Define Flatness. 158.Define Surface Finish. 159.Explain a method used in the measurement of surface finish and flatness. 160.Briefly explain Com! devices. 461.Explain the working of Leven ter ote a i es of = aes See rvadonal features and application of cm. puter Aided inspection and Digital i rious methods of measuring torque. 164Briefly excplelalees ats methods of measuring 165.Briefly expla! temperature-Metrology and Measurements - Questions and Answers aon 166.Briefly explain various methods of measuring flow. 4167.Briefly explain various methods of measuring power, 168.Briefly explain various methods of measuring force, 469.Explain working of Pressure thermometer resistance thermometer. 170.Explain the construction and working of Venturimeter and Rotameter. 471.Explain the construction and working of Bimetallic strip and Thermocouple. 172.Define force. 173.What are Load cells? 174.Give the basic p! ple of equal Arm balance. 175.Give the basic principle of strain Gauge Load Cell. 176.Give some bimetallic strip metals. 177.What are the metals used in Thermocouple? 178.What is the principle behind Thermocouple? 179.Name any four flow meters. 180.Define Coefficient of Discharge. 181.Write in short steps the study of pressure losses in pipe flow using an experiment. 182.Describe the tools which used for estimate pressure losses in pipe flow. 183.Write in short steps one method used for Flow rate measurements. and 184What are the objectives of the experiment used for flow rate measurements. 185.What are the characteristics of Venturi and orifice Meters.(Draw). 186.What othe the characteristics of Rotameter. t 187.Explain the steps used for Flow rate measureme”yology and Measurements - Questions and Ancwe, we! rs 2014 ' pressure Head. , ii. Velocity Head and 4g9.Define Loss Coefficient, . Define Coefficient of pj. ae ance in flow rat Discharge and what Its signific: ‘© measurement, 4g1.Write the Procedure used for Calib Gages-(Draw). 492.Write in four points report about Calibration of Pressure Gauges- 193.Draw the Apparatus which are used for verifying the Bernoulli Equation. 194. Write in four points report about Bernoulli Equation. 195. What are the tools you need for Recording and measuring temperature of some Materials. 196. What is the method used for Recording and measuring temperature of some Materials.( using the thermometer). 197.In two points only analyze the results of using the thermometer in temperature measurements. 198.Using Resistance Temperature panei »write 2 short sentences the procedure of Temperature eee Ss. 199.Draw and explain the RTD Sensor in Bridge Circuit. 200, TINUM RTD. pe Draw the Ee in some of RTD specifications. 201.In short notes explain ss Z "4c the limitations of RTDs accuracy. 202. Write in six points ' ications of Resistance Temperature 203.What are the Applic Detectors. : ce Temperature Detectors are USED? pee When pacers advantages and disadvantages of 05.What are tectors? Resistance Temperatir am 206.which one of pera Detector or THEFM? 207.what is the Elevation Head. ration of Pressure more used: Resistance Temperature (why)- edure of Thermistor. ental Proc Experim'~S jons and Answers Metrology and Measur 2014 208.What is the Experimental Procedure of Thermocouple? 209.Draw Experimental setup for Thermocoupig measurements. 210.Write the Principle of operation when useq Potentiometer. 211.Write the absent elements in the following draw: 212. What are the characteristics of Potentiometers. 213. What are the characteristics of Linear variable displacement transducer. 214. Write the absent elements in the following draw: or Core Coil (3) voli (4) oill5) >il(3) coil 4) Soul / 215.What is the construction of LVDT. 216.Explain the Operation method of LVDT. 217.Write abstract about the Sonic and ultrasom’ transducers. |vay 08 measurements - Questions and Answers 2014 yenrte the absent elements in the following draw: Boat Transmutte (3) 119.Write the absent elements in the following draw: ~_ coaxial Cavie Connector ~~ signal Wre Ground Wire (2) Pulse-echo transducer 20.Write about the principle of operation for Capacitance tispta icement sensor. ay We the Principle of operation for Laser - ie acme Bee ts in the following draw: 22. Write the absent efemenMetrology and Measurement “4 Transmitted Laser (1) Photodetector 223.Write about the Principle of operation for Strain-gauge accelerometer. 224.Write the absent elements in the following draw: [bisection of (1) Housing 225.Write about the Principle of operation for Piezoelectric accelerometer. 226.Write about the Principle of operation for Servo accelerometer. 227. Write the absent elements in the following draw:y and Measurements - Questions and Answe rs 2014 (3) () 28. Write about the Principle of operation for Contacting tachometer. 29. Write about the Principle of operation for Stroboscopic tachometer. 20. Write the absent elements in the following draw: (2) pulley. ete ‘painted dot or mark = \ @) .2014 logy and Measuremen NTS: DIFINITIONS AND TOOLS OF MEASUREME! 1. Differentiate between precision and accuracy. Accuracy - The maximum amount by which the result differ from true value. F ; Pres n - Degree of repetitiveness. If an instrument is not precise it will give different results for the same dimension for the repeated readings. 2. What is Scale interval? It is the difference between two successive scale marks in units. 3. Define Repeatability. The ability of the measuring instrument to repeat the same results g the act measurements for the same quantity is known as at ability. 4. What is the basic Principle of measurement? It is the physical phenomenon If energy kind of quantity mea measure it. So this wil number of that unit. utilized in the measurement. ‘sured, there must be a unit to ve the quantity to be measured inMetrology and Measurements - Questions and Answers aura 5. What are the applications of Legal metrology? 4. Industrial Measurement. 2. Commercial transactions 3. Public health and human safety ensuring. 6. What is the need of inspection? To determine the fitness of new made materials, products or component part and to compare the materials, products to the established standard. 7. What is Response time? The time at which the instrument begins its response for a change measured quantity. 8. Explain the term magnification. It means the magnitude of output signal of measuring instrument time’s increases to make it more readable. AHMED M.EASAwestions and Answers 2014 Metrology and Measurement 9. What are the important elements of measurements? The important elements of a measurement are: 4. Measurand 2. Reference 3. Comparator. 10. What is LEGAL METROLOGY? Legal metrology is part of Metrology and it is directed by a National Organization which is called "Notional service of Legal Metrology". The main objective is to; maintain uniformity of measurement in a particular country. 11. What is Range of measurement? The physical variables that are measured between two walues: One is the higher calibration value H, and the other is Lower value L. The difference between H, and L, is called range. : 12. What is Resolution? The init i id ea value of the input signal is required to cause Ppreciable change in the output known as resolution.Metrology and Measurements - Questions and Answers A 014 13. Differentiate between sensitivity and range with suitable example. Example: A Instrument have a scale reading of 0.01mm to 100mm. Here, the sensitivity of the instrument is 0.0Imm i.e. the minimum value in the scale by which the instrument can read. The range is 0.01 to 100mm i.e. the minimum to maximum value by which the instrument can read. 14, Define system error and correction. Error: The deviation between the results of measured value to the actual value. Correction: The numerical value which should be added to the measured value to get the correct result. 15. Define: Measurand. Measurand is the physical quantity or property like length, diameter, and angle to be measured. 16. Define: Deterministic Metrology. The metrology in which part measurement is replaced by Process measurement. The new techniques such as 3D error compensation by CNC systems are applied. Question Bank of Pro! HMED M.EASA_ns and Answers 2014 Metrology and Meas 17.Define over damped and under damped system. The final indication of measurement ii Over damped : ‘ approached exponentially from one side. Under damped : The pointer approach the POSition corresponding to final reading and makes a number g oscillations around it. 18.What are the considerations while manufacturing the slip gauges? The following additional operations are carried out to obtain the necessary qualities in slip gauges during manufacture. 1. First the approximate size of slip gauges is done by preliminary operations. 2. The blocks are hardened and wear resistant by a special heat treatment process. 3. To stabilize the whole life of blocks, seasoning process is done. 4. The approximate required dimension is done by a final grinding process. 19. List the various linear measurements and draw. (i) Length (ii) Heights and (iii) Thickness. 9Page Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements - Questions and Answers 2014 Length and Thickness. Spindle clamp ) /~ Fiducial tine a Length and Thickness. 10Page Question Bank of Prof. Fs auestions and Answers: 2014 Metrology and Measurement Spindle face Sleeve Thimble Look nut | { Length and Thickness.2014 Thickness. Metric steel! rules (Length). 12Page Question Bank of Prof. Dr. AHMED M.EASA ».uestions and Answers 2014 Metrology and Measurement: Guiding edge _ Beam face _-> Beam __— Fine adjustment clamp Scales Upper face of jaw— — — Slider clamping measuring face) screw Measuring jaw Lower face of jaw” ine SUA Depth of measuring | Jew _- Base Vernier Height Gauge (Height). QuestionMetrology and Measurements - Questions and Answers 2014 20.What are the various types of linear measuring instruments? The various devices used for measuring the linear measurements are i. Vernier calipers rometers iii. Slip gauge or gauge blocks iv. Comparator.(See the previous figure). 21.Draw and explain the offset caliper. The jaw on the head end of the main scale of offset calipers can be vertically adjusted by loosening a clamp screw. This makes it possible to measure dimensions on stepped work pieces that cannot be measured with standard types of calipers.Metrology and Measurements - Questions and Answers eon 22. Draw and explain the calipers of swivel jaw. ive This type of caliper has a jaw that can be rotated by +90 about an axis that is parallel with the line of measurement, It can measure stepped work pieces and shafts having off. centered sections that cannot be measured with standard types of caliper. 23.Draw and explain the long jaw caliper. Outside measuring face SSmpSee S Vernier clamp serea Reference surface Jaws.Metrology and Measurements - Que: ions and Answers pore This type of caliper has longer fixed and sliding jaws than standard types of caliper. It can be used to measure inside diameters of deep holes and large outside diameters that cannot be measured with standard type callipers. The standard jaw lengths of this type of caliper are 90 mm for a caliper with a measuring range of 300 mm and 200 mm for one with a measuring range of 500 mm. 24, Draw and explain the dial Calipers of constant force. FT ned XA (we. we L Stopper \F 4 vb Polymer materials are now extensively used for machine parts and require accurate dimensional measurement. Because these materials are often soft, they can be deformed by the measuring force applied by ordinary calipers and micrometers, resulting in inaccurate Measurements. Constant force dial calipers have Consequently been developed to allow the measurement of materials that are easily deformed. Question Bank of Prof. Dr. AMetrology and Measurements - Questions and Answers oon 25.Draw and explain the offset calipers for hole distance measurement. This type of caliper has cone shaped jaws (cone angle 400) to facilitate the measurement of the center line distances between holes (with the same or different diameters), between holes on different surfaces on a stepped workpiece or the distance from a datum face to the center of a hole. 26.Explain the caliper performance. No measuring instrument can be manufactured to be absolutely free from errors. As the accuracy requirements of a measuring instrument become higher so the difficulty manufacturing increases and the manufacturing costs rise accordingly. Therefore, measuring instruments should be selected according to the accuracy requirement of the intended application. It should be noted that even if a very accurate instrument is used, measurement errors still may still occur due to variations in environmental conditions and e Question Bank of Prof. Dr. AHMED M.EASAy and Measurements - Questions and Answers 2014 Met operator errors. The instrumental error (deviation of reading) is the error that is inherent to a measuring instrument. In other words, it is the difference between the true value and the measured value, when a measurement is taken under the standard conditions specified for that instrument. It is important to know the instrument error because by compensating for the error more accurate measurements can be obtained. Instrumental errors are determined by calibration and are usually given in the inspection certificate or technical specifications that are supplied with the instrument. When compensating a measured value for the instrumental error, you need to change the sign of the instrument error value and add it to the measured value. The Performance of caliper is checked according to the following procedures. 27. Explain how you evaluate the different errors of outside calipers. Insert a gauge block between the two faces used for external measurement. Record the reading. Determine the instrumental error by subtracting the calibrated dimension of the gauge block from the reading on the caliper. This test should be performed at a minimum of five approximately equally spaced positions covering the measuring range of the main scale and the Vernier scale. Check the parallelism of the faces by inserting a gauge block at different points on the jaw. The use of a second gauge block of different length allows this test to be performed at two positions in the measuring range. One on should be close to zero and the other close to fullns and Answers 2014 Metrology and Measurements range. Check that parallelism is not affected by clamping the slider. The squareness of the fixed face to the guiding edge should be checked with a knife-edge square. The flatness of the faces should be checked with an optical flat. 28. Explain how you evaluate the different errors of inside calipers. Produce a known internal dimension using a gauge block and holding device and jaws from an accessory set. Measure the dimension between the jaws using the faces for internal measurement and record the reading. Determine the instrumental error by subtracting the dimension of the gauge block from the reading on the caliper. The parallelism of the faces for internal measurement should be checked with a micrometer with small diameter anvils. 29. Explain how you evaluate the Straightness of inside and outside measuring faces. Set a lever type dial indicator on a surface plate so that its contact point can move parallel to the outside and inside measuring faces of the caliper. Measure the straightness of the outside and inside measuring faces by sliding the dial indicator stand (see Figure below) and noting the change in reading. Question Bank of Pro!westions and Answers Metrology and Measurements Straightness of inside faces 30.How to Set-up and preparation the caliper for measurement. 4.Select the caliper that bests suits the application by ensuring that the type, measuring range, graduation and other specifications of the caliper are appropriate for the measurement to be made. 2.Check that the caliper calibration has not expired. If the ration has expired, use another caliper whose c calibration is valid. 3.Inspect the caliper measurement faces for signs of damage. Damaged callipers should not be used. 4.Before taking a measurement, remove cutting chips, dust, burrs, etc. from the workpiece. Make sure that the workpiece is at room temperature.Metrology and Measurements - Questions and Answers 2014 5.Wipe off any dust and oil from the caliper before use. Thoroughly wipe the sliding surfaces and measuring faces, using only clean lint free paper or cloth. 6.When measuring, slowly move the slider while lightly pressing the finger hold against the main scale. The slider should not feel loose or have any play. Correct any problems found by adjusting the pressing screw and setscrew on the slider (if fitted). Tighten the pressing screw and setscrew, then loosen them in a counter clockwise direction about 1/8 of a turn (45°). Check the sliding action again. Repeat the procedure while adjusting the angular position of the screws until an appropriate ing smoothness is obtained. 7.Check the zero reading. 31. Explain briefly the Steps of measurement on the caliper. Steps of measurement are as follows; 41.Close the jaws and set the caliper zero. 2.Open the calipers to a length larger than the size of the object to be measured. 3.Placed the fixed jaw in contact with the workpiece, which should be as close as possible to the main scale. 4.Align beam of caliper to be parallel with dimension to be measured and bring the sliding jaw into contact with the workpiece ensuring that the measuring faces are in even contact. Do not use excessive force to avoid distorting either the work piece or instrument frame. If a clamping screw is Question Bank of Prof. Dr. AHMED M.EASA2014 Metrology and Meas: fitted, use this to reduce angularity error. The clamping screw should not be regarded as a memory device. 5.Record the caliper reading. 6.Recheck the zero reading. If the zero is incorrect this may be a sign that a piece of dirt has transferred from the work piece to the caliper faces. Clean the faces and workpiece and repeat the measurements from step 1. Consistency of measurement may be gained by first using the caliper on a standard length bar assembly. This is particularly useful when the operator is required to ‘feel’ the jaws in contact with the item to be measured. Taking several measurements on any one dimension and mean can give extra confidence in for estimating the recording the measurements and is necessary uncertainty of measurement. 32.What are the Sources of uncertainty with calipers. The sources of uncertainty in using a pair of callipers will arise as defined in the following steps: a- not applying the corrections for calibrated errors of the calipers or relying on the caliper errors being within specification. b- Errors due to face flatness. c- Errors due to face parallelism d- Errors due to face squareness. e- Errors due to resolution. f- Errors of a random nature ascertained from repeated measurements. f Dr. AHMED M.EASAMetrology and Measurements - Questions and Answers 2014 6-The spindle should be easy to clamp. The micromete, reading should not change by more than 2 ym when the spindle is clamped. 7-The ratchet stop should rotate smoothly. 8-The clearance between the thimble and the sleeve shoulq be even around the circumferences. 9-The run out of the thimble should be minimal (should not be seen by the naked eye). 40-When the zero line on the thimble is aligned with the index line on the sleeve, the end of the thimble should be aligned with a graduation line on the sleeve but should not overlap the graduation line so as hide it. 38.Explain the steps of daily inspection to maintain micrometer accuracy. -Checking the zero point: Even if the zero point of a micrometer has been accurately adjusted, it may need to be adjusted again after a few hours use since changes in temperature and other environmental conditions can cause the zero point to change. -Checking the measuring force: A variation in the measuring force significantly affects the accuracy. For micrometers with a ratchet stop, check that the ratchet barrel turns smoothly and otherwise functions correctly. -Checking the fit: Check the fit of the spindle and spindle guide, and the threads of the spindle and inner sleeve. Make sure that the luestion Bank of Prof.Metrology and Measurements - Questions and Answers ae spindle and other threaded parts move smoothly and evenly over their entire traverse. Eliminate excessive play or backlash with the adjusting device (taper nut). -checking the micrometer after it has been dropped or subjected to a blow If the micrometer has been dropped or subjected to a blow, check the zero point, measuring force, fit conditions, run out of the thimble, parallelism between the measuring faces and the instrumental error. 39.Brefily describe the steps of Cleaning and rust prevention for micrometers. -After using the micrometer, wipe off oil, cutting or grinding fluid, fingerprints and contaminants (fingerprints may cause rust). Carbide tipped measuring faces should be wiped thoroughly with a dry cloth. If the measuring faces are not carbide tipped, wipe clean and apply a rust-preventing oil. Separate the two measuring faces slightly before storing the instrument. -Wipe cutting or grinding swarf from the spindle before using the micrometer as these particles may become trapped between the spindle and the spindle guide. -If a micrometer is not going to be used for an extended period of time, wipe it thoroughly and apply high-grade rust- preventing oil. Protect the micrometer from dampness by tightly wrapping the instrument with an oil soaked paper or cloth before putting it in the case. Select a storage place where humidity is low and temperature changes are smalMetrology and Measurements - Questions and Answers 2014 the micrometer has been stored for a long period of time, inspect it thoroughly before use. 40. Explain the methods of storage the micrometers. The following points should be noted when storing a micrometer. 1-When storing the micrometer do not expose it to direct sunlight. 2-Store the micrometer in a low humidity, well ventilated and dust free environment. 3-Leave the measuring faces separated by 0.1 mm to 1 mm. 4-Do not clamp the spindle. 5-Store the micrometer in a case. 41.Explain the methods of Maintenance and Periodic Inspection of micrometers. To enable effective quality control it is essential to preserve the measuring accuracy and performance of measuring instruments. Poor maintenance leads to poor quality control, which may result in considerable losses due to out of tolerance parts. For example an inaccurate rometer could result in an entire batch of products failing to meet specifications. Even worse, the shipped products might be sent back to the company because of their poor quality, resulting in the company's reputation and image becoming tarnished. Neglecting periodic inspection of measuring instruments may resul variations of measurements, which may resu! ee Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements - Questions and Answers Bord in problems arising between the design department, shop floor and inspection room. Proper maintenance cannot be maintained unless all employees concerned understand the importance of maintaining precision measuring equipment. As with any instrument, deterioration of micrometers is unavoidable after a long period of service. The degree of deterioration depends on the frequency of use, environmental conditions and handling. To implement a periodic inspection schedule the following must be established: 4- Inspection criteria (e.g. Manufacturers specification, National or International Standard or company internal mn). spection interval (dependent on usage and spe 2-Pel calibration history) 3-ltems and procedures of inspection (defined equipment and procedure documents). 4-Criteria for inspection result judgments (Pass/Fail rules). 42.Explain a method which used for special care when using and storing electronic micrometers. Because electronic micrometers can be easily damaged they require greater care than conventional micrometers. The following additional precautions must be observed: 41-Do not subject the micrometer to direct sunlight or ultraviolet (UV) radiation. UV radiation accelerates the deterioration of Liquid Crystal Displays (LCD). 2-Do not subject the micrometer to sudden changes of temperature, as this may cause internal condensation which Question Bank | | |Metrology and Measurements - Questions and Answers 204 could detrimentally affect the adhesive used in the assembly of the instrument. 3-Do not apply voltage to the damage the internal integrated circuits. For example do not use an electric marker pen on the instrument. 4-Electrical interference may cause failure or malfunction of electronic components. Micrometers that use the mains power via an alternating current (AC) adapter can be affected by electrical interference from other equipment that shares the same power outlet. Electromagnetic fields, current leaks and static electricity can also interfere with electronic rometer as this may micrometers. 5-Do not use an organic solvent to clean the surface of the micrometer, it may cause deterioration of the plastic parts, instead use a neutral detergent for cleaning. 6-Make sure the battery is orientated correctly, otherwise the micrometer will not operate and its electronic components may be damaged. If the micrometer is not going to be used for an extended period of time, remove the battery to prevent damage that may be caused by battery leakage. 7-If a fault occurs do not disassemble the micrometer but return it to the manufacturer for repair. 43.Draw and explain the one type of Dial indicator. Dial indicators are instruments used to accurately measure of a small distance. They may also be known as a Dial gauge, Dial Test Indicator (DTI) or as a “clock”. ee n Question Bank of Prof.Metrology and Measurements - Qui 2014 However the range between 1mm 0.040") and 50mm (2”) may be thought of as typical with a travel of 10mm (approx. 0.5") being perhaps the most common. ren es ee accion Rotate the bezel to j t Tighten to lock the zere the needle. bezel ‘Tune counter Counts the turns of the needle. Markers Move these to provide reference points. - | Point Can be replaced with other shapes. Plunger Moves in and out. 44,What are the different applications of different types of dial gauges. There are many applications for different types of dial gauges as follow; 1.In a quality environment to check for consistency and accuracy in the manufacturing process. 2.0n the workshop floor to initially set up or calibrate a machine, prior to a production run. 3.By toolmakers (mold makers) in the process of manufacturing precision tooling.ions and Answers 2014 Metrology and Measurements - Que: 4.In metal engineering workshops, where a typical application is the centering of a lathe's workpiece in a four jaw chuck. The DTI is used to indicate the run out (the misalignment between the work piece's axis of rotational symmetry and the axis of rotation of the spindle) of the work piece, with the ultimate aim of reducing it to a suitably small range using small chuck jaw adjustments. 5. In areas other than manufacturing where accurate measurements need to be recorded( physics). The dial indicator typically consist of (shown in figure before) a graduated dial and needle to record the minor increments, with a smaller embedded clock face and needle to record the number of needle rotations on the main dial. They may be graduated to record measurements of between 0.001" down to 0.00005" for more accurate usage. The dial face can be rotated to any position, this is used to orient the face towards the user as well as set the zero point, there will also be some means of incorporating limit indicators (the two metallic tabs visible in the right image, at 90 and 10 respectively), these limit tabs may be rotated around the dial face to any required position. The dial indicators are normally set up in a fixture (possibly a magnetic base) which would secure the dial indicator and allow its adjustment to read zero at the optimal size of a sample part. 45.Explain the set-up which are used for different operation of dial indicator. The following steps are used for different operation of dial indicator; eaeags ia Sa Question Bank of Prof. Dr. AHMED M.EASAns and Answers 2014 metrology and Measurements - Ques! 4, Attach dial indicator unit to magnetic base as shown in magnetic base diagram below. 2.Place the assembled unit on the out-feed table of your machine with the tip of the dial indicator touching top dead center of your parts making sure there is a slight amount of pressure on the indicator tip. Adjustments in pressure can be made by turning the micro-adjustment knob in the center of the magnetic base arm. 3.Turn the magnetic base to the "ON" position to secure the unit to your out-feed table. At this point using the thumb screw on the right side of the dial indicator set the dial to read "0" (Loosening the screw will allow you to rotate the face of the dial to any point you choose). 4. Slide the magnetic base unit so that while the dial indicator tip is in contact with the part. The measurements obtained should fall within the specifications set in your owner's manual. The dial indicator can be used also for measuring run-out on table of saw, drill press and many other shop items. 46. Drive example which explain how to read the dial gauge. The following reading is taken at one type of dial gauge has the following specifications: -Dial face has dual directional -Revolution counter is graduated in 0.1”. -One full revolution of large pointer is one increment of graduation of 0.001. revolution counter. 34Page. - uestions and Answers 2014 Metrology and Measurements Example: The small pointer is between 1. and 2. or between 6 ang 7=0.1. or 0.6. The large pointer is close to line 21 of black digit=0.021. So the reading is 0.1.+0.021.=0.121. Or 0.6.+0.021.=0.621 47. What are the Indicator components. The dial indicator components are as follow; Match the description with the corresponding part number in the illustration above. 1. The adjustable markers can be moved along the circumference of the dial. 2. The dial lock secures the dial face after being rotated around the indicator body. 3. On the scale, the distance be: 0.001" (one thousandths of an inch). 4. These numbers represent 0.010" inch). tween the lines equals (ten thousandths of an 5. The contact Point touches the 6. Each number on the dec: rotation of the needle and thousandths of an inch).(Se: surface to be measured. ade counter represents one full is equal to 0.100" (one hundred © figure below).48.What are the components of magnetic base. List of the magnetic base components is as follows(see figure): 4. The column supports the mounting assembly. 2. The lock knobs secure the mounting assembly after adjustments are made. 3. The indicator mounting stud fastens indicator to the boom. 4. The ON/OFF switch for the magnet. 5. The magnetic base. One mounting surface on the back and one on the bottom. 6. The fine-tune adjustment knob allows the indicator to be adjusted in small increments. 7. One of 2 pivot joints that allows articulation of the mounting assembly. ‘Question B: of. Dr. AHMED M.EASAns and Answers 2014 Metrology and Measurements 8. The boom supports the mounting assembly. Magnetic base components 49.What are the preparation (SET) of Dial Indicator for measurements. The indicator must be secured to the base prior to use(see figure 4). 1. Loosen the lock knob that secures the mounting stud to the boom and remove the stud. 2. Unscrew and remove the knurled nut and flat washer from the mounting stud, and insert the threaded end of the stud into the flange on the back of the dial indicator. The stud can be inserted from the left- or the right-hand side, depending on your mounting needs. 37P: ‘age _____ Question Bank of Prof. Dr. AHMED M.EASA a iMetrology and Measurements - Questions and Answers 2014 3. Attach the washer and thread the knurled nut back onto the threads on the stud. Insert the plain end of the stud into the pivot joint. Be mindful that this pivot joint has 2 holes and only one is sized correctly for the stud. Also, it may be necessary to rotate the sleeve on the pivot joint to correctly align the parts so the stud can be inserted. 4. Tighten the lock knob for the pivot joint. 5. Tighten the knurled nut with a flat blade screwdriver to lock the dial into place. 50.What are the basic operations of Dial Indicator for measurements. The dial indicator can be used in many ways and the magnetic base can be positioned on flat or round surfaces. The list below detail guidelines for use and see figure below also: 1. Use the ON/OFF switch on the magnetic base whenever moving the unit to help avoid marring the surface that it resting on and to prevent sudden jarring which could damage the internal components of the indicator. 2. Make adjustments to the support assembly only with the base magnetically secured to a steel or iron object. This will help guard against damage to the indicator should the base fi 3. Loosen the lock knobs to adjust the height and angle of the support boom. Trying to defeat the locks to move the indicator a small amount will cause premature wear on the system. Pagens and Answers ora Metrology and Measurements - Ques: try to lock the base after turning the switch to the 4. Gently, u sure that the setup is secure. ON position to en: 4 ” oy es; Movement of base components 51. Explain the Adjusting method of the Assembly of dial indicator. The magnetic base and indicator can be positioned in many ways. The bottom of the magnetic base is notched to allow for mounting to curve surfaces as well as having a ground, flat surface. The back of the base is ground flat for mounting as well- Care must be taken to secure the base to a suitable surface- r. AHMED M.EASA Question Bank of Prof.d Measurement 2014 uestions and Answers Metrology Hanging the base upside down or from the side of a machine may cause the unit to fall. Also, sheet metal may not have the mass need to properly support the unit. Dropping the dial indicator will reduce its accuracy and may make it unusable (See figures below). | | The indicator can be oriented in any direction By loosening the mounting stud ,loosening the boom and raising the boom along the column. i. Dr. AHMED M.EASAuestions and Answers Hin Metrology and Measurement Fine tuning the dial to read zero or any other reference point Is made easy with the fine-tune adjustment knob. 52. Probe type, Lever type and Digital type are three types of indicators, Draw and explain. They typically consist of a graduated dial and needle (thus the clock terminology) to record the minor increments, with a smaller embedded clock face and needle to record the number of needle rotations on the main dial.Metrology and Measure: its - Questions and Answers 2014 Probe type. A Lever arm test indicator or finger indicator has a smaller movement range (perhaps mm depending on the model) and measures the deflection of the arm, the probe does not retract but swings in an arc around its hinge point. A2Page ‘Question Bank of Prof. Dr. AHMED M.EASA / $e ASEuestions and Answers ee jogy and Measurement ronics and LCDs the clock face ang eplaced with digital displays, these ge of being able to record ang With the advent of electi analog display has been r have the added advanta transmit the data electronically to a computer. Digital type. 53.What are the uses of the dial indicator. They may be used in a quality environment to check for consistency and accuracy in the manufacturing process. -On the workshop floor to initially set up or calibrate 4 machine, prior to a production run. -By toolmakers (mold makers) in the process of manufacturing precision tooling. -In_ metal engineering workshops, where a_ typical application is the centering of a lathes workpiece in a four jaw chuck. The DTI is used to indicate the run out of themetrology and Measurements - Questions and Answers 2014 work piece, with the ultimate aim of reducing it to a suitably small range by small huck jaw adjustments. 54.Explain the method of read an angle using (a bevel protractor). Exampl -Main div. = 1° = 60°, r div. = 1/42th of main div. = 0.0833° = 5, -The highest figure: 50 * (main div.) = 50°, -The matching figure: 4 * (vernier div.) = 0.333° = 20°, -The final reading is: = 50.333° or 50° 20°. 55.List out any four angular measuring instrument used in metrology (i) Angle gauges (ii) Divided scales (iii) Sine bar with slip gauges (iv) Autocollimator (v) Angle dekkor. 56. Define the Inspection. It means checking the dimensions of the produced or under-process piece to compare it with the specified dimensional accuracy. Traditionally, measurements were made after the part has been finished, this is known as Post-Process Inspection. The Current trend is to make measuremy ent while the piece isQuestions and Answers 2014 Metrology and Measurement: under process. This is known as In-process or Real inspection. 57.What is the amount of time required for the inspection? -The amount of time required for the inspection depends on: 4. The nature of the product. 2. The degree of accuracy required, 3. Type of equipment used, and, 4. How skilled the operator is. 58. What are the basic requirements of the inspector? The basic requirements of the inspector should be: 41. Given an authoritative position for certain de 2. Ability to do his work. 3. Impartial, and 4. Good experience in his field. 59. What is the Measurement? It is the process of quantitative comparison between 4 predetermined standard and an unknown magnitude. Dr. AHMED M.EASAMetrology and Measurements - Questions and Answers 2014 60.What are the Conditions for acceptance of a measurement process? In order that the process of measurement may be acceptable, it may be as follow; 41. The procedure used in the process must be provable. 2. The apparatus used in the process must be provable. 3. The instrument used in the process must be correct, and, 4, The standard used for comparison must be correct. 61.What is Metrology ? -It is the field of knowledge that is concerned with measurement. 62.What are the principal fields of metrology? ‘The principal fields of metrology are: (A) Units of measurements and their standards (B) Measurement Process. (C) Instruments. (D) Observers. 63. What are the several parts of metrology? ‘There are several parts of metrology as follow; 1) General Metrology: It is the part of metrology that deals with problems common to all metrological fields irrespective of the quanti: ‘y to be measMetrology and Measurements - Questions and Answers Bate 2) Technical Metrology: It deals with problems of metrology in technology. 3) Quality Metrology: It deals with problems of quality control. 4) Theoretical Metrology: It deals with the theoretical problems measurement. 5) Legal Metrology : It deals with all aspects of measurement e.g. instrument, process units in relation to the mandatory (legal and technical) requirements with the main aim of ensuring public safety and appropriate accuracy. 64, What is the Fields of sciences needed for metrology? -Fields of sciences needed for metrology. This branch of science requires sound knowledge in certain basic mathematical and physical principles. Some knowledge of applied mathematics, mechanics and physics are considered an asset to the proper understanding of the operation of instruments and the design of the gauges and measuring equipment. Some of the fields of sciences that are required are: 1) Mathematics: since most of the calculations used in metrology are trigonometrically in nature and the majority can be solved involving the right angle triangle rules. Further, most of the equations involved are linear in nature and can be easily solved using elementary rules of algebra. 2) Mechanics: from this branch of science we are mainly interested in the theory of elasticity of materials. ‘47P; ag Question Bank of Prof. Dr. AHMED M.EASAmetrology and Meas! 2014 This theory tells us among many other things that nothing is rigid or unchangeable in shape and position. This fact is extremely important when accuracy is of utmost importance e.g. accuracy of about 1/1000 mm. 3) Optics: though this is not so strictly within the realm of metrology, however, most of the modern instruments utilize optical principles in their operation. Basic knowledge of reflection and interference of light is needed. 4) Heat and temperature: this part of the science is one of the greatest problems in the science of metrology as it affects the precision of measurement. This is due to the fact that most of the materials change their dimensions as their temperature changes, which affects the accuracy of measurement. Therefore, the standard temperature for engineering measurement is 20 °C (68 °F) and all accurate measurements should be made within this temperature range. 65. What is the relation between Metrology and inspection? -All engineers, regardless of their field of specialization, are constantly faced with the problem of measurement. It may be of length, time, temperature ...etc. ‘Almost invariably, the result of this measurement process will decide the next course of action to be taken by the engineer. Therefore: 1) The purpose of measurement is to provide service of certain type to enable certain decisions to be taken. This Service is not completed. Question Bank of Prof.Metrology and Measurements - Questions and Answers 204, 2) The accuracy of measurement is attained as requirey Therefore, it is necessary not only to state the quantity to be measured, but also the degree of accuracy to which the measurement process has been executed. 3) The operator has to have a sound knowledge of the systems used and followed by different countries. 4) The operator has to use the proper standard in the proper way. 66. What are the Classification Methods of measurement instruments? The Classification Methods of measurement instruments. Most of the mechanical measurements can be classified as: 4) Based on their operational method: -Self-operated type and Power type. 2) According to the arrangement of its parts: -Remote sensing and Self-contained. 3) Based on the nature of their operation: -Manual type and Automatic type. 67. What are the Fundamental Methods of measurements? Based on the nature of comparative procedure used in the measurement they can be classified as: 1. Direct method. In this method the parameter to be measured is directly compared with either a primary or secondary standard. 2. Indirect method. —- eee nS — aaeags) _ Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements - Questions and Answers 2014 In this method the comparison is done with a standard through use of calibrated system. 68. What are the Factors affecting the selection of measurements systems? The factors affecting the selection of measurements systems are; whenever any quantity is to be measured, the following fundamental points has to be present in the mind: 1. Degree of accuracy of measurement to be made. 2. Time of delivery of final data. 3. The cost criteria. 4, The form in which the data has to be presented. 5. The type of data to be measured. In view of the above, the most fundamental rule of measurement states: “Never demand an accuracy of measurement higher than that which is really needed, and never forget that each degree of accuracy, if demanded, is likely to have a disproportionate effect on the complexity and cost of the measuring apparatus.” 69. What are the Measurement Systems? There are three or four phases in most of the measuring Systems, each phase being made up of a distinct component °r grouping of components which perform required and definite steps in measurement viz , 1-Primary sensing device, 1-TransducerQuestions and Answers 204 Metrology and Measurement 3-Intermediate modifying stage, : 4 4-Terminating stage, i.e. secondary indicating instrument, 70. What are the basic stages of measuring systems? All measuring systems include three basic stages. They are: (A) A detecting and measuring element (Transducer) which detects the physical variable to be measured (Measurand) e.g. pressure, temperature, rate of flow ..etc., and converts it into more usable form. (B) An intermediate stage, which modifies the signal from the transducer so that a desirable output, is available. (C) An indicating and recording stage. Which provides the required output and necessary action? Measured Transducer Modifying stage Output. 71. What is the final instrument may be required. The final instrument may be required to do the following functions: (i) Indication. The value of the quantity can be read by the movement of needle on a calibrated scale Provided in the instrument. In fact where highly accurate and exact readings are desired, use of digital readouts is recommended. (i) Signaling. In this case the instrument is provided with signaling contacts which can be set at any value throughout the scale of the instrument. When the indicating needle Shows the reading corresponding to the value at which Se MED M.EASA n Bank of Prof. Dr.metrology and Measurements - Questions and Answers 14 signaling contact has been set, a contact is made or broken ting audible or visual alarm or for taking some corrective action in the plant automatically. Registering. In such instruments the instrument merely indicates, by numbers or some other symbol of discrete increments the value of some quantity. (iv)Recording. In this case the instrument continuously records, with pen and ink, the value of the measured quantity against some other variable or against time. (v) Transmitting. In certain instances, transmitters are also provided in the instrument which provides a signal corresponding to the value of the quantity being measured. (vi)To perform various manipulations. In certain cases, instruments may be req operations such as addition, subtraction, multiplication, differentiation, integration, ratio control etc. Sometimes instruments are used to find solution of rather larger complex or algebraic or differential equations. ed to do 72, Explain the basic functions of each stage of the system. The basic functions of each stage of the system used in measurement can be explained as follow; 1. Transducers. These are the devices which converts the quantity being Measured (measured) into optical, mechanical or more frequently electrical signal. 2. Signal modifying or conditioning. It is the process of preparing these signals before they are being displayed or recorded is called signal conditioning. 3. Recording and displaying units.ons and Answers Metrology and Measurements - Que: fn It is the component that provides the results of the measurements. A ‘ ‘ The basic difference between recording and displaying fh that recording produces permanent record of the Signal, while displaying unit does not. 73. Explain the Functions of the Instrument. It has already been pointed out that the primary sensing element of the instrument first utilizes energy from the measured medium to produce a condition representing the value of the measured variable. Then a secondary element known as transducer merely converts the condition produced by the primary element into a more useful quantity, usually an electrical impulse which can be amplified sufficiently to operate the actuating mechanisms. Sometimes a manipulation element is also incorporated in between which modifies the signal of the transducers, e.g., it may correct the non-linearity in the Preceding conversion processes or may automatically compensate for change of temperature ....etc. Finally the output is indicated in the form of a movement of the needle. 74. Give classification of measuring instruments. 1. Angle measuring Instruments. 2. Length measuring Instruments.metrology and Measurements - Questions and Answers 2014 a Instruments for surface finish. 4. Instruments for deviations. 75, List the various linear measurements? (i) Length (ii) Heights and (iii) Thickness. 76. What are the various types of linear measuring instruments?- Draw one type only. The various devices used for measuring the linear measurements are: i. Vernier calipers. ii. Micrometers. . Slip gauge or gauge blocks and . Comparator. Guiding edge Scale Fine adjustment screw. Clamp Upper face of jaw — - — measuring face) Measuring jaw Lower face of ja Depth of measuring jawMetrology and Measurement: Questions and Answers 2014 77. Give any four methods of measurement. 1. Direct method. 2. Indirect method. 3. Comparison method. 4. Coincidence method. 78. Give classification of measuring instruments. and draw, 1. Angle measuring Instruments. 2. Length measuring Instruments. 3. Instruments for surface finish. 4. Instruments for deviations. Limited hana —Stem Spindle Contact2014 /> Spindle clamp > Fiducial line ‘Friction or ratchet drive 7 “Thumble ‘ Se Length measuring Instruments. Magnifying lenseMetrology and Measurements - Questions and Answers 2014 Angle Plate Dial Indicator Clamp Slip Gauges Angle measuring Instruments. Drive unit Reference surface Surface Being Measured—| Instruments for surface S7Pa a2. Question Bank ofmetrology and Measurements - Questions and Answers 79 .Define True size. te size is Theoretical size of a dimension. 80. Define Actual size. Actual size = Size obtained through measurement with permissible error. 81. What is Hysteresis. All the energy put into the stressed component when loaded is not recovered upon unloading. So the output of measurement partially depends on input called hoteresis. 82, Differentiate accuracy and Uncertainty with example. Accuracy - Closeness to the true value. Example: Measuring accuracy is + 0.02mm for diameter 25mm. Here the measurement true values lie between 24. 025,02 mm. Uncertainty about the true value = + 0.02mm.metrology and Measurements - Questions and Answers 2014 83,What are the causes of workpiece variation. 4.The machines which perform operations on the workpiece may have inherent inaccuracies built into them. 2.The tools used on the machines are subject to dulling, general wear, chipping, breaking, and differences occurs due to regrinding. 3.The material used is subjected to variations. 4.The involvement of human elements. 5.Any other cause by Chance. 84, Define the following : Allowance - Geometric Tolerance. Allowance :Specific variation in the size and geometry of a part. Geometric Tolerance: Allows for specification of tolerance for the geometry of apart separate from its size. 85. Why is tolerance necessary? - It is impossible to manufacture a part to an exact size or geometry. - Since variation from the drawing is inevitable the acceptable degree of variation must be specified. -Large variation may affect the functionality of the part. - Small variation will affect the cost of the part. “requires precise manufacturing. “requires inspection and the rejection of parts.2014 86. How is tolerance Specified Size. Limits specifying the allowed variation in each dimension (length, width, height, diameter, etc.) are given on the drawing. 87.Draw and explain the relations when assembled two mating parts. Deviation 88.What are the Classification of Fit. Clearance Fit -Interference Fit and Transition Fit as shown in figure below. Clearance Fit:metrology and Measurements - Questions and Answers 2014 Interference Fit: SHAFT Transition Fit: 89.What are the basic systems of fits. There are two famous types of fits as follow; ‘HOLE BASED SYSTEM Size of hole is kept constant; shaft size is varied to get different fits.Metrology and Measurements - Questi i BASIC SIZE SHAFT SHAFT CLEARANCE TRANSITION INTERFERENCE ii) SHAFT BASED SYSTEM Size of shaft is kept constant; hole size is varied to get different fits. BASIC SIZE_ CLEARANCES TRANSITION INTRFERENCEmetrology and Measurements - Questions and Answers er 2 90. Draw and explain the basics of different possible combinations of fits. TAA Epp OE liftfy ( Hole ( Enveloped surface) = ly us Wye x Basic she | i warn ee 91.Calculate the different tolerances of the following dimensions: 45 H8/g6 and H9/d9. From tolerance tables and for 45 H8/g96 The allowance is equal: +0.039 , 0.000 mm And for g6: The allowance is equal : -0.010 , 0.029 mm Thus: The max. dimension of hole = 45.039 mm, The min. dimension of hole = 45.000 mm, The max. dimension of shaft = 45.000 mm, The min. dimension of shaft = 44.071 mm,ology and Measurements - Questions and Answers a The max. tolerance between hole and shaft =45.039 -44.97, =0.068 mm, =45.000 - 44.97, The min. tolerance between hole and shaft =0.029 mm, The type of fit is clearance fit. 92. Draw the diagram of Hole and Shaft basis. Tolerance zone a k. for shaft Interferance fit iE pcleaeanee te / Transition fit Tolerance fit ‘clearance fit ‘AHMED M.EAS*srotrotogy and Measurements - Questions and Answers 2014 93. Draw the indication of tolerances on Angular pimensions. 60° 10’ + 0°0'30” 40°15" a 30° -0°39" 5258 phe 15° 94.What are the Tolerance Grades. 1-18 tolerance grades related to part size ranges. 2- Standard tolerances related to zero line by deviation. 3- Standardized by BS4500: ISO Units and Fits.r uestions and Answers Metrology and Measurements 2014 95.Draw the different types of fits. SHAFT AND WHOLE FITS: Clearance Interference MIN Clearance =—— ALLOWANCE ="; MAX Interlerenca MAX Clearance — | eae | 7 MIN Interterence tee [ Tolerece i LY ] 1 om) 10010. HOLE 50.000; 96.What are the basics of fits Selection. -Design a fit in a . system. hole basis system or in a shaft basi -Use hole tolera ince: tolerance. S greater or equal to the sha‘ n Bank of Prof. Dr. AHMED MEAS"-Tolerances of the hole and shaft should not differ by more than two grades, 97. The following fits are used in different applications , Drive two for every type. H9/d9, D10/h9: -Multiple fits of shafts of production and piston machines, parts rotating very rarely or only swinging. H9/e9, H8/e8, E9/h9: -Main fits of machine tools. General fits of shafts, regulator bearings, machine tools, H7/k6, K7/h6: -Demountable fits of hubs of gears, clutches, brake disks. H7/s6, S7/h6: -Permanent bushings. ing rods. coupling of gears with shafts, bearinguestions and Answers Metrology and Measurements = 98. Draw all types of Geometric Characteristics Symbols, Geometric Characteristic Symbols 3 Description Straightness jtness iS 4 No datum or datums neede Gircularity Individual 4 features Cylindricity Profile line Individual or i related Depending on the situation Profile surface features Perpendicularity END) >eloul: Parallelism Related features A datum or datums are required symmetry Runout Circular Runout Total + Either filled or unfilledTHIRD PART COMPARATORSMetrology and Measurements - Questions and Answers, A — 4 COMPARATORS: 99.What is comparators? Comparators are one form of linear measurement device which is quick and more convenient for checking large number of identical dimensions. 100. Classify the comparator according to the principles used for obtaining magnification. The common types are: Mechanical comparators. (ii) Electrical comparators. (iii) Optical comparators. (iv) Pneumatic comparators. 101. How the mechanical comparators work? The method of magnifying small movement of the indicator in all mechanical comparators are effected by means of levers, gear trains or a combination of these elements. 102. State the best example of a mechanical comparator. A dial indicator or dial gauge is used as a mechanical comparator.nd Measurements - Questions and An: Perrlog oes Meee eter area 2014 403. Define least count and mention the least count ofa mechanical comparator. Least count: The least value that can be measured by using any measuring instrument known as least count. Least count of a mechanical comparator is 0.0 1 mm 104. How the mechanical comparator is used? State with any one example. Let us assume that the required height of the component I's 32.5mm. Initially, this height is built up with slip gauges. The slip gauge blocks are placed under the stem of the dial The pointer in the dial gauge is adjusted to zero. The gauge. Now, the component to be slip gauges are removed- checked is introduced under the stem of the dial gauge. If tion in the height of the component, it wi there is any devia’ be indicated by the pointer. 105, State any four advantages of reed type mechanical comparator. pact and easy to handle. (i) Itis usually robust, com| icity, air (i) There is no external supply such as elect! required. (iii) It has very simple mechanism and is cheaper when pean to other types. v) It is suitable for ordinary wo Portable, rkshop and also easilyuestions and Answers Metrology and Measurement: ae 106. Mention any two disadvantages of reed type mechanical comparator. (i) Accuracy of the comparator mainly depends on the accuracy of the rack and pinion arrangement. Any slacknes, will reduce accuracy. (ii) It has more moving parts and hence friction is more ang accuracy is less. 107. What are the major types of on electrical comparator? An electrical comparator consists of the following three major parts such as: (i) Transducer (ii) Display device as meter ( i) Amplifier 108. On what basis the transducer works? An iron armature is provided in between two coils held by 4 leaf spring at one end. The other end is supported against 4 plunger. The two coils act as two arms of an A.C. wheat stone bridge circuit. Question Bank of Prof. Dr. AHMED MEA A |metrology and Measi 1s and Answers 2014 409. How is the accuracy of an electrical comparator checked? To check the accuracy of a given specimen or work, first a standard specimen is placed under the plunger. After this, the resistance of wheat stone bridge is adjusted that the scale reading shows zero. Then the specimen is removed. Now, the work is introduced under the plunger. 110. State the working principle of an electronic comparator. In electronic comparator, transducer induction or the principle of application of frequency modulation or radio oscillation is followed. 111. Mention the important parts of an electronic comparator. (i) Transducer, (ii) Oscillator, ) Amplifier, (iv) Demodulator and (v) Meter. 112. Classify pneumatic comparators. re type. (i) Flow or Velocity type and (ii) Back pressutjons and Answers: Metrology and Measurements 204 113. What are the advantages of electrical and electronic comparator? (i) It has less number of moving parts. Magnification obtained is very high. |) Two or more magnifications are provided in the same instrument to use various ranges. (iv)The pointer is made very light so that it ‘IS more sensitive to vibration. 114, What are the disadvantages of electrical and electronic comparator? (i) External agency is required to meter for actuation. Variation of voltage or frequency may affect the accuracy of output. ) Due to heating coils, the accuracy decreases. ) It is more expensive than mechanical comparator. 115. List the various parts of an optical comparator. The optical comparator consists of the following parts such a ivoted lever, (ii) Objective lens, (iii) Scale, (iv) Plunger, (v) Table and (VI) Base. 115. What are the advantages of pneumatic comparator? ‘75Page| <Metrology and Measurement: 204 Upper coil Bridge os | ee | R Bri al __Phase sensitive demodulato, Senna O tS | Bes “| AD) a n7. ___| Amplifer Electric Comparator. Height adjustable Reading headology and Measurements - Questions a we ory ind Answers 2014 Air escaping joes Airjet at a2 A Pneumatic comparator details. 118. How the mechanical comparator works? The method of magnifying small movement of the indicator in all mechanical comparators are effected by means of levers, gear trains or a combination of these elements. 119. State the best example of a mechanical comparator. A dial indicator or dial gauge is used as a mechanical Comparator,Metrology and Me: 204 Limited hand § Bezel clamp Dial gauge details. a Question Bank of Prof. Dr. AHMED M.EAand Measurements - Questions and Answers motrolod¥ wer 2014 120.Define least count and mention the least count of a mechanical comparator. Least count: The least value that can be measured by using any measuring instrument known as least count. Least count of a mechanical comparator is 0.0 1 mm. 121. How the mechanical comparator is used? State with any example. Let us assume that the required height of the component is 32.5mm. Initially, this height is built up with slip gauges. The slip gauge blocks are placed under the stem of the dial gauge. The pointer in the dial gauge is adjusted to zero. The slip gauges are removed- Now, the component to be checked is introduced under the stem of the dial gauge. If there is any deviation in the height of the component, it will be indicated by the pointer. 122. State any four advantages of reed type mechanical Comparator. y to handle. (i) tis uw: suall mpact and eas. z i padeooun com h as electricity, air i!) There is no external supply suc "equired, Bank of Prof. Dr. AHMED M.EASAns and Answers 2014 Metrology and Measurements - Que: (iii) It has very simple mechanism and is cheaper when compared to other types. (iv) It is suitable for ordinary workshop and also easily portable. 123. Mention any two disadvantages of read type mechanical comparator. (i) Accuracy of the comparator mainly depends on the accuracy of the rack and pinion arrangement. Any slackness reduce accuracy. It has more moving parts and hence friction is more and accuracy is less. 124, What are the major types of on electrical comparator?- Draw one type. An electrical comparator consists of the following three major parts: (i) Transducer (ii) Display device as meter (iii) Amplifier. Height adjustable handle _____ Question Bank of Py i. Dr. AHMED M.EASA2014 45, on what basis the transducer works? an iron armature is provided in between two coils held by a jeaf spring at one end. The other end is supported against a plunger. The two coils act as two arms of an A.C. wheat stone bridge circuit. 126. How is the accuracy of an electrical comparator checked? To check the accuracy of a given specimen or work, first a standard specimen is placed under the plunger. After this, the resistance of wheat stone bridge is adjusted that the scale reading shows zero. Then the specimen is removed. Now, the work is introduced under the plunger. 127, State the working principle of an electronic comparator. In electronic comparator, transducer induction or the Principle of application of frequency modulation or radio °scillation is followed. 128. Mention the important parts of an electronic Comparator. Amplifier(iv) Demodulator (v) (i nansducer (ii) Oscillator ried EASA <2 "Question Bank of Prof. Dr. AHMED M.EASAi Answers ae Measurements - Questions an Metrology and sify pneumatic comparators. Draw one type. s: 129. Cla: (Flow or Velocity type and (il) Back pressure type. Gauging head Water tank Pneumatic comparator details __-Bleed valve for zero adjustment Seale Float Tapered —__ Fe gauging heat eecisicn. through plastic tubing Constant pressur. air supply Magnification adjustment Zero ai ; nd magnification adjustment inflow type of pneumatic comparator a -. tion Bank of Prof, Dr. AHMED M-E*metrology and Measurements - Questions and Answors 4 130. What are the advantages of electrical and electronic comparator? (i) It has less number of moving parts. (ii) Magnification obtained is very high. (iii) Two or more magnifications are provided in the same instrument to use various ranges. (iv)The pointer is made very light so that it ‘IS more sensitive to vibration. 131. What are the disadvantages of electrical and electronic comparator? (i) External agency is required to meter for actuation. (ii) Variation of voltage or frequency may affect the accuracy of output. (iii Due to heating coils, the accuracy decreases. (iv) It is more expensive than mechanical comparator. 132, List and draw the various parts of an optical Comparator. The optical comparator consists of the following parts such as: (i) Pivoted lever, (ii) Objective lens, ( ) Table and (vi) Base. Scale, (iv) Plunger, ‘Question Bank2014 femen' Metrology and Measurem Lever for mechanical magnification 133. What are the advantages of pneumatic comparator? (i) The wear of measuring heads is avoided due to absence of direct contact. Friction is less due to less number of moving parts. (iii)Work piece is cleaned by supplying of all during the measurement. (iv)High magnification is possible. (v)There is no interference of measuring head and indicating device because the measuring head is kept away from the indicating device. (vi) It is a suitable method to check ovalty and taperness of circular bore, 87P a ve. Question Bank of Prof. Dr. AHMED MEAS“and Measurements - Questions and Answers 2 014 motrolo9¥ 194. what are the advantages of comparators? 4, Not much skill is required on the part of operator in its use 2. The calibration of instrument over full range is of no importance as comparison is done with a standard end length. 3. Zero error of instrument also does not lead to any problem. 4.Since range of indication is very small, being the deviation from set value, a high magnification resulting into great accuracy is possible. 135.Which operation the comparators are used. The comparators are generally used for measurements, and various comparators available Principally in the method used for amplifying and recording ording to the principles used agnification of the e in the dimension the variations measured. Acc‘ for obtaining suitable degrees of ™ indicating device relative to the chang being measured.Metrology and Measurements - Questions and Answers eT 136.What are the various fundamental requirements whic, every comparator must fulfill. These fundamental requirements are as follow: 4. The instrument must be of robust design and construction so as to withstand the effect of ordinary usage without impairing its measuring accuracy. 2. The indicating device must be such that readings are obtained in least possible time and for this, magnification system used should be such that the readings are dead beat. The system should be free from backlash, and wear effects and the inertia should be minimum possible. 3. Provision must be made for maximum compensation for temperature effects. 4. The scale must be linear and must have straight line characteristic. 5. Indicator should be constant in it return to zero. 6. Instrument, though very sensitive, must withstand @ reasonable ill-usage without permanent harm. 7. Instrument must have the maximum versatility, i-e., it design must be such that it can be used for a wide range operations. 8. Measuring pressure should be low and constant. a iii siand Measurements - Que: rotoay 3 2014 met! 1 (37.What are the uses of Comparators. the various ways in which the comparators can be used are as follows: 4, In mass production, where components are to be checked ata very fast rate. 2, As laboratory standards from which working or inspection gauges are set and correlated. 3, For inspecting newly purchased gauges. 4, Attached with some machines, comparators can be used as working gauges to prevent work spoilage and to maintain required tolerances at all stages of manufacturing. 5, In selective assembly of parts, where parts are graded in three or more groups depending upon their tolerances. 138, Explain the term magnification. It means the magnitude of output signal of measuring instrument time’s increases to make it more readable. 139, How the mechanical comparator works? The method of magnifying small movement of the indicator Hy all mechanical comparators are effected by means of "vers, gear trains or a combination of these elements.ns and Answers ments Metrology and Measu 2014 140. Explain the characteristics of mechanical comparators, Mechanical comparators, magnification is obtained by mechanical linkages and other mechanical devices. 1.Systems of Displacement Ampl ation used Mechanical Comparators: in (i) Rack and Pinion. In it the measuring spindle integral with a rack, engages a pinion which am ies the movement of plunger through a gear train. (Refer Fig. 1). (ii) Cam and gear train. In this case the measuring spindle acts on a cam which transmits the motion to the amplifying gear train. (Referring to Figure below). Pointer Amplifying Gear train ‘Measuring spindle (iii) Lever with toothed sector. toothed sector at its end engag: crown gear sector which furthe; to produce indication, In this case a lever with 2 jes a pinion in the hub of 4 r meshes with a final pinio" below). with band wound around drum (Fi9:ogy and Measurements - Questions and Answers metroloSY 2014 causing straining which further causes the twisted taut ‘and to rotate proportionally. The motion of strip is displayed by the attached pointer. Measuring spindle (vi) Lever combined with band wound around drum. In this case, the movement of the measuring spindle tilts the hinged block, causing swing of the fork which induces rotation of the drum. Lever Toothed sector (vii) Reeds combined with optical display. In this case *rallelogram reeds are used which transfer measuring QuestiQuestions Metrology and Measurement: 2014 spindle movement to a deflecting reed whose extens, i carries a target utilized in optical path. oy ‘or projecting light spots. (viii) Tilting mi Pivot A Measuring spindle 93Page ica Question Bank of ‘Dr. AHMED M.EAS*| a ology and Measurements - Que: tr : nS and Answers 2014 y) Twisted Taut Strip. The movement of measuring spindle knee tilts the 141. Draw the comparator of Johansson Mikrocator. Light pointer Twisted strip Bell crank lever Dr. AHMED M.EASA15 - Questions and Answers Metrology and Measurements - Qu a 142, Draw the reed type mechanical comparator. Output displacement 143(a)What are the method which used to adjust th magnification. (b)Draw sigma comparator. (a)The distance must be changed by slackening até tightening the two screws attaching the knife edge to the plunger. (b) Sigma comparator shown in figure below; 95Page a ___ Question Bank ofand Measurem ology nS and Answers met is 2014 (Top position bending plate) nife - edge Pointer Sapphire plate : Fixed block ne Crossed strip datum ‘ending plate (Bottom position) Sigma comparator. 144, What are the advantages of mechanical comparators. 1. These are usually cheaper in comparison to other devices of amplifying. 2. These do not require any external supply such as electricity or air and as such the variations in outside Supplies do not affect the accuracy. 3. Usually the mechanical comparators have linear scale Which is easily understood. 4. These are usually robust and compact and easy to handle, 5: For rdinary workshop conditions, 8 portable can be Issued from a store. these are suitable andns and Answers 204 Metrology and Measurements - QUES 145. What are the disadvantages of Mechanica, comparators? 4.The mechanical comparators have got more moving part, than other types. Due to more moving parts, the friction j, more and ultimately the accuracy is less. 2.Any slackness in moving parts reduces the accuracy considerably. 3.The mechanism has more inertia and thi: instruments to be sensitive vibration. 4.The range of the instrument is limited as the pointer moves over a fixed scale. 5.Error due to parallax is possible as the moving pointer moves over a fixed scale. iS may Cause the 146.Explain diagrammatically Mechanical Optical Comparators. The whole system could be explained diagrammatically bY (Two _Figures) which give very simple arrangement and explains the principle of the comparator. ‘AHMED D MAAS! westion Bank of Prof.and Measurements - Questions and Answers metrology oy 2014 Return spring 3 Pivot = Put displacement + xt SS =a 1 Lever for mechanical magnification Thus it is obvious that optical comparators are capable of giving a high degree of measuring precision owing to high magnification and the reduction of moving members to minimum. Further these possess better wear resistance qualities as the only wearing members are the plunger and its guide and the mirror pivot bearing. Another advantage of ion of an illuminated the optical comparators is that provi: scale enables readings to be taken without regard to the room lighting conditions. The point of importance in optical comparator is that mirror used must be of front reflection type and not normal back reflection type. In normal back teflection type there are two reflected images, one each from front and back. Thus the reflected image is not well defined one, as one bright and other blurred image are observed. If front reflection type of mirror is used, then it Tequires considerable care in its use to avoid damage to the 'eflecting surfaces. In the actual instrument, the optical Path is longer than is shown here and a prism is used in "stead of a mirror. mem A aesSs nswers 2014 Metrology and Measurements - Questions and A\ Scale —= a ! | ~ / Target.) Mirror Lens ] Lamp) fal Movable block ZZ, Main reed oe Fixed block . Fixed” $pindle Fine adjusting : “Sleeve block el - Spindle A smalll displacement of the spindle(a) result in a long swing of the pointer (b). An optical lever is used to amplify the reed. 147. What are the advantages of optical comparators? 1. It has small number of moving parts and hence a higher accuracy. 2. In the optical comparators, the scale can be made to move past a datum line and thus have high range and no Parallax errors. 3. It has very high magnification. 4. Optical lever is weightless.and Measurements - Questions and Answers motrolodY = 2014 148. What are the disadvantages of optical comparators? 4, As the instrument has high magnification, heat from the lamp; transformer etc. may cause the setting to drift. 7, an electrical supply is necessary. 3. The apparatus is usually large and expensive. 4. When the scale is projected on a screen, then it is essential to use the instrument in a dark room in order to take the readings easily. 5. The instruments in which the scale is viewed through the eyepiece of a microscope are not convenient for continuous use. 149. Draw one type of electrical and electronic comparators. Height adjustable handle ‘jon Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements - Quest 204 150. What are the advantages of electrical comparators, 4.The electrical comparators have got small number of moving parts. 2.It is possible to have a very high magnification ang the same instrument may have two or more magnifications, Thus the same instrument can be used for various ranges, 3.The mechanism carrying the pointer is very light and not sensitive to vibrations. 4.As the instrument is usually operated on A.C. supply, the cyclic vibration substantially reduces errors due to sliding friction. 5.The measuring unit can be made very small and it is not necessary that the indicating instrument be close to the measuring unit, rather it can be remote also. 151. What are the disadvantages of electrical comparators. 1.It requires an external agency to operate i.e., the A.C: electrical supply. Thus the variations in voltage or frequency of electric supply may affect the accuracy. 2.Heating of coils in the measuring unit may cause zero drift and alter the calibration. 3.1f only a fixed scale is used with a moving pointer the" with high magnifications a very small range is obtained. 4.This is usually more expensive than mechanical instrument. 101Pageand Measurements - Quest rol09¥ 2014 met What are the characteristics of pneumatic a comparators. the following are the important characteristics. g.very high amplifications are possible. It can be used to measure diameters, length, squareness, parallelism, and concentricity, taper, center distance between holes and other geometric conditions. 2.As no physical contact is made either with the setting gauge or the part being measured, there is no loss of accuracy because of gauge wear. For this reason, air spindle and air snap gauges last very long. Also very soft parts which are easily scratched can be gauged. 3,Internal dimensions can be readily measured not only with respect to tolerance boundaries but also geometric form. In other words, while measuring a bore it can reveal complete story of size, taper, straightness, camber and bell mouth etc. 4.lt is independent of operator skill. ne with cleansing of SHigh pressure air gauging can be doi ors due to dirt and the parts which helps to eliminate err foreign matter. 8.Gauging pressures can be kept sufficiently low to prevent at deflection. (In general, high pressure gauges a *uitable for those parts in which tolerances are relatively ‘arge and low pressure air gauges are preferable for highly "cise work).ns and Answers 2014 Metrology and Measurements - Ques 7.Dimensional variations throughout the length of shaft or cylinder bore can be explored for out of roundness, tape, ness, concentricity, regularity and similar conditions. 8.Not only it measures the actual size, but it can also be used to salvage oversized pieces for rework or to sort out for selective assembly, i.e., it is suitable both for variable inspection (measurement of size) and attribute inspection (GO and NO GO) gauging and limits. 9.The total life cost of the gauging heads in much less. 10.It is accurate, flexible, reliable, universal and speedy device for inspecting parts in mass production. 11.It is best suited for checking multiple dimensions and conditions on a part simultaneously in least possible time. It can be used for parts from 0.5 mm to 900 mm diameter having tolerance of 0.05 mm or less. It can be easily used for on line measurement of parts as they are being machined and take corrective actions. 153. What are the systems of pneumatic comparators. These may be classified as: 1.Flow or velocity type. 2.Back pressure type. 103Page_asurements - Questions and Answers Ao Metrology and 7.Dimensional variations throughout the length of shaft on der bore can be explored for out of roundness, tape, cylin r conditions. ness, concentricity, regularity and si 8.Not only it measures the actual size, but it can also be used to salvage oversized pieces for rework or to sort out for selective assembly, i.e., it is suitable both for variable inspection (measurement of size) and attribute inspection (GO and NO GO) gauging and limits. 9.The total life cost of the gauging heads in much less. 10.It is accurate, flexible, reliable, universal and speedy device for inspecting parts in mass production. 11.It is best suited for checking multiple dimensions and ms on a part simultaneously in least possible e. It can be used for parts from 0.5 mm to 900 mm diameter having tolerance of 0.05 mm or less. It can be easily used for on line measurement of parts as they are being machined and take corrective actions. 153. What are the systems of pneumatic comparators. These may be classified as: 1.Flow or velocity type. 2.Back pressure type. ‘AHMED MEAS!and Measurements - Questions and An: metrolody ae 2014 3,Flow oF velocity type pneumatic gauges operate by sensing and indicating the momentary rate of air flow. Flow could be sensed by a glass tube with tapered bore, mounted over a graduated scale. Inside the bore a float ifted by the air flow. 4,.Free Flow Air Gauges. 154.Draw one type of pneumatic comparators. Filter Gauging head Air escaping ‘Question Bank of Prof. Dr. AHMED M.EASAMetrology a! - nd Answers rology and Measurements Questions a! je ? 155. How the mechanical comparator works? The method of magnifying small movement of the indicato, in all mechanical comparators are effected by means levers, gear trains or a combination of these elements. 156. State the best example of a mechanical comparator, I gauge is used as a mechanical A dial indicator or di comparator. Limited hand |Bezel clamp Contact point Dial gauge details.ogy and Measurements - Questions and Answers 2014 metrolo’ The support assembly of dial gauge can be positioned In any fashion by loosening the two povit joints. 157. Define least count and mention the least count of a mechanical comparator. least count: The least value that can be measured by using any measuring instrument known as least count. Least Sount of a mechanical comparator is 0.01 mm. 1 58. How the mechanical comparator is used? State with any one example. Let $a) 1 28sume that the required height of the component I m. Initially, this height is built up with slip gauges. EASA QiMetrology and Measurements - Questions and Answers 2014 The slip gauge blocks are placed under the stem of the diay gauge. The pointer in the dial gauge is adjusted to zero, Th, slip gauges are removed- Now, the component to ‘s checked is introduced under the stem of the dial gauge, t there is any deviation in the height of the component, it will be indicated by the pointer. 159. State any four advantages of reed type mechanical comparator. (i) It is usually robust, compact and easy to handle. (ii) There is no external supply such as electricity, air required. (iii) It has very simple mechanism and is cheaper when compared to other types. (iv) It is suitable for ordinary workshop and also easily portable. 160. Mention any two disadvantages of read type mechanical comparator. (i) Accuracy of the comparator mainly depends on the accuracy of the rack and pinion arrangement. Any slackness reduce accuracy. (ii) It has more moving parts and hence friction is more and accuracy is less.jeasurements - Questions and Answe: metrology and Mi di 2014 161. What are the major types of on electrical comparator?. | praw one type. an electrical comparator consists of the following three major parts : (i) Transducer, (ii) Display device as meter and (iii) Amplifier. Fi Weight najustaiia Component oN work —4 | Display screen FBleotrical supply besieisne sii Details of electrical comparator. 162. On what basis the transducer works? An iron armature is provided in between two coils held by a leaf spring at one end. The other end is supported against a Plunger. The two coils act as two arms of an A.C. wheat Stone bridge circuit. 1 °3. How is the accuracy of an electrical comparator checkeap x 7 peweetl the accuracy of a given specimen or work, first a “8 ecimen is placed under the plunger. After this, ‘Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements ns and Answers 2014 the resistance of wheat stone bridge is adjusted that the scale reading shows zero. Then the specimen is Fremoveg, Now, the work is introduced under the plunger. 164. State the working principle of an electronic comparator. In electronic comparator, transducer induction or the principle of application of frequency modulation or radio oscillation is followed. 165. Mention the important parts of an electronic comparator. (i) Transducer (ii) Oscillator Meter. i) Amplifier(iv) Demodulator (v) 166. Classify pneumatic comparators. Draw one type. (i)Flow or Velocity type _ and (ii) back pressure type.jogy and Measurements - Ques| metro! Air escaping Pac Manometer jometer Water tank Pneumatic comparator details. Bleed valve for zero adjustment __ seate Float Te gauging head Taperea —— through plastic glass tube tubing Constant Preseui air suppt, os Magnification adjustment cation adjustment inflow type of pneumatic comparator Zero and mag} a = stion Bank of Prof. Dr. ‘AHMED M.EASAMetrology and Measurements - Questions and Answers ao 167. What are the advantages of electrical and electronic comparator? (i) It has less number of moving parts. (ii) Magnificatio, obtained is very high. (iii) Two or more mag instrument to use various ranges. (iv) The pointer is made very light so that it ‘IS more sensitive to vibration. ations are provided in the sam, 168. What are the disadvantages of electrical and electronic comparator? (i) External agency is required to meter for actuation. (ii) Variation of voltage or frequency may affect the accuracy of output. Due to heating coils, the accuracy decreases. (iv) It is more expensive than mechanical comparator. 169. List and draw the various parts of an optical comparator. The optical comparator consists of the following parts suc" as: (i) Pivoted lever. (ii) Objective lens (iii) Scale. (iv) Plunger (v) Table and (vi) Base. pom a jon Bank of Prof. Dr. AHMED M-E*>and Measurements - Questions and Answer metrologY rs aa Pivot Put displacement “Lever for mechanical magnification 170. What are the advantages of pneumatic comparator? (i) The wear of measuring heads is avoided due to absence of direct contact. Friction is less due to less number of moving parts. Work piece is cleaned by supplying of all during the measurement. (iv)High magnification is possible. (There is no interference of measuring head and indicating device because the measuring head is kept away from the indicating device. i) tis a suitable method to check ovalty and tape! circular bore. rness ofyr Pear | pe 208 Measurements 2014 sulP GAUGES: 71. What are the Classifications of Slip gauges? stip gauges are classified according to their guaranteed accuracy? AA for master slip gauges, | Afor reference purpose, and B for working slip gauges. Johannes AA slip gauges are accurate to plus or minus two microns per meter. type A is guaranteed accurate up to plus or minus four micfons per meter, While type ‘B’ for plus or minus eight microns per meter. The guaranteed error is not divided for a block which is less than 25 mm ; such a slip gauge has same tolerance as 25 mm gauge. The workshop type, i.e., B type gauges are finished on their measuring faces approximately to within 250 um for flatness and parallelism. The corresponding figures for types A and AA are 125 and 75 pm respectively. 4s regards grades or classes of slip gauges, these could also be designed in five grades as under: Grade 2. This is the workshop grade. Typical uses include setting up Machine tools, positioning milling cutters and checking mechanical widths. a 1. Used for more precise work, 2 oy my @ good-class tool room. Typical uses includ “s ine bars and sine tables, checking gap gauges and "9 dial test indicators to zero. such as that carried je settingjons and Answers jogy and Measurements - Que: aot Grade _ 0. T! is more commonly known as the Inspection grade, and its use is confined to tool room or machine sho, inspection. This means that it is the Inspection Department only who have access to this grade of slips. In this way it is not possible for these slip gauges to be damaged or abused 4, the rough usage to be expected on the shop floor. Grade 00. This grade would be kept in the Standard Room and would be kept for work of the highest precision only. A typical example would be the determination of any errors present in the workshop or Grade 2 slips, occasioned by rough or continual usage. Calibration grade; this is a special grade, with the actual sizes of the slips stated or calibrated on a special chart supplied with the set. This chart must be consulted when making up a dimension, and because these slips are not made to sper ic or set tolerances, they are not as expensive as the Grade 00. It must be remembered that a slip gauge, like any other engineering component, cannot be made to an exact size. All slip gauges must have tolerances on the length, flatness and parallelism of measuring faces. Except for the calibration grade, all slip gauge sets are manufactured to within specified is; the closer the limits the more expensive the slip gauges, but in the case of the calibration grade, greater tolerances on length are permissible. Because the actual lengths are known or recorded in thé calibration chart, due allowance can be made when the sliP® are used. aaahegeleements Onesticas/aralaia ier 472.What are the Groups of Slip Gauges, As example: Slip gauge set of 56 slips is made up as shown below : _g slips 1.001 to 1.009 in steps of 0.001 mm. -9 slips 1.01 to 1.09 in steps of 0.01 mm. -9 slips 1.0 to 1.9 in steps of 0.1 mm. .25 slips 1 to 25 in steps of 1.0 mm. ips 25 to 75 in steps of 25 mm. -Slip of 1.0005 mm. 173.What are the basic forms of Slip Gauges. Slip gauges with three basic forms are commonly found. These are rectangular, square with center hole, and square without center hole. 174, What are the Major Requirements for Slip Gauges? The essential purpose of slip gauges is to make available end standards of specific lengths by temporarily Combining several individual elements—each representing a Standard dimension—into a single gauge bar. The “ombination of single blocks must result in a bar of soRable cohesion, whose actual dimension truly "Presents, the nominal dimension cough Within specific limits, for a particular application. Nera, ‘Question Bank of Prof.fetrology and Measurement: 1s and Answers 2014 This objective is accomplished by making slip gauges ;, dimensions (arithmetically deter-mined sizes) needed ;, achieve any combination of sizes within the designed rang, and graduation of the set ; ensuring the accuracy 4 individual blocks to be within accepted tolerance limits . attaching the individual blocks so closely to each other that the resulting bar will have a length equal to the added size, of the individual blocks ; further the attachment of the elements to each other should be firm enough to permit a reasonable amount of handling as a unit, and yet when taken apart, the individual pieces should be reusable without any harm to their original size or other essential Properties. Slip gauges are used to provide end standards of specific length by temporarily combining several individual elements- each representing a standard dimension—into 2 single gauge bar. The success of system depends on formation of a bar of reasonable cohesion between individual elements and its actual dimension truly representing within specific limits, the desired nominal dimension. For achieving this, the individual gauges must be available in dimensions needed to achieve any combinatio" with minimum number of gauges. The accuracy of individu! blocks must be within accepted tolerance limits. The individual blocks must be attached so closely to €2¢" other that length of built-up combination is equal to th? added size of the individual blocks of the assembly. This is achieved by wringing the slip gauges. Further th? attachment of individual gauges must be firm enough “ permit a reasonable amount of handling as a unit. 117Page ep MEAS _ Question Bank of Dr. AHME!serology and Measurements - Questions and Answers 201, it should be possible to detach a individual elements so that these are re-usable without any harm to their original size oF other essential properties, For this Purpose, control of geometry of form, i.e., flatness : and parallelism of faces, squareness of the gauging surfaces; surface condition, appearance, homogeneity of gauging surfaces, etc. is warn essential. The accuracy of gauges can be affected by the dimensional instability of material or by wear in use, damage during storage and handling. care of by periodic calibration. or These can be taken 175. What is the normal set of the block gauges? The normal set is made up of the following blocks: (All dimensions in Range _— Step mm) | Pieces. 4.001 to 1.009.001 9 4.01to10.9 (0.01 9 haters [ot | 9 1t09 ~ lea (a ie 410 to 90 40 [io |. Peres Total 45logy and Measurements - Questions and Answers 176. What is the special set of the block gauges. | Range | 1.01 01.49 |0.01 49 | osto95 | 05 10 to 90 10 | 9 eer. | 4.0005 | — “| Total 85) 177. Describe a method for block gauges protection. These are two additional 2 mm blocks with a letter Po" measuring faces and are provided with high-grade sets g gauge blocks. These are accommodated at each end of? combination so that all the wear occurs on them. Thes¢ 2” made from tungsten carbide or other suitable material 4" take all the wear due to rubbing on surface plates.Measurements - Questions and Answers metrology and ieee 2014 178. Describe a method for correction of Accumulative error on block gauges. Though the error by combination of two gauges in thickness due to separation is negligible (of the order of 6.35 x 1QT6 mm), it is advisable to select least number of gauges for a given size when combining slip gauge blocks. 179.Explain briefly the method of selection when used slip gauges. Let us say that the dimension to be arranged is 58.975 mm. Always start with the last decimal place e.g., here it is 0.005 mm and for this 1.005 mm slip gauge is selected. Now dimension left is 50.975—1.005 = 57.970 mm. Take second decimal place ; and for it select 1.47 mm slip gauge. Therefore, the remainder is 57.970 - 1.47 = 56.500 mm. [Note : One could have selected 1.07 mm piece also, but that way we would have been left with 56.900 and for it we need another 1.4 mm piece. Our aim should be to choose minimum number of slip gauges for a given dimension.]. Next for 56.500 mm, we choose 6.500 mm piece and finally 50.000 mm piece. Thus, we have 50.000 + 6.550 + 1.47 + 1.005 = 58.975 mm. All these four slip gauges are wrung properly to get ‘“auired dimension. When the dimension to be measured is os and is to be found using slip gauges, coe Saline Cotemmiic) (9 ip Tees aeata and 47.4 T etc. Let us say that size lies between 47. as and we have to estimate it correct up to 3 decimal of miMetrology and Measurements - Questions and Answers ea for 0.005 mm and 1.01 to 1.09 mm for .01 to 0.09 mm, Thus 2 mm must be taken off from 47.3 mm to account for these three decimal figures. Thus first make combinations of 473 _ 2.0 = 45.3 mm ie. 1.3 + 19.0 + 25.00 mm pieces. Next with these and 1.005 and all the rest, i.e. 1.01 to 1.09 m,, pieces. Then starting from 1.09 pieces one of these will giv. large dimension and next one small. Then decide whether 1.005 mm piece is needed or not by taking it out and adjusting the dimension near that value. The sense of' feel’ is very important in the use of slip gauge and depends upon the skill of the operator. Since during the combination operation the gauges are in contact with body temperature, their dimension actually increases. 180. Describe the sequence of slip gauges manufacturing. The following sequence of operations is followed in order that slip gauges possess certain desirable qualities: (i) Marking the approximate size by preliminary operations: (ii) A special form of heat treatment to make the blocks hard and wear resistant. (iii) An artificial and natural seasoning process to ensu® stabilizing for the whole life of the blocks. Stabilizing * generally carried out by heating and cooling the gau9° successively, after rough grinding. The success” temperatures used in the four stages of stabilizing are 47’ 70", 130° and 200°C, the gauges being heated in sand 2" cooled slowly at each stage. Tirsse eneand Measurements - Questions and Answer metrology ie 2014 (w A final grinding process to reduce the block to the approximate required dimension, w A final-lapping operation to reduce the blocks to exact size and impart a beautiful finish to the surface. A special lapping machine is used for lapping. Lapping is done in a room maintained at 20° C and controlled humidity of 50%. The blocks are held in a moving spider between upper and lower cast iron laps. The spider is imparted both rotating and reciprocating motion to produce a complicated path of travel for each block and wear is distributed all over uniformly. (vi) Comparison of finished gauges with grand master sets. 181.Describe one of slip gauges calibration method. Workshop and inspection grade gauges are calibrated by direct comparison against the calibration grade gauges in a comparator. A variety of comparators are available which “se mechanical, optical, electrical and pneumatic means of amplification. Eden-Rolt Millionth comparator and Brook- 'evel comparator have been specifically designed for slip Sauges, 1 *2. What is meant by Calibration by Interferometry. The interferometer is suitable for measuring sets of slip ‘uc fat’® UP to 100 mm. accurate meas' : a Waves slip gauges and other end gauges. urements of surface These light ave wavelengths of the order of 0.000375 touestions and Answers logy and Measurement won 0.000675 mm and by estimation of the widths of jig, interference bands, measurements to within 0.000025 ,, 0.00005 mm are possible. Interference methods are Suitable for determining the absolute size of calibration ang reference grade gauges. For this the gauges must Satisty the following basic requirements: (a) The end faces must be flat and parallel to each Other | (b) They must have a high degree of surface finish , (c) The actual size must agree with its nominal size to within a very small tolerance , and (d) The edges must be properly rounded off and debarred, Various types of interferometers have been designed from time to time over the last 50 years for the specific purpose of inspecting block gauges. 183. Explain one method for corrected the length of slip gauge. The measured lengths as derived interferometry in ambient air require corrections on account oft (a) Difference in temperature of the gauge from the reference temperature of 20°C i (b) Difference between conditio F d ns of ant standards air. of ambient air (c) Phase change due to . the diffi ir i. he exposed surface of iverence in finish between ¢ and gauge and top surface of base plate i (d) Obliquity errors due to the inc! o ina\nd Measurements - Questions and Answe: otot09 2 id Answers, 2014 with the normal oo the surface of base plate. The temperature correction is calculated on the basis of an average value for the co-efficient of thermal expansion of ardened steel of 12 parts in a million per 41°C and is applied as 12! (20 -1) x 10~6, where 1 is the observed length of the gauge at the value corresponding to 20°C, and t = room temperature. The wavelength correction comprises of two parts, one for barometric pressure and air temperature, and the other for vapor pressure. The total value of the wavelength correction is obtained by adding algebraically the value of the two terms and applying the results as a correction to the length of the gauge. Thus, if + x and + y are the values of the terms for a particular set of conditions t, h and f, then the correction to a gauge of nominal length N is given by: NG x+y) x 10% 184.Describe the methods which used for care and use of slip gauges. 4) All the surfaces are protected against climatic conditions *y being covered with a high graduation preparation or Petroleum jelly or other suitable anti-corrosive preparation. 4) The slip Gauges are kept in a suitable case in which there Sa separate compartment for each gauge. °) The Sizes of the gauges are marked on the case, i i. "Mediately adjacent to the appropriate compartment. 1 ‘Question Bank of Prof.rement: s and Answers jeasui ind their case should be protected from dust d)The gauges a and dirt. e) The gauges should be used only in air-conditioned rooms free from dust and maintained at constant temperature. f) Every care should be taken to protect the gauges from getting magnetized otherwise they will attract metallic dust. g) Should be handled using a piece of chamois leather or perspex tongs. h) During the actual use, the fingering of the lapped faces should be avoided as far as possible in order to preclude the risk of tarnishing, and the handling should be as minimum as possible to avoid transfer of heat from body to the gauges. i) During the actual use, the fingering of the lapped faces should be avoided as far as possible in order to preclude the risk of tarnishing, and the handling should be as minimum as possible to avoid transfer of heat from body to the gauges. f) The gauges should always be slid apart and the wringing joint between them should never be broken. 425Pagesotosy and Measurements - Questions and Answers e 2014 195.0raw the diagram of the instrument whic ich esting the flatness of slip gauges, Used for Light source Condensing Green filter lens Pinhole aly Glass plate Eye 6 =< reflector Collimating _ coed Optical flat Workpiece Base plate Optical arrangement of interferometer for testing flatness of surfaces "26. How do you calibrate the slip gauges? C z = °Mparators are used to calibrate the slip gauges as follow; In ™anual calibration, the operator will have tendency of K of Prof. Dr. AHMED M.EASA ‘Question Ban!.s and Answers 2014 play safe and thus high grade slip gauges may be Classeq ,. low grade which can be costly mistake. Automas, calibrator utilizes microprocessor technology and PFOVides ual calibration and grading, and print-out of every gauge checked. It may take as small as 10 seconds to calibrate a gauge. Grading is done by measuring its length, parallelism between measuring faces and flatness of each face. Since the length tolerance on highest grade gauge is + 50 mm, it is imperative that machine be capable o measuring 10% of this value, i.e. + 5 nm. The handling by machine should not produce any scratch because a scratch of 1-2 micron width would affect the accuracy of slip gauge and lead to its rejection. The machine should be able to measure gauges of all sizes. The machine has to be installed in a tightly temperature controlled room, totally free of dust and totally vibration free foundation. Such a machine is totally enclosed and is fitted with hinged covers for access to the working zone and for loading and unloading of gauges: Operation is performed from a control station and @!! measuring cycles are performed automatically. Each set gauges is loaded into a cassette with a previously calibrate! master gauge of the same nominal size and calibrated »! interferometry. The cassettes are then loaded on to one end of a stor” rack and a walking-beam mechanism brings them in turn? the measuring position. At measuring head, the mast” gauge i measured first and other gauges fin sequen” Measuring heads consist of Specially designed high- =z | Question Bank of Prof. Dr. AHMEDand Measurements - Questions and Answers metrology 2014 sensitivity, capacitive transducer to minimize risk of e to the measuring faces, gamag' The gauges being measured are Precisely positioned petween two measuring heads, each of which incorporates fine probes to take measurements at the corners of each face. Extra probes are also included to cater for differences in cross-sectional area over the range of gauges which can be measured. The probes comprise steel rods inserted into holes in the measuring head but are insulated from it bya thin film of epoxy resin. The measuring head acts as a guard ring to eliminate fringing of the electrical field between the gauge of the probes. The raise and lower measuring head also incorporates three gauge support rods on which the slip gauge rests while being measured. The heads are moved apart during gauge insertion. The lower measuring head is fixed and “Upper one is mounted on a ram which is raised/lowered hydraulically to adjust the separation of the measuring heads to suit the nominal size of the gauge being measured. Each step of the control sequence is initiated only when a Signal from a sensor has indicated completion of the "evious action. The sequence is as follows : automatic cmcng of cassettes from the storage rack on to the beam ; ‘stment of ram height to give the correct gap between tuna and the upper measuring head, the placement, in °f each gauge at the measuring position ; and 5 “nloag; hay @i"9 the cassette from the beam after all the gauges een measured,westions and Answers logy and Measurement: ein 187.What are the considerations while manufacturing the slip gauges? The following additional operations are Carried oyt to obtain the necessary qualities in slip gauges uring manufacture. 1. First the approximate size of slip gauges is done by Preliminary operations. 2. The blocks are hardened and wear resistant by a specia| heat treatment process. 3. To stabilize the whole life of blocks, seasoning process is done. 4. The approximate required dimension is done by a final grinding process. 188. How do you calibrate the slip gauges? Comparators are used to calibrate the slip gauges.2014 LIMIT GAUGES: 189.Why the limit gauges- A quick, simple, cost effective Me nce checking Part was needed as a result of the industrial revolution and batch type production. Assembly line concepts requirey Ease of use, little to no training and fixed limit gauges wer, the answer to this need. 190.Draw the flow chart of design for manufacturing. Marketing Functional aspects aspects Operational aspects dependability Durability and | Economic re aspects esthetic aspectstrology and Measurements - Questions and Answers Co 2014 191.Draw the implications manufacturing flowchart. aspects Manufacturing Fitit is the interrelatio between dimensions of mating parts before their assembly —| Key functional requirements Fit between the mating parts __| Tolerances,dimensions onmating pats (I> __,| Manufacturing processes 0 and sequences be Cost of Mfg. a Cost of manufacturingtions and Answers - Ques! Metrotogy and Measurements 192.Draw the steps involved in the evaluation of limits of tolerances. Selection of an appropriate FIT based on Functional requrement Selection of type of shaft and hole Selection of tolerance grade for shaft and hole Evaluation of standard tolerance Evaluation of limits of tolerance Evaluation of Limits of Tolerances.y and Measurements - Qu nS and Answer: metrolog} 2 2014 193.What are the advantages and benefits of using fixed limit gauges: .The cost per piece gauged is the lowest of all inspection methods making fixed limit gauging the most cost effective of all methods. fixed limit gauging is both fast and portable. The size range, both small and large, is constrained by manufacturing “part size” limitations only. it is certifiable; offering traceability to industry accepted standards. “And, fixed limit gauging, when properly manufactured and calibrated, offers a unique “assurance of fit” with mating parts unavailable using virtually any other gauging method. 194.Which materials are used for manufacturing limit gauges. Are generally made of steel, chrome or carbide. 195. Which operation the following gauges are used? "Phin gauges , ii) Standard gauges , iii) Limit gauges, iy ’ r i. 4 Workshop Gauges , v) Inspection Gauges, vi) Purchase ’Ction Gauges and vii) Reference or master gauges. PC rrr ‘Question Bank of Prof.Metrology and Measurements - Ques! ns and Answers 204 i)Plain gauges are used for checking plain (unthreade, holes and shafts. ii) Standard gauges- made as an exact copy of OPPosey (mating) Part. .o the limits of the dimensions. iii) Limit gauges- made t iv) Workshop Gauge: To Check Dimension after manufacture, v) Inspection Gauge: To check part before final acceptance, vi)Purchase Inspection Gauge: To check part of other factory. vii) Reference or master gauges: To check the dimension of Gauge. 196.Classified the gauges According to the form of the tested surface. (a) Plug gauges for checking holes. (b) Snap and ring gauges for checking shafts. 197. Classified the gauges according to their design. it and double limit gauges. (a) Single I (b) Single ended and double ended gauges. (c) Fixed and adjustable gauges. ease jon Bank of Prof. Dr. AHMED.d Measurements - Questions and Answe! metrology 2” ce 2014 jgs,raw and describe the cylindrical plug gauge. cylindrical plug gauges are used to check hole diameters. the style or type may vary because of size or manufacturer, put the basic concept of deciding gage size and tolerance is universal for cylindrical gages. The concept is to have two gages, one at each end of the product tolerance or limits. If the diameter being inspected is in size’, (made to the product specifications) the smaller or ‘Go’ gage will easily enter the hole, while the larger or 'No Go' gage will not enter the hole. This concept will not tell us the size of the hole, but it will tell us if the hole is correct or incorrect, making it quick and easy to accept or reject a part, The gauge shown below is a style of go/no go with ~—eF 1 a Explain how to determine the GO and NOGO gauge *S and the gauge tolerance. To to, handle. etermine the GO and NOGO gauge sizes and the gauge - a nc® required we must first start with the part sions to be checked.Metrology and Measurements - Questions and Answers oA For discussion purposes we will use as an example a pay hole of 0.5000 +/- 0.0005. Because the tolerance in this case is applied in bot, directions (bilaterally), we will have to subtract to find the Iow limit (minimum size) and add to find the high limit (maximum size). The low limit is 0.4995 (0.5000 minus 0.0005) and the high limit is .5005 (0.5000 plus 0.0005) therefore, we will need a 0.4995 go gauge and a 0.5005 no go gauge. The gauges must also have a manufacturing and there are several standard options. To decide which option is best we use the generally accepted theory that a measuring instrument should, if possible, be 10 times more accurate. In our example we have a tolerance on the hole diameter of + / - 0.0005, which is a total tolerance of .001. To use a maximum of 10% for both the Go and No Go gages, so we compute 5% for each gage, which comes to 0.00005 (50 mi onths of an inch). tolerance, is applying as a plus tolerance for the 's tolerance for the larger gauge p farther to see if we ca" Our 0.00005 50 ical The gauge tolerance i smaller gauge and as a minu: Now it must be take this one ste lerance grade for the gages. lerance we want to use: tolerance chart for cylindl gages from the standard, ANSI B89.1.5. Using the size range row for our hole size, we are looking for 0.00005 % something smaller. The class X tolerance is 0.00004, slight” less, so we will use the class X gage tolerance. use a standard to or 5% is the maximum tol we check our gauge maker's Guestion Bank of Prof. Dr. AHMED ™: enssurements - Questions and Answers y and Mes 2014 oto 200: Explain how to measure with fixed limit gauges. qo measure with fixed limit gauges, we now will use Ring Gauges with a 0.5005 GO and 0.4995 NOGO. When we use them to check the part, the GO gage should freely slide over the shaft and the NOGO should not go on to the shaft. Notice the GO gauge is the larger or maximum size and the r or minimum size, therefore the Go NOGO is the smalle! a PLUS gauge has a MINUS tolerance and the NOGO has tolerance. At the “Gauge Makers Tolerance Chart” it can find the tolerance class to order our gauge. Notice in our chart that 9.000040 is less than .000050 therefore our gauge needs to be Class x, rof. Dr. AHMED M.EASA tion Bank of PMetrology and Measurements - Questions and Answers log) jor 2014 201. Draw the limit gauge terminology. "7 ¥ olerancs | 4 Hole HOS | } v if C ‘ = Qi/ \ \ | { ie i Ee | Low limit Es s Nisliie-r 4-—-: i = ‘ High limit 60) High 24 ] | | | limit Ley | GO 202. What are the basics which used for the design of limit gauges. 1- Allocation of Tolerance. a- Manufacturing Tolerance. b-Wear Allowance. 2. Taylor’s Principle of gauge Design. 3. Fixing of Gauge elements with handles. a-Taper lock design, b- Trilock Design. a ‘AHMED MEASy and Measurements - Questions and Answers tl 2014 provision of Guards. ,, Provision of Pilot Correct Centering. «materials. 7- Hardness and Surface finish. ity. 9. Alignment of Gauge faces. 203, Explain the elements of allocation of Tolerance. - Allocation of manufacturing Tolerance: (Single Limit). High limit (Hole) = Tolerance on "Not GO" gauge imo ‘on "GO gauge =s0 z Low limit(Hole) (Double Limits)Metrology and Measurements - Questions and Answers a Tolerance on ‘NOT GO gauge : ea vigh be SIZZLE (a Work tolerances J Eee aa ee: a Motetanes eaod ‘gauge Low lt Example ,let the size of the hole to be tested be 25 +0.02mm, Therefore, High limit of hole = 25.02 mm. Low limit of hole = 24.98 mm. Work tolerance =0.04 mm. Gauge tolerance= 10% of tolerance =0.004mm. Dimension of GO Plug/gauge: +0.004 = 24.98 mm. ___Question Bank of Prof Drv AHMED MEAS*and Measurements - Questions and A\ 2014 yet pimension of NOT GO Plug/gauge 40.000 = 25.02 -0.004 204. Give example for calculate the wear allowance. Referring to the previous example: Wear allowance = 5 % of work tolerance = 0.002 mm. Nominal size of ‘GO’ plug gauge = 24.98 + 0.002 =24.982 mm. $0: Dimensions of ‘GO’ plug gauge = 24.982 +0.004 --0.000 mm Dimensions of ‘NOT GO’ plug gauge=25.02 + 0.000 -0.004 mm ltcan be seen the solve of this example in the following figure,westions and Answers Metrology and Mi 25.02mm 24,98mm x y ¥ Application of wear Allowance 205. Taylor’s Principle is the key to design of limit gauges, How. 1-This theory is the key to design of limit gauges, and defines the function (hence the form) of most limit gauges- 2-The GO gauge checks the Maximum Material Condition" (MMC)and should check as many dimensions as possible. 3-The NOT GO gauge checks the Least Material Conditio" (LMC) and should only check one dimension. 4-The GO gauge is used to ensure that the MMC is "% exceeded. Thus, it should be made to the MMC based wear and gauge tolerances which are explained in th following slides. 5-Thus, it should be made to the MMC based on wear a” gauge tolerances which are explained in the followind slides. 143Page_otrology and Measurements - Questions and Answors 2014 eevee a te ime. GO gauge is made to both dimens! 7 Sapa? a condition would arise where the width Cee is within specified limits whereas the length is oversize. Such a gauge will not enter the work, and therefore the work will be accepted although the length is outside the limits (see the figure). Had separate NOT GO gauges been used for checking two dimensions, the width gauge would have accepted the work, but it would have been rejected by the length gauge. Thus, a separate NOT GO gauge is required for each individual dimension. 7-The NOT GO gauge is always relatively short, and approximately equal in length to the hole diameter. The GO gauge should be equal in length to about three or four diameters. This enables to check that the MMC is not exceeded due to geometric errors (e.g. straightness as illustrated in figure). 8-For a hole to be measured; GO gauge is a cylinder whose diameter is equal to the minimum hole size whereas NOT GO gauge is a cylinder that is equal in diameter to the maximum hole size. 9-However, this is not as simple as it is due to the fact that the limits of size are required for the work which states that nothing can be made to an exact size including also the gauges. : The gauge maker needs a tolerance to which the gauges may work. Defining this gauge tolerance relative to the nominal gauge size is critical. For instance; if the gauge tolerance increases the size of GO plug gauge and decreas i NOT GO gauge, then the gauge w es the sina is near the upper or lower tend to rej ich i i reject good work whic Z £® of limits on the other hand; if the vice versa hopper © gauge will tend to accept doubtful work which is jus' >. ‘Question Bank of Pro!‘ions and Answers | Metrology and Measurements - Que: ra d limits. This decision has been made j, in outside the spec’ B.S. 969 as follows: 41) The tolerance on the tolerance zone. 2) The tolerance on the NOT GO gauge shall be outside the work tolerance zone. Allowance must also be made for the initial wear which takes place on a new gauge. Thus, the GO gauge shall be within the Work tolerances shall be: 41) Gauge tolerance = 40% of work tolerance. 2) Wear allowance = 5% of work tolerance. Length of GO plug gauge prevents it entering a non-straight hole. Gauge tolerance Direction of wear Wear allowance | Gauge toterance within Nominal dia. of “Nog GO" of “GO ~ gauge “Not GO" plug gauge "GO" plug gauge Gauge Tolerances. Question‘ogy and Measurements - Questions and Answers Se 2014 06. Expiain Tolerance System in Limit Gauges, there are two systems for the allocation of manufacturing and gauge tolerances: unilateral and pilateral systems. _ unilateral system; the gauge tolerance zones lie entirely within the work tolerance zone. The disadvantage of this gystem is that certain parts may be rejected as if they were cutside the limits. In bilateral system: The gauge tolerance zones are bisected by high and low limits of work tolerance zone. The disadvantages of this system are that parts within working limits can be rejected and parts outside the working limits can be accepted. In modern limit systems, unilateral system is preferred. 8ecause in a hole basic system, the basic size will always be the GO size of: A*limit gauge, which is convenient and Practical, The figure shows the designation for hole "easurement using a plug gauge. For shaft measurement as 4 snap gauge, the order of tolerances between GO “NOT GO must be reversed. In the given example: +0.000 ime F "sion of Go snap gauge is 25.02 -0.000Metrology and Measurements - Questions and Answers a +0.000 Dimension of NOT GO plug gauge = 25.02 -0.004 The above expressions are based on unilateral system, tt bilateral system is used, then the gauge dimensions wouq 24.98+0.002 and 25.02 +0.002, -0.002 Tolerance on High limit Tolerance on ‘not go' gauge ‘not go’ Jnot go'gauge a —'Not go’ Work tolgrance Work ¢olerance go gauge gauge For instance, size of the hole to be tested is 25 + 0.02 mm High limit of hole = 25.02 mm. Low li it of hole = 24.98 mm. Work tolerance = 0.04 mm. Gauge tolerance = 10% of work tolerance = 0.004 mm. Dimension of GO plug gauge = 24.98. -0.000 mm.y and Measurements - Questions and Answers 19) wet 2014 7, How the designer calculate the wear allowance. 0. Y aware allowance is added to gauge dimensions, which is ually taken as 5% of work tolerance .Mostly the voasutind surfaces of GO gauges which constantly rub the surfaces of parts inspection are subjected to sear and hence they lose their initial size. NOT GO gauges gre not subjected to so much wear as GO gauges, so there is considerable wear on GO gauges only. Thus, the wear allowance added to the nominal GO gauge diameter in a direction opposite to wear before the gauge tolerance is applied. against The size of GO plug gauge is reduced while that of GO snap gauge increases. Considering the example in previous part: Wear allowance = 5% of work tolerance = 0.002 mm. Nominal size of GO plug gauge = 24.98 + 0.002 = 24,982(- 0.000) Sinension of GO plug gauge = 25.02 ( -0.004) Ns configuration is illustrated in the figure. Not go Ltlogy and Measurement juestions and Answers 2014 208. Check the following: i) Checking a Bush with a curved Axis. ii) Check Circular Shaft. i)Go Plug Gauge Should Have a Full Circular Section, Lengy, should be equal to the length of the hole. Checking a Bush with a curved Axis. ii) -Ring Gauge should be used as Go Gauge. -Length should be equal to the length of the shaft. am SScaen nna ar rot Be aEand Measurements - Questions and Answers e087 2014 snap Gauge also used as Not Go Gauge. An ould check the low limit of shaft. sho! for non-circular shaft, snap gauge will not pass through. Shaft accepted — _ in this position Shaft rejected in this position How to check Thread or Screw Gauge. Nuts and internal threads are checked with Plug thread Sige and screws with Ring thread gauge. “Thee types of Fits "Close Fit, x "edium Fit, u Free Fit,ons and Answers Metrology and Measurements - Que: . at 210. Designing a Gauge for A 25mm H8-f7 fit. The limit of size for H8 Hole are: High Limit - 25.033mm. Low Limit - 25.000mm. The limits for the f7 shaft are: High limit - 24.980 mm. Low limit - 24.959 mm. Taking the gauge makers tolerance to be 10% of the work tolerance, design plug gauge and gap gauge to check the fit. 211.What are the steps which are used for design limit gauge. The following steps are follow to design limit gauge: 1-Find tolerance for hole and shaft. 2-Find gauge tolerance. 3-Basic Size for “Go” Plug Gauge is LL of Hole. 4-Basic Size for “Go” Plug Gauge is HL of Hok le. And For plug gauge the following steps are used: a- High limit of “Go” Plug gauge. 15114 Measurements - Questions and Answers joay a” petro! Low limit of “Go” Plug gauge. Be qcHigh limit of “Not Go” Plug gauge. glow limit of “Not Go” Plug gauge. e- Repeat for Snap gauge | praw the Diagram of “Go”, “Not Go” Plug gauge and “Go”, “Not Go” Snap gauge. 212. What are the advantages of limit gauges? The advantages can be summarized as follows: Limit gauges are conveniently used in mass production for controlling various dimensions. They can easily be used by semi-skilled people. They are economical in their own cost as well as engaging cost. 213. What are the limitations of limit gauges? ‘Do not indicates the actual size of the component. " Susceptible for wear, expansion and collapse. F Large number of gauges is required necessitating larger Pace, “annot handle finer quality jobs due to precision issues. SR, ‘ Require frequent checking of gauge dimensions.Metrology and Measurements - Questions and Answers PART SIX ERRORS OF MEASUREMENTS Question Bank of Prof. Dr. AHMED MEAS!sa.explain the following types of errors, 2h systematic errors and Random errors, systematic errors due to faulty or improperly calibrated instruments. These may be reduced or eliminated by careful choice and calibration of instruments. Sometimes bias may be linked to a specific cause and estimated by analysis. In such a case a Correction may be applied to eliminate or reduce bias. Bias is an indication of the accuracy of the measurement. Smaller the bias more accurate the data. Random errors are due to non-specific causes like natural disturbances that may occur during the measurement process. These cannot be eliminated. The magnitude of the spread in the data due to the presence of random errors isa measure of the precision of the data. Smaller the random error more precise is the data. Random errors are statistical innature. These may be characterized by statistical analysis, 415. Explain a method for analyzing the sample error. ree Sample error analysis assumes the following system tctications, The resolution of the DMI system is 0.31nm but tn “fal system accuracy can exceed 300nm due to other ter Sentributors. The most significant error contributors are te, pee ; : te 9, ORSibility of the user (U) with the two largest being "egy ooment and the quality of the target optic. The errorjetrology and Mea: (m) ments - Questions and Answers ms 2 OY clude the laser frequency stability, interte, polarization mixing and electronics linearity. Om ~U__| Temperature variation 1,0C° gaa U | Pressure vari tion _| 0.25 mmHg _U__|Humidity variation 10% __U__|Range of motion commis io |Deadpath distance 42:7mm) M Interferometer deadpath /10.96mm_ _ M__ Thermal coefficient [0.014pm/co M_ Laser stability |0.01ppm q M Electronics accuracy 1.3 counts(1.6nm) _ __M _| Polarization mi: _ | 2.0 nm U Target mirror angle | Surad Sy U__| Abbe’ offset |imm U__| Target mirror flatness [N10 P-V(63.3nm) 216. what is the cosine error results from. Cosine error results from an angular misalignment betweer | the measurement axis and the axis of motion. Ta‘ uniformity represents the error caused by uncompensaté surface figure variation in the target mirror. Abbé © results measurement axis and the axis of motion of the part ¥™ test. Typically, target mirror non-uniformity is the !4! geometrical error source. 155Page >. from an offset between the plane of Question Bank of Prof. Dr. / "AHMED MEE ,y and Measurements - Questions and Answers 109) metrol 2014 yi7.explain Abbé Error. axis to be medSured Distance measured Abbe’ error (:) = L. tan@ When the axis of measurement is offset from the axis of interest, Abbé errors will occur. As first described by Dr. Emst Abbé of Zeiss: ‘If errors of Parallax are to be avoided, the measuring ‘ystems must be placed coaxially to the line in which ‘isplacement is to be measured on the workpiece.” “8.Explain Opposite Axis Errorns and Answers surements - Ques! ' Metrology and Mea: Opposite axis errors are often present in mechanic, measuring systems. 1 i i n pe i An opposite axis error is caused when perpendicular Axey are not truly orthogonal to each other. This error is typicay, eliminated when a standard DMI system alignmen procedure is followed. 219.Explain Instrumentation Errors. + Laser 1.6nm + Electronics 0.4nm + Interferometer 2.0nm * Data age uncertainty 0.2nm Total (sum) 4.2 (rss) 2.6nm Instrumentation errors are not under the user’s control. These errors are based on the supplier’s system parameters: The basis of a DMI is the wavelength of the laser source: Stability circuitry within the laser head is designed ! control the output frequency of the laser tube at a fixed value. The contribution of the electronic uncertainty to the ef analysis is a product of the electronic accuracy of th? measurement board and the be pemecceent optical resolution of poet” mixing errors are caused by imperfections in Beg on roneteaend thelr coatingssiThiserrer cag be by optimizing the rotation of the interferome!™” Question Bank of Prof. Dr. AHM!metrol09Y and Measurements s and Answer 2014 the optical axis. ost ee a xis. The magnitude of th ain ot rease if the optical align: ee cage one eres eee ment causes the mesa to the plane of optical components with dielectric coati polarization sensitive and can induce Sit ae ional errors if not aligned properly. oo.explain Polarization Leakage Err. ‘or. Polarization leakage cause: Ss frequency mixii a y mixing Minimize leakage by maintaining square beam P. im Path. Polarizati Te Within nee of the laser’s frequency components eiieen tna ‘erometer causes a nonlinear relationship ‘sHlacoment measured displacement and the actual iting, a a To cal imize errors caused by polarization : ce ae relationship must be maintained = the ee frequency components of the laser head Wonents, ‘ion of the polarization-sensitive opt > TR ces hon i of rot Dr, ANNED MESS ticaly and Measurements - Questions and Answers 2oy The angular rotation of the interferometer about the ° axis should be limited to less than 1 degree to mj polarization errors. tic, Nimizg 221.Explain Environmental errors. Index change(measurement) : Index change(deadpath) | 16.8nm Interferometer thermal 18.0nm Substrate expansion 0.0nm Turbulence 9.4nm Total ( sum) 407.5nm | (rss) 364.3nm Environmental errors are usually the largest contributor toa DMI error budget. Variations in the index of refraction of the air alter the wavelength of the laser source and change the apparent length of the optical path. The index of refraction changes with deviations in the temperature, pressure and humidity. Controlling or monitoring the environment % minimizing the measurement time will reduce environmentally induced errors. Question Bank of Prof. Dr. AHMED MEASotto! and Me: 2014 22. explain Deadpath Error yon pead Path Target at position [Al to interfrometer REE Reference path Sy distance ae (le | Interferometer Deadpath =R-M Measurement path Deadpath=(R-M) + D distance Deadpath distance Dead path is the difference in distance in air between the reference and measurement paths of an interferometer configuration. The deadpath error is caused by a change in the environment during the measurement. To minimize deadpath distance, locate the interferometer as close to the target mirror as_ possible. Mini 3 environmental changes during the time of the measurement also reduces the deadpath error. 223.Explain air turbulence ‘Movement of thermal gradients in the air through ‘he beam path. “Magnitude of the air turbulence effects can be Large. en air turbulence. 'S Covering the beam path. 160 . AHMED M.EASA Question Bank ofuuestions and Answers 2014 -Operating in helium atmosphere. Air turbulence is movement of thermal gradients in the air through the beam path. The magnitude of the air turbulene, effects can be large if precautions are not taken, 1), simplest precaution is to place tubes along the beam Path, except where there is actual motion. More extreme, and effective, methods include operating in a helium atmosphere or operating in a vacuum. 224. Classify the Absolute error. The absolute error is classified into. 1. True absolute error, 2. Apparent absolute error. 225. What is Relative error? Relative error is defined as the results of the absolute error and the, value of comparison used for calculation of that absolute error. The comparison may be true value or conventional true value or arithmetic mean for series * measurement. 226. Classify the errors The errors can be classified into 1. Static errors - Reading errors 161Page __Question Bank of.d Measurements - Questions and Answe: petrology an = 2014 “gharacteristic errors, “Environmental errors 5 Loading errors 3. Dynamic error, wo7, classify the Absolute error. the absolute error is classified into 1. True absolute error, 2. Apparent absolute error. 228. What is Relative error? Relative error is defined as the results of the absolute error and the, value of comparison used for calculation of that absolute error. The comparison may be true value or conventional true value or arithmetic mean for series of measurement. 229. Classify the errors fe errors can be classified into "Static errors - Reading errors ; ““haracteristic errors, eel errors 'Ng errors 3. Dynamic error.