METROLOGY TUTORIAL

CHAPTER 1

CALCULATION OF MEASUREMENT UNCERTAINTY

1. An electronic caliper (resolution – 0.01 mm) was used to measure the length of an object.
Five measurements were made. The results of the five measurements are: 21.53 mm,
21.51 mm, 20.52 mm, 21.48 mm, 21.42 mm. The workshop temperature during
measurement was 210C. The calibration certificate of the electronic caliper says that the
device will read within ±0.004 mm of the correct answer if it is used correctly and when
the temperature is within 0 to 400C. Estimate the expanded uncertainty at a coverage
factor of 2 providing coverage probability of approximately 95%.
2. An MCB was calibrated using a Digitizer with Amplifier. Five readings were taken and they
are 250.2 V, 250.3 V, 250.1 V, 250.2 V, 250.3 V. The accuracy of the digitizer with amplifier
from its calibration certificate is 0.16% of reading. The Uncertainty of calibration of the
digitizer with amplifier from its calibration certificate is 0.281%. The distribution is normal
and the coverage factor is 2 for approximately 95% confidence level. The resolution of the
software is 0.0001 V. Estimate the expanded uncertainty at a coverage factor of 2
providing coverage probability of approximately 95%.
3. A vernier caliper is used to measure a particular dimension in a component in a laboratory
whose temperature is maintained at 200 C ± 0.50C. Ten readings are taken and are given to
be – 299.40 mm, 299.42 mm, 299.40 mm, 299.40 mm, 299.40 mm, 299.40 mm, 299.42
mm, 299.40 mm, 299.42 mm, 299.40 mm. The calibration chart of the vernier caliper
states that the uncertainty of the caliper is 0.001% of the reading with a coverage factor of
k = 2 at a confidence level of 95%. The vernier caliper has a least count of 0.02 mm. The
coefficient of thermal expansion applicable to the vernier caliper and component is 11.5
μm m-1 0C-1. Estimate the expanded uncertainty at a coverage factor of 2 providing
coverage probability of approximately 95%.
4. A micrometer of resolution 0.01 mm is calibrated using a gauge block. The certified length
from the calibration certificate of the standard gauge block at 200C is 20 mm. Five readings
are taken and the mean of the five readings is 20.01 mm with a standard deviation of
0.007071 mm. The associated uncertainty in the nominal dimension is 0.6 μm at a
coverage factor of 2 with a 95% confidence level. The drift with time of the certified length
of the standard gauge block is zero with an associated uncertainty of ±0.15 μm. A
triangular distribution can be assigned to this uncertainty contribution because prior
experience shows that the drift reached the limits only with diminishing probability. The
coefficient of thermal expansion applicable to the gauge block and micrometer is 11.5 μm
m-1 0C-1 with limits of ± 1 μm m-1 0C-1. The difference between the mean temperature of
the micrometer and the gauge block and the reference temperature of 200C was
 measured and was assigned limits of ±0.20C. Estimate the expanded uncertainty of the
calibration process at a coverage factor of 2 providing coverage probability of
approximately 95%.
5. A digital micrometer is calibrated at 25 mm using Grade 0 steel gauge blocks. The readings
obtained are 25.000 mm, 25.001 mm, 24.998 mm, 24.999 mm, 25.000 mm, 25.005 mm,
25.003 mm, 25.002 mm, 25.001 mm, 25.000 mm. All dimensions are in mm. The
coefficient of thermal expansion of the gauge block is 10.8±0.5 (10-6/K). The limit deviation
of grade 0 gauge blocks upto 25 mm lengths is given to be ±0.2 μm as per ISO specification
for grade 0 gauge blocks. The resolution of the micrometer is 1 μm. The laboratory
temperature is maintained 200 C ± 0.5 0C. Considering the laboratory’s procedure for
thermal soaking, the lab estimates a maximum temperature deviation of ± 0.5 0C between
the parts. What is the uncertainty of the calibration process?
CHAPTER 2
LIMITS
1. Calculate the limits of sizes for 100 G7/e8 and identify the fit.

2. A hole and shaft have a basic size of 25 mm and are to have a clearance fit with maximum
clearance of 0.02 mm and a minimum clearance of 0.01 mm. the hole tolerance is to be
1.5 times the shaft tolerance. Determine limits for both hole and shaft using (i) hole basis
system (ii) shaft basis system.

3. A 100 mm diameter journal and bearing assembly has a clearance fit with the following
specifications:
 Tolerance on bearing = 0.005 mm
 Tolerance on journal = 0.004 mm
 Allowance = 0.002 mm
Determine the sizes of the bearing and journal on (i) hole basis system (ii) shaft
basis system. Take unilateral system of tolerances.

GAUGE DESIGN
1. Determine the actual dimensions to be provided for a shaft and hole of 90 mm size for
H8e9 type clearance fit. 90 mm falls in the diameter range 80 and 100. The fundamental
deviation for e shaft is -11D0.41. Design the GO and NO GO ‘workshop’ and ‘inspection’
gauges as well as gauges as per the present British system (‘general system’).

2. Design the “general” type GO and NO GO gauges for a 50H7/d8 fit. 50 mm lies in the
diameter range 30 to 50. Show graphically the disposition of gauge tolerance zones
relative to the work tolerance zones. The upper deviation for the shaft = -16D0.44.