Metrology and Measurements QUESTIONS AND ANSWERS 2015 DIFINITIONS AND TOOLS OF MEASUREMENTS: 1. Differentiate between precision and accuracy. Accuracy - The maximum amount by which the result differ from true value. Precision - 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 utilized in the measurement. If energy kind of quantity measured, there must be a unit to measure it. So this will give the quantity to be measured in number of that unit. 5. What are the applications of Legal metrology? 1. 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. a SS SPage ‘Question Bank of Prof. Dr. AHMED M.EASA‘Metrology and Measurements QUESTIONS AND ANSWERS 2015 8. Explain the term magnification. It means the magnitude of output signal of measuring instrument time's increases to make it more readable. 9. What are the important elements of measurements? The important elements of a measurement are: 1. Measure, 2. Reference and 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 values. One is the higher calibration value H, and the other is Lower value L. The difference between H, and Lis called range. 12. What is Resolution? The minimum value of the input signal is required to cause an appreciable change in the output known as resolution. 13. Differentiate between sensitivity and range with suitable example. Example: An Instrument have a scale reading of 0.01mm to 100mm. Here, the sensitivity of the instrument is 0.0mm 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. cei ot ‘Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2025 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 be measured. y like length, diameter, and angle to 16. Define: Deterministic Metrology. The metrology in which part measuremen The new techniques such as 3D error compensation by CN is replaced by process measurement. \C systems are applied. 17. Define over damped and under damped system. Over damped: The final indication of measurement ii approa from one side. Under damped: The pointer approach t and makes a number of oscillations around it. ched exponentially he position corresponding to final reading ile manufacturing the slip gauges? 18. What are the considerations whi s are carried out to obtain the necessary The following additional operation: qualities in slip gauges during manufacture. 1. First the approximate size of slip gauges is 2. The blocks are hardened and wear resis! 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. done by preliminary operations. tant by a special heat treatment 49. List the various linear measurements and draw. (i) Length (ii) Heights and (iii) Thickness. ‘Question Bank of Prof. Dr. AHMED M.EASA PageMetrology and Measurements QUESTIONS AND ANSWERS 2015 Outer member Reading of diameter Sliding member Length and Thickness. Length and Thickness. Page ‘Question Bank of Prof. Dr. AHMED M.EASA2015 |ONS AND ANSWERS Metrology and Measurements QUEST Thinch verines 8)Lock. 4)Outside jows. 2)Inside jows. ‘2)Depth probe. 4)Main scale. Length and Thickness. ‘Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 a aE Metric steel rules (Length). — 10Page Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 Guiding edge. Beam face Scale Beam Fine adjustment screw, Clamp Upper face of jaw- - — measuring face) \ Measuring jaw Lower face of jaw Fine.adjustment clamp Seales \ Depth of measuring jaw Vernier Height Gauge (Height). ————— cr tuestion Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS: 2015, 20. What are the various types of linear measuring instruments? The various devices used for measuring the linear measurements are i. Vernier calipers ii. Micrometers iii. Slip gauge or gauge blocks iv. Comparator.(See the previous figure). 21. Draw and explain the offset caliper. Outside jaw Offest jaw 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. 22. Draw and explain the calipers of swivel jaw. Swivel Jaw be =—— 12Page ‘Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS, 2015 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 ste} shafts having off- of caliper. pped work pieces and centered sections that cannot be measured with standard types 23. Draw and explain the long jaw caliper. Slider Outside measuring face Reference surface Thumb hold Inside measuring faces 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. Reading Fixing Nut Workpiece 13Page ‘Question Bank of Prof. Dr. AHMED M.EASA.Metrology and Measurements QUESTIONS AND ANSWERS 2015 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. 25. Draw and explain the offset calipers for hole distance measurement. tt Ww Saws 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 in 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 operator errors. The instrumental error (deviation of reading) is the error that is inherent to a measuring instrument. 1aPage ‘Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 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 position should be close to zero and the other close to full 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 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 position should be close to zero and the other close to full range. Check that parallelism is not affected by clamping the slider. The squareness of the fixed face to the guiding edge should faces should be checked with an optical flat. ——_ 1sPage Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 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. Straightness of inside faces 30. How to Set-up and preparation the caliper. ‘for measurement. 1. 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 calibration has expired, use another caliper whose 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. ‘Question Bank of Prof. Dr. AHMED M.EASA 16PageMetrology and Measurements QUESTIONS AND ANSWERS 201g 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 (452). Check the sliding action again. Repeat the procedure while adjusting the angular position of the screws until an appropriate sliding smoothness is obtained. 7. Check the zero reading. 31. Explain briefly the Steps of measurement on the caliper. Steps of measurement are as follows; 1. 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 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 recording the mean can give extra confidence in measurements and is necessary for estimating the uncertainty of measurement. ———— ‘Question Bank of Prof. Or. AHMED M.EASA 17PageMetrology and Measurements QUESTIONS AND ANSWERS 2015 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. 33. Explain the methods of Handling and storage of Calipers. Calipers are often used in hostile environments and their maintenance tends to be overlooked perhaps because of their apparently simple construction and the low accuracy use to which they are often put. However, in order to obtain the best possible performance from calipers and to ensure economical use, it is essential to implement effective maintenance control. As with other types of measuring instruments, companies should have standardized rules that govern purchasing, training, handling, storage, maintenance and periodic inspection of calipers. 34, Explain an effective method for maintenance the calipers. ‘An effective method of maintenance control for measuring tools, such as calipers, which are frequently used on the shop floor, is to limit the number of tools in the tool room and on the shop floor. Although calipers are relatively cheap, they are not consumables and should not be treated as such. When purchasing a caliper, the type, size, accuracy and service life ofithe caliper should all is considered with respect to the user's specific application. For example, if an application requires aMetrology and Measurements QUESTIONS AND ANSWERS 2015 discrimination of 0.05 mm the purchase of a caliper with a discrimination of 0.02 mm would be uneconomical and could possibly increase the inspection time. 35. Explain the steps which should be observed when storing calipers. The following precautions should be observed when storing calipers: 1. Select a place where the callipers will not be subject to dust, high humidity or extreme temperature fluctuations. The storage area should not be damp and it is worth taking the extra precaution of placing a bag of silica gel in the tool draw. 2. Lay calipers so that the main scale beam will not bend and to protect the vernier from damage. 3. Leave the measuring faces so that they are not in contact. A gap of about 2 mm is suggested. 4, Do not clamp the slider. 5. Store the caliper in a case or plastic bag. 6. When storing large size callipers, which are not frequently used, apply a rust preventative to the sliding and measuring faces and separate the two jaws. Avoid Tust preventatives that leave a coating on the material being protected. This type of rust preventative material can affect the calibration of dial type calipers. 7. At least once a month, check the storage condition and movement of calipers that are seldom used and kept in storage to ensure that no deterioration has occurred. 8. Prevent vapors from chemicals such as hydrochloric or sulphuric acid from permeating storage rooms. 9. Keep a record of calipers that are stored. Ensure that detailed information is maintained on all calipers in use on the shop floor. It is also good practice, during the daily use of a caliper, to wipe it clean of dirt and finger prints with a clean lint-free cloth and store it with the outside jaws slightly open after the measurements have been carried out. 10. Calipers should never be left unprotected on a swarf-covered bench or in an environment where the graduated face is regularly exposed to cutting chips and dust, since the graduations may become hard to read due to scratches or stains and slider movement may become uneven. Once a measurement is complete, the calipers should be cleaned and stored properly. ee 19Page ‘Question Bank of Prof. Dr. AHMED M.EASAM ]etrology and Measurements QUESTIONS AND ANSWERS 2015 36. What are the causes of uncertainty when using micrometers? Because measurements are Never made under perfect conditions, errors and er of sources: these errors include bias, changes due to agein wear drift, poor readability etc, i ae 2-The item being measured component after machining process, ~ the workpiece may not be dimensionally stable. A can be hot due to heat generated in the machining 3-Form and surface finish errors can also contribute to the overall measurement uncertainty. 4-The measurement process - the measurement may be difficult to make. Remember maximum accuracy may be obtained only when the scale (in this case the axis of the spindle thread) is in line with measured. 5-Ignoring the errors given on the calibration certificate. 6-Imported uncertainties - When the micrometer is calibrated the measured errors have an uncertainty which is then built into the uncertainty of the Measurements you make. the axis of the object being 7-Temperature effects e.g. measuring a brass arte fact with a steel micrometer at a temperature other than 20.0 °C. 37. Explain the method which used for handling and storage of micrometers. The following routine covers the handling and storage of micrometers .Checks should be made on a regular basis. 1-Check the condition of the plating and paint. There should be no discoloration, peeling or rust. 2-The measuring faces should be free from scratches and burrs. 3-Check the fit of the threads: The screw should turn freely over the entire operation and be free from backlash. / ; 4-The threads of the spindle and inner sleeve should permit easy adjustment of the fit when they become worn. : 5-Any misalignment that may exist between the spindle and the anvil should be small enough so as not affect measurement (0.002 inch for a 0-1 inch micrometer). uestion Bank of Prof. Dr. AHMED M.EASA 20Page QuesMetrology and Measurements QUESTIONS AND ANSWERS 2015 6-The spindle should be easy to clamp. The micrometer reading should not change by more than 2 um when the spindle is clamped. 7-The ratchet stop should rotate smoothly. 8-The clearance between the thimble and the sleeve should be even around the circumferences. 9-The run out of the thimble should be minimal (should not be seen by the naked eye). 10-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. The steps of daily inspection to maintain micrometer accuracy are as follow: ‘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. 2-Checking the measuring force: A variation in the mea affects the accuracy. For micrometers with a ratchet stop, barrel turns smoothly and otherwise functions correctly. 3-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 spindle and other threaded parts move smoothly and evenly over their entire traverse. Eliminate excessive play or backlash with the adjusting device (taper nut). 4-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. suring force significantly check that the ratchet 38. Briefly describe the steps of Cleaning and rust prevention for micrometers. The steps of Cleaning and rust prevention for micrometers are as follow: L-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 ‘Question Bank of Prof. Dr. AHMED M.EASA 21PageBT Metrology and Measurements QUESTIONS AND ANSWERS 2015 carbide tipped, wipe clean and apply a rust-preventing oil. Separate the two measuring faces slightly before storing the instrument. 2-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. 3-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 small. If the micrometer has been stored for a long period of time, inspect it thoroughly before use. 39, 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. 40. 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 micrometer 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 result in variations of measurements, which may result 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. Pare ‘Question Bank of Prof. Dr. AHMED M.EASA,Metrology and Measurements QUESTIONS AND ANSWERS | 2015 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: 1- Inspection criteria (e.g. Manufacturers specification, National or International Standard or company internal specification). 2-Periodic inspection interval (dependent on usage and calibration history) 3-Items and procedures of inspection (defined equipment and procedure documents). 4-Criteria for inspection result judgments (Pass/Fail rules). 41. 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: 1-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 could detrimentally affect the adhesive used in the assembly of the instrument. 3-Do not apply voltage to the micrometer as this may 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 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 23Page Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS | 2015 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. 42. 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". 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. [Bezel Lock Tighten to lock the bezel in place. Bezel Rotate the bezel to zero the needle. [Tune counter Mia ‘Markers [Counts the tums of the ‘ Move these to provide Ineedl reference points. Pai Can be replaced with other shapes. 43. 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 [Piunger IMoves in and out. manufacturing process. 2. On the workshop floor to i production run. . _ f 3, By toolmakers (mold makers) in the process of manufacturing precision tooling. 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 Question Bank of Prof. Dr. AHMED M.EASA 2aPage nitially set up or calibrate a machine, prior to aMetrology and Measurements QUESTIONS AND ANSWERS 2015 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 ina 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. 44. Explain the set-up which are used for different operation of dial indicator. The following steps are used for different operation of dial indicator; 1. 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, press and many other shop items. drill (eiaeRaRe ‘Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 45. 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: a- Dial face has dual directional graduation of 0.001. b- Revolution counter is graduated in 0.1”. c- One full revolution of large pointer is one increment of revolution counter. Example: The small pointer is between 1. And 2. Or between 6 and 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 46. 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 between the lines equals 0.001" (one thousandths of an inch). 4. These numbers represent 0.010" (ten thousandths of an inch). 5. The contact point touches the surface to be measured. 6. Each number on the decade counter represents one full rotation of the needle and is equal to 0.100" (one hundred thousandths of an inch).(See figure below). =—_—_=— 26Page >f. Dr. AHMED M.EASA,Metrology and Measurements QUESTIONS AND ANSWERS | 2015 ——_——_— 47. What are the components of magnetic base? List of the magnetic base components is as follows (see figure below): 1. 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. 8. The boom supports the mounting assembly. Magnetic base components 48. Whee are the preparation (SET) of Dial Indicator for measurements? The indicator must be secured to the base prior to use (see figure below). i aa the lock knob that secures the mounting stud to the boom and remove e stud. 27P age Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS | | 2015 2 Unscrew and remove the knurled nut and flat washer from the mounting stud, oe 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. 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. 9. 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 is 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 fall. TT Ter TviTCe 22Page Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS | 2015 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. 4. Gently, try to lock the base after turning the switch to the ON position to ensure that the setup is secure. = Fine - tune adjustmeant fa Movement of base components 50. 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. 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). 29Page Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 The indicator can be oriented in any direction by loosening the mounting stud, loosening the boom and raising the boom along the column. ae a3 [Fins “tune adjustmeent knpb || ahr S Fine tuning the dial to read zero or any other reference point is made easy with the fine-tune adjustment knob. 51. 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. ee 30Page Question Bank of Prof. Dr. AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 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. al Lever type. With the advent of electronics and LCDs the clock face and analog display has been replaced with digital displays, these have the added advantage of being able to record and transmit the data electronically to a computer. 1n Bank of Prof. Dr. AHMED M.EASA 31PageMetrology and Measurements ments QUESTIONS AND ANSWER: S 2015 Digital type. 52. 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 a 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 work piece, with the ultimate aim of reducing it to a suitably small range by small hock jaw adjustments. 53, Explain the method of read an angle using (a bevel protractor). °=60', “Vernier div. = 1/12th of main div. = 0. “The highest figure: 50 * (main div.) = 50° : “The matching figure: 4 * (vernier div.) = 0.3332 = 20°, The final reading is: = 50.3332 or 50° 20°. 32Page QuMetrology and Measurements QUESTIONS AND ANSWERS | 2015 54. 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. 55. 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 measurement while the piece is under process. This is known as In-process or Real-Time inspection. 56. What is the amount of time required for the inspection? -The'amount of time required for the inspection depends on: 1. The nature of the product. 2. The degree of accuracy required, 3. Type of equipment used, and, 4. How skilled the operator is. 57. What are the basic requirements of the inspector? The basic requirements of the inspector should be: 1. Given an authoritative position for certain decision making. 2. Ability to do his work. 3. Impartial, and 4. Good experience in his field. 58. What is the Measurement? It is the process of quantitative comparison between a predetermined standard and an unknown magnitude. ——_—_—$ 112Page Question Bank of Pr2015 Metrology and Measurements QUESTIONS AND ANSWERS ; ing systems. Opposite axis errors are often present in mechanical ean a An opposite axis error is caused when perpendicular axes are not truly ; DMI to each other. This error is typically eliminated when a standard DMI system alignment 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 sou! the laser head is designed to control the out, fixed value. ce. Stability circuitry within Put frequency of the laser tube at a The contribution of the electronic uncertaint the electronic accuracy of the measurement the interferometer. 'y to the error analysis is a product of it board and the optical resolution of Polarization mixing errors are caused by imperfections in the Optical components and their coatings. This error can be minimized by optimizing the rotation of the interferometer about the optical axis, The Magnitude of the polarization mixing error will increase if the optical alignment causes the incident beam not to lie perpendicular to the plane of incidence, Optical components with dielectric coatin, Kc ‘8 are very polarization sensitive and can induce additional errors if not aligned properly, 220. Explain Polarization Leakage Error, Polarization leakage causes frequency mixing - Minimize leakage by maintaining Square beam Path, ana Question Bank of Prof. Dr. AHMED M.EASAM }etrology and Measurements QUESTIONS AND ANSWERS 2015 Polarization mixing of the laser’s frequency components within the interferometer causes a nonlinear relationship between the measured displacement and the actual displacement. To minimize errors caused by polarization mixing, a perpendicular relationship must be maintained between the two frequency components of the laser head and the orientation of the polarization-sensitive optical components. The angular rotation of the interferometer about the optical axis should be limited to less than 1 degree to minimize polarization errors. 221. Explain Environmental errors. Environmental errors are usually the largest contributor to a 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 or minimizing the measurement time will reduce environmentally induced errors. IMED MEAS 14Page Question Bank of Prof. Dr. AH SA| 2015 ERS Metrology and Measurements QUESTIONS AND ANSW 222. Explain Deadpath Error Dead Path Target at position to interfromoter R Reference pat distance wl? 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. Minimizing 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 the beam path, - Magnitude of the air turbulence effects can be Large. - Minimize air turbulence. -Tubes covering the beam path. -Operating in vacuum. -Operating in helium atmosphere. Air turbulence is movement of thermal gradients in the aj path. The magnitude of the air turbulence effects can been ee a not taken. The simplest precaution is to place tubes along the beam See are where there is actual motion. More extreme, and effective, method. except operating in a helium atmosphere or operating in a vacuum, S include 115Page Questo westion Bank of Prof. Dr ‘AHMED M.EASAMetrology and Measurements QUESTIONS AND ANSWERS 2015 224, Classify the Absolute error. The absolute error is classified into: 4. True absolute error and 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 of measurement. 226. Classify the errors The errors can be classified into 1, Static errors - Reading errors - Characteristic errors,- Environmental errors 2. Loading errors and 3. Dynamic error. 227. 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 The errors can be classified into 1. Static errors - Reading errors - Characteristic errors,- Environmental errors 2. Loading errors 3. Dynamic error. 116Page Question Bank of Prof. Dr. AHMED M.EASA