ME1035 METROLOGY AND

QUALITY CONTROL
 UNIT- I
INTRODUCTION TO METROLOGY
 Metrology

Metrology defines as the Science of

pure measurement. But in engineering
purposes, it in restricted to
measurements of length and angles
and other qualities which are
expressed in linear or angular terms.
 Units and Standards
• Units of Measurement:
• C.G.S. System of Units
• Centimeter – Gram – Second system of unit
• M.K.S. System of Units:
• Meter – kilogram – second system of units
• International System (SI) of Units:
• the meter (m), kilogram (k), second (s), and
ampere (A) of the MKSA system and, in addition,
the Kelvin (K) and the candela (cd) as the units of
temperature and luminous
 Terminology in instrumentation

• Precision  Degree of repetitiveness. If an

instrument is not precise it will give different
results for the same dimension for the
repeated readings.
• Accuracy  The maximum amount by which
the result differ from true value(ie) Closeness
to true value
• Calibration
• is the process of establishing the relationship
between a measuring device and the units of
measure. This is done by comparing a devise
or the output of an instrument to a standard
having known measurement characteristics.
• Sensitivity
• It is ratio between output signal to input signal
• Readability is a measure of an instrument's
ability to display incremental changes in its
output value.
• True size  Theoretical size of a dimension
which is free from errors.
• Actual size  size obtained through
measurement with permissible error
• Repeatability is the variation in measurements
taken by a single person or instrument on the same
item and under the same conditions. A
measurement may be said to be repeatable when
this variation is smaller than some agreed limit.
• Reproducibility is one of the main principles of the
scientific method, and refers to the ability of a test
or experiment to be accurately reproduced, or
replicated, by someone else working
independently.
 LEGAL METROLOGY
• Legal metrology is that part of metrology which treats units of
measurement, methods of measurement and the measuring
instruments, in relation to the statutory, technical and legal
requirements.
• It assures security and appropriate accuracy of measurements.
• Lack of legislation regarding various measures will lead to great
uncertainty.
• It is directed by a national organisation viz., National service of
Legal metrology whose object is to resolve problems of legal
metrology in a particular country.
• Its functions are to ensure the conservation of national standards
and to guarantee their accuracy by comparison with international
standards and also to impart proper accuracy to the secondary
standards of the country by comparison with international
standards.
• Methods of measurement.
• 1. Direct Method
• 2. Indirect Method
• 3. Comparison Method
• 4. Coincidence Method.
• Classification of measuring instruments.
• 1. Angle measuring instruments
• 2. Length measuring instruments
• 3. Instruments for surface finish
• 4. Instruments for deviations.
 Sources of error
• Controllable Errors-
• Calibration Errors ,ambient Conditions , Stylus
pressure, avoidable errors
• Random Errors
• These occur randomly and the specific causes of
such errors cannot be determined, but likely
sources of this type of error are small variations
in the position of setting standards and
workpiece, slight displacement of lever joints in
the measuring joints in the measuring
instrument,
Parallax Error :
• On most dials the indicating finger or pointer
lies in a plane parallel to the scale but
displaced a small distance away to allow free
movement of the pointer. It is then essential
to observe the pointer along a line normal to
the scale otherwise a reading error will occur.
Line and End standard measurements
• Line standard
• Length is expressed as the distance between
two lines.
• End standard
• Length is expressed as the distance between
two flat parallel faces
 PRINCIPLE OF LEAST SQUARES
• Assessment of deviation of errors relative to some particular datum may
be done with the help of the principle of least squares.
• The principle states that the most probable value of observed quantities is
that which renders the sum of the squares of residual errors a minimum.
• Let the most probable value be assumed as x’
• Then the deviation of any particular value from the most probable value x’
is (x-x’). From the least sqaure principle Ʃ(x-x’) should be minimum (i.e)
d Ʃ(x-x’) = -2 Ʃ(x-x’) = 0
dx’

Therefore, Ʃx – nx’ = 0 or x’ = Ʃx/n = arithmetic mean

 Linear measuring instruments
• Straight edge.
• Outside caliper.
• Inside caliper.
• Vernier caliper
• Screw gauge
• vernier height gauge
• vernier depth gauge
• Dial gauges
 Comparators
Classification of comparators
• Mechanical
• Electrical and Electronics comparators
• Optical comparators
• Pneumatic comparators
• Fluid displacement comparators
• Projection comparators.
• Multi check comparators
• Automatic Gauging Machines
• Electro-Mech. Comparators.
 Classification of measuring
Instruments
According to the functions:
• Length measuring instrument
• Angle measuring instrument
• Instrument for checking deviation from
geometrical forms
• Instrument for determining the quality of
surface finish.
According to the accuracy.
• 1. Most accurate instruments
Example - light interference instrument
• 2. Less accurate instrument
Example - Tool room Microscope,
Comparators, Optimizer
• 3. Still less accurate instrument
Example - Dial indicator, vernier caliper.
 Angular measurements

Measuring the angle of Taper.

• 1. Vernier bevel Protractor

• 2. Tool room microscope
• 3. Sine bar and dial gauge
• 4. Auto Collimator
• 5. Taper measuring machine
• 6. Roller, Slip gauge, and micrometer.
Angle measurement
• Sine bar
• Sine Centre:
• Sine Table
Taper Measurement
• Using Precisions Balls and Rollers
Slip Gauges
• Direct precise measurement, where the accuracy of the work piece
demands it.
• For checking accuracy of venire calipers, micro metes, and such
other measuring instruments.
• Setting up a comparator to specific dimension.
• For measuring angle of work piece and also for angular setting in
conjunction with a sine bar.
• The distances of plugs, spigots, etc. on fixture are often best
measured with the slip gauges or end bars for large dimensions.
• To check gap between parallel locations such as in gap gauges or
between two mating parts.
• Slip gauges are rectangular blocks of high grade steel with
exceptionally close tolerances. These blocks are suitably hardened
though out to ensure maximum resistance to wear. They are then
stabilized by heating and cooling successively in stages so that
hardening stresses are removed.
 Surface finish measurement
• Surface finish refers to the quality finish or
roughness over the surface.
• Surface texture :
• Repetitive or random deviations form the normal
surface which form the pattern of the surface.
Surface texture include roughness, waveness, lay
and flows.
• Primary texture : This refers to the roughness
of a surface, as opposed to its waviness
(secondary texture)
 Methods of measuring surface finish
1. Surface Inspection (or) comparison method
2. Direct Instrument
a) Touch Inspection
b) Visual Inspection
c) Scratch Inspection
d) Microscopic Inspection
e) Surface photograph
f) Micro - Interferometer
g) Wallace surface Dynamometer
h) Reflected light Intensity
 Roughness measurement
• Maximum Peak to Valley. Height of
Roughness.
• Root Mean Square Value (R.M.S. Value)..
• Centre Line Average Method (C.L.A. Value)
 Surface finish measuring instruments
• Profilometer.
• The Tomlinson Surface Meter
• Taylor-Hobson Talysurf.