Unit – 5

Metrology & Instrumentation

Engineering metrology: Defined as the measurements of
dimensions: Length, thickness, diameter, taper, angle, flatness and
profiles.
In-process inspection: Making the measurement while the part s
being produced on the machine.
Types of measurement and Instruments
Line Graduated Instruments
Line Graduated Instruments are used for measuring length (linear
measurement) or angles (angular measurement)
Linear measurement:
a) Rules: Simplest and most commonly used instrument for
making linear measurements is a steel rule, bar, tape with
fractional or decimal graduations.
b) Vernier calipers: Can be used to measure inside or outside
lengths, also available with digital readouts.
These electronic devices are easier to read and less subject to
human error.

c) Micrometers: Commonly used for measuring the thickness and

inside or outside dimensions of parts
Digital micrometers are also available and are equipped with
digital readouts
Micrometers are also available for measuring depths
(micrometer depth gage) and internal diameters (inside
micrometer)
Angle – Measuring Instruments
a) Bevel Protractor:
A bevel protractor is a direct reading instrument similar to a
common protractor, except that it has a movable element.
The two blades of the protractor are placed in contact with
the part being measured and the angle is read directly on the
Vernier scale
b) Sine bar:
Measuring with a sine bar involves placing the part on an
inclined bar plate and adjusting the angle by placing gage
blocks on a surface plate.
After the part is placed on the sine bar, a dial indicator is used
top scan the top surface of the part
Gage blocks are added or removed as necessary until the top
surface is parallel to the surface plate
Angle on the part is then calculated using trigonometric
relationships

Surface plates are made of Cast iron or natural stones such as

granite. Granite surface plates have the desirable properties of
being resistant to corrosion, non-magnetic and low thermal
expansion.
Comparative length-measuring instruments:
Dial Indicators: Simple mechanical devices that convert linear
displacements of a pointer to the amount of rotation of an
indicator on a circular dial
Indicator is set to zero at a certain reference surface and the
instrument or the surface to be measured is brought into contact
with the pointer.
Movement of the indicator is read directly on the circular dial
to accuracies as high as 1 micron.

Electronic Gages:
Electronic Gages sense the movement of the contacting pointer
through changes in the electrical resistance of a strain gage or
through inductance or capacitance.
Electrical signals are then converted and displayed digitally a
linear dimensions (DRO)
`Used for measuring bore diameter and vertical length
Commonly used Electronic Gage is the Linear Variable
Differential Transformer (LVDT), used extensively for
measuring small displacements.

Advantages:
Ease of operation
Rapid response
DRO
Less human error
Flexibility
Capability to be integrated into automated system through
microprocessor and computers.
Laser Scan Micrometers:
Laser beam scans the work piece at a speed of 350 times per
second
Capable of resolutions as high as 0.125 microns and are
suitable for on – line measuring of stationary, rotating or
vibrating parts.

Geometric features:
Straightness:
Can be checked using a straightedge or a dial indicator
Flatness:
Interferometry is a method of measuring flatness using an
optical flat.
The device, a glass disk or fused quartz with parallel flat
surfaces is placed on the surface of the work piece.
When a monochromatic light beam (a light beam with one
wave length) is aimed at the surface at an angle, optical flat
splits the light beam into two beams, appearing as light and
dark bands.
Number of fringes that appear is related to the distance between
the surface of the part and the bottom surface of the optical flat.
Perfectly flat w/p will not split the light beam and fringes will
not appear.
Roundness:

Profile:
Coordinate Measuring Machine:
CMM consists of a platform on which the w/p is placed and
moved linearly or rotated.
A probe, attached to a head capable of lateral and vertical
movements, records all measurements.
Capable of recording measurements of complex profiles with
high sensitivity and with high speed.
Equipped with DRO and can be linked to computers for online
inspection of parts
Gages:
Gage Blocks: They are Individual Square / rectangular / round
metal blocks of various sizes made very precisely from heat
treated and stress relieved alloy steels or carbides.
Surfaces are lapped, flat and parallel within a range of 0.02 to
0.12 microns
Available in sets of various sizes, containing almost 100
blocks.
Can be assembled in many different combinations to reach
desired height.
Dimensional accuracy can be as high as 0.05 microns
Four basic grades of gage blocks, in decreasing order of
accuracy:
• Grade 0.5: Reference gages, for very high precision work
• Grade 1: Laboratory grade, for calibration of instruments
• Grade2: Precision grade, for tool rooms and inspection
• Grade 3: Working grade, for use in production shops

Fixed Gages:
Do not measure the actual dimensions, indicate whether the
part is accepted or rejected.
a) Plug gages: Commonly used to check the holes
Two gages are required to check the quality of hole / bore
Go Gage and No Go gage
b) Ring Gage: Used to check shafts and round parts
Two gages: Go Gage and No Go Gage
c) Snap gages: Used to check the external dimensions

Pneumatic gages (Air gages):

The gage head has holes through which pressurized air is
supplied by a constant-pressure line, escapes
Smaller the gap between the gage and the hole, the more
difficult it is for the air to escape, and higher the back pressure.
Back pressure is sensed and indicated by a pressure gage which
is calibrated to measure dimensional variations of holes.

General Characteristics and selection of measuring instruments

The characteristics and quality of measuring instruments are
generally described by various specific terms
• Accuracy: Degree of agreement of the measured dimension
with its true magnitude.
• Calibration: Adjusting or setting an instrument to give
readings that are accurate within a reference standard.
• Linearity: Accuracy of the readings of an instrument over its
full working range.
• Amplification / Magnification: Ratio of instrument output to
the input dimension.
• Precision: Degree to which an instrument gives repeated
measurement of the same standard.
• Resolution: Smallest dimension that can be read on an
instrument.
• Sensitivity: Smallest difference in dimension that an
instrument can distinguish or detect.
• Stability / Drift: Instrument’s capability to maintain its
calibration over a period of time.
Profilometer:
• Electro-mechanical instrument, most widely used to measure
surface roughness
• Actually measure the difference in the depth of the surface
irregularity
• Two main units of the profile meter are the tracer and
amplifier
• Tracer has stylus at its tip made of diamond with a point
radius of about 12 micron and is suspended on the flat
spring
• Upper end of stylus is linked to an induction coil, which is
located in the field of a permanent magnet
• Any movement in the coil induces a voltage
• As the tracer moves across the surface the stylus will follow
the contour of the irregularities
• Up & down movements of the stylus are converted into a
small fluctuating voltage
• Voltage is fed into the amplifies
• Amplified voltage is fed into the roughness meter
• Meter shows the variations in average roughness height.
Tool Maker’s Microscope
• Used to measure different tool angles
• Consists of an optical head which can slide along the guide
ways of the vertical column and can be clamped with screw
at any position
• Focusing is performed by adjusting on an optical head
• W/p is kept on the table which consists of a transparent glass
plate secured on a heavy hollow base
• Table is equipped with clips / clamps / vise / centers for
holding various types of work piece
• Table has a compound slide to give longitudinal and lateral
measurements actuated by accurate micrometer screw
• Light source is incorporated at the back of the base:
horizontal beam of light is provided.
• Beam of light is reflected at right angle by a mirror upwards
towards the table
• Light beam passes through the transparent glass plate of the
table on which the w/p is placed
• A shadow image of the w/p contour passes the objective of
the optical head and gets projected on a screen after
reflections from three prisms
• Observations are made thru the eyepiece to facilitate
measurements
• Cross lines are engraved on the screen which can be rotated
thru 360 deg.
• Eye piece field of view contains an illuminated circular scale
with minimum reading of 1 minute
• Has its greatest utility in measuring odd profiles, hole
locations and locations of odd profiles, angles etc.
• Measurements of external threads, tool angles, gages etc.
Autocollimator:
Resembles a telescope with a light beam that bounces back
from the object, is used to accurately measure small angular
deviations on a flat surface.
Profile Projector:
Used to check geometry of cutting tools for machining screw
threads and to check all profiles on the surface of w/p
The image of the w/p is projected onto a screen at
magnifications of 100 X or higher