Metrology

by

P.Venkateswara Rao
Professor in Mechanical Engg.
IIT Delhi
 International Prototype: Meter
____________________________
 Sub division of Standards
Primary Standards
Secondary Standards
Tertiary Standards
Working Standards
 Wavelength Standards
1 metre = 1650763.73 wavelengths of the
red-orange radiation of the isotope
Krypton-86

Also equal to the length of the path

travelled by light in vacuum during a time
interval of 1/299792458 of a second.
 Standard Terminology
Basic Size: Designer’s dimension and is
same for both shaft & hole
Limits of Size: Maximum & Minimum
permissible sizes of the part
Upper Limit: Maximum size
Lower Limit: Minimum size
(BIS:919)
 Standard Terminology contd..

Upper Deviation: Algebraic difference

between the upper limit & the basic size

Lower Deviation: Algebraic difference

between the lower limit & the basic size
(BIS:919)
 Standard Terminology contd..
Fundamental Deviation: Either of the
upper or lower deviation which is the
nearest to the basic size. It fixes the position
of the tolerance zone with respect to the
basic size
(BIS:919)
 Standard Terminology contd..
Tolerance: Difference between the upper &
the lower limit
Fits: The relationship existing between the
two mating parts which are to be assembled
with regard to the difference in their sizes
(BIS:919)
Standard designation of Fit
Basic size followed by an alphabet
(capital letter representing “hole” &
small letter representing : “shaft” and
quality numbers
For example: 40 H7 g9
Alphabets represent the position of the
tolerance zone w.r.t. the basic dimension
Position of fundamental deviation
Standard designation of Fit
Numbers represent the tolerance grade
(quality): 18 grades of tolerances are
provided i.e. 01, 0, 1, 2, 3, 4, 5, 6, 7, 8,
---------------------,16. The actual
tolerances 5 to 16 are production grade
and are multiples of “ Fundamental
Tolerance Unit (FTU)”
Standard designation of Fit
FTU (i) = (0.45 D1/3 + 0.001 D) in m
and D is in mm where D is the geometric
mean of the lower & upper of a particular
diameter step in which the diameter lies
 The diameter steps are 0-3, 3-6, 6-10, 10-
18, 18-30, 30-50, 50-80, 80-120, 120-180,
180-250, 250-315, 315-400, 400-500.
 Standard designation of Fit
The tolerance value of the each of the
grades are listed below:

Grade 5 6 7 8 9 10 11 12 13 14 15 16

Values 7 i 10 i 16 i 25 i 40 i 64 i 100 i 160 i 250 i 400 i 640 i 1000 i

 Types of Inspection

Inspection by Measurement
◦ Direct
◦ Indirect
Inspection by Gauging
(Limit Gauging)
 Limit Gauging

No attempt is made to determine

the size of the workpiece
To see whether the component
size lies within the specified limits
The inspection is carried out by
GO & NOGO gauges
Plug Gauges (BIS:3484)

16
17
Plain Ring/Snap gauges
(BIS:3485)
Go' plain ring gauge for dimension 'Go' plain ring gauge for dimension
from 3 to 70 mm from 70 to 250 mm

18
19
20
 Inspection by Measurement
Direct Measurement
◦ Vernier Caliper, Vernier Height
gauge, Verneir Depth gauge
◦ Outside Micrometer, Inside
Micrometer, Depth Micrometer,
◦ Slip gauges (gauge blocks), length
bars,etc.
Indirect Measurement
◦ Comparators
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Slip gauge Box

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 Comparators
Comparing the manufactured part to the
master part envisaged by the designer
Dimensional variation from the master
part can be amplified and measured so as
to get the deviation and the instruments
for doing that are called comparators
◦ Mechanical Comparators
◦ Optical Comparators
◦ Pneumatic Comparators

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 Design Considerations
The instrument must be sufficiently
robust
The system response should be faster
The contact plunger should be provided
with a hardened steel or diamond to
minimize wear & tear
Means should be provided for easy lifting
of the plunger

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 Design Considerations
Magnification should be as high as
possible, but it should also be capable of
measuring the wide range
The recording scale should be linear
The system should have good
repeatability
Comparator should be versatile

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Mechanical Comparators
Dial Indicators

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