Lecture 01

MEC 263
Measurement & Quality Control

Department of Mechanical
Engineering
IUBAT
 What is Metrology?
Metrology is the Science of
Measurement, includes all aspects both
theoretical and practical with reference
to measurements, whatever their
uncertainty, and in whatever field of
science or technology they occur.
 Objectives of Metrology
The basic objective of metrology is to
determine whether a component has been
manufactured to the required specification.
To provide required accuracy at minimum cost.

Through evaluation of newly developed

products, and to ensure that components are
within the specified dimensions.
To reduce the cost of rejections and rework by
applying statistical quality control techniques.
 To standardize measuring methods by using
proper inspection methods at the development
stage itself.
To reduce the cost of inspection by effective and
efficient utilization of available facilities.
To determine the process capabilities.

To prepare designs for gauges and special

inspection fixtures.
To maintain the accuracies of measurement
through periodical calibration of the measuring
instruments.
 Basic Principles of measurements
The process or act of measurement
consists of obtaining a quantitative
comparison between a predefined
standard and a measurand.

The term measurand is used to

designate the particular physical object
or parameter being observed and
quantified. 5
 Standard

Process of
comparison Result/Reado
Input
/Measurand (Measuremen ut
t)

Fundamental Measuring
Process

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Fundamental Methods of Measurement

There are two basic methods of

measurements:
1. Direct comparison with either a primary
or secondary standard. E.g.,
measurement of length by ruler scale.

2. Indirect comparison through the use of a

calibrated system. E.g., measurement of
strain using strain gauge.
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Generalized Measuring System

Calibration Auxiliary Auxiliary Indicator

input Power (Not Power
always (Usually
required) required)
Recorder

Measuran Sensor Signal Computer

d Transducer Transduc
Conditione Analogous
ed Signal r Driving
Signal
(Analogo
us to Processor
input)

Controller

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General Measurement System
Detector-transducer or sensor stage
Intermediate or signal conditioning stage
Terminating or readout stage
Feedback control stage (optional)

Detector-transducer or sensor stage:

The physical variable to be measured is detected.
Signal is transformed into more usable form.
Insensitive to every other possible input.
Minimize loading error.

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Intermediate or signal processing stage:
The transduced signal is modified by one or more basic
operations, such as amplification, filtering,
differentiation, integrating or averaging etc.
Terminating or readout stage:
Acts to indicate, record or control the variable being
measured. Output may be analog or digital.
Feedback control stage:
In those measurement systems involved in process
control, feedback control stage contains a controller
that interprets the measured signal and makes a
decision regarding the control of the process. 10
 Types of input quantities
According to time dependence the
input quantities can be classified as
1. Static input: the input which does not
change with time is called static input.

2. Dynamic input: the input which

changes with time is called dynamic
input.

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 Dynamic Input
Dynamic input may be classified further as
a) Steady-state periodic: Steady-state periodic
quantity is one whose magnitude has a definite
repeating time cycle.

b) Non repetitive or transient: Non repetitive

or transient quantity is one whose magnitude
does not have a definite repeating time cycle.
They are:
i) Single pulse or aperiodic
ii) Continuing or random 12
 Physical Measurement
Nominal size (Basic Size): It is the size on
which the limits of size are based and which is
assigned to a part in accordance with its
function.
True size: It is the theoretical size of a
dimension, which is free from any errors of
measurement.
Actual Size: It is the value of size obtained
through measurement with the permissible
measuring error.
 Approximate Size: It is the value of size obtained
with an error exceeding the permissible error of
measurement and requiring refinement.
Error of measurement: It is the difference between
the true value of the size being measured and the
value found by measurement. Error pertains to a
measurement and not to an instrument.
Correction: It is the amount which should be
algebraically added to the indicated value to obtain the
actual value of the size being measured. The correction
is numerically equal to the error, but opposite in sign.
 Calibration
Calibration affords the opportunity to check the
instrument against a known standard and
subsequently to reduce errors in accuracy.
At the preparation of a measuring system, known
magnitudes of the input quantity must be fed into
the sensor transducer and the systems output
behavior must be observed.
Such a comparison allows the magnitude of the
output to be correctly interpreted in terms of the
magnitude of the input.
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 Accuracy & precision

Low Accuracy High Accuracy High

High Precision Low Precision Accuracy
High
Precision
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 Error

The error of a measurement is defined as

the difference between the measured value
and the true physical value of the quantity.
The error cannot be calculated exactly
unless we know the true value of the
quantity being measured.
Error = = Xm Xtrue

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 Classification of Errors

1. Bias Error
2. Precision Error
3. Illegitimate error
4. Errors that are sometimes bias and
sometimes precision

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1. Bias or Systematic error
a. Calibration errors
b. Certain constantly recurring human errors.
c. Certain errors caused by defective equipments.
d. Loading errors
e. Limitations of system resolution
2. Precision or Random error
a. Certain human errors
b. Errors caused by disturbance to the equipments
c. Errors caused by fluctuating experimental
condition.
d. Errors derived from insufficient measuring-
system sensitivity.
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3. Illegitimate error
a. Blunders and mistake during an
experiment.
b. Computational errors after an experiment.
4. Errors that are sometimes bias and
sometimes precision
a. Errors from instrument backlash, friction
etc.
b. Errors from calibration drift and variation
in environmental condition.
c. Errors resulting from variations in
procedure or definition among
experimenters.
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