MFE2101

Engineering Metrology

MFE 2101 ENGINEERING METROLOGY

Month

October

November

December

January

Week

Date

1
2
3
4
5
6
7
8
9
10
11

01/10/2015
08/10/2015
15/10/2015
22/10/2015
29/10/2015
05/11/2015
12/11/2015
19/11/2015
26/11/2015
03/12/2015
10/12/2015

12

17/12/2015

13
14
15

24/12/2015
31/12/2015
07/01/2016

Lecture
Lecture 1
Lecture 2
Lecture 3
Lecture 4
Lecture 11
Lecture 5
Lecture 6
Lecture 7
Lecture 8
Lecture 9
Lecture 10

Prefix: Dimensioning & Tolerancing

Introduction to Apparatus and Measurement
Measurement of Length & Internal Diameters
Measurement using Optics
Uncertainty in Measurements
Straightness, Flatness and Perpendicularity
Angle Measurement
Taper Measurement & Surface Texture
Radius Measurement & Roundness
Thread Measurement
Gear Metrology & CMM
Tutorial 1
Assignment Deadline
CHRISTMAS RECESS
Tutorial 2

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Notes / Tutorial Sheets / Lab Sheets will be

uploaded on VLE
Books:
1. Fundamentals of Dimensional Metrology by C. Dotson
(ISBN: 978-1-4180-2062-0)
2. Handbook of Dimensional Measurement by Curtis,
Farago
(ISBN: 978-0-8311-0204-3)

MFE 2101 ENGINEERING METROLOGY

What is Metrology?
Why Metrology?
Manufacturing Process Variation
The Product Development Cycle and Metrology
Part Dimensioning and Tolerancing
Conclusion

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Engineering Metrology

MFE 2101 ENGINEERING METROLOGY

METROLOGY is the science of measurement, and

measurement is the language of science. It is the
language we use to communicate about size, quantity,
position, condition and time.

Grammar

Composition

Language

Metrology
Techniques

Experience

Metrology

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Mass

Length

Egyptian Jewelers' Balance

(circa. 2000BC)

Egyptian Royal Cubit

(circa. 3000BC)

Time

Greek Sun Dial

(circa. 200BC)

MFE 2101 ENGINEERING METROLOGY

Time Measurement:
Stopwatch on Mobile Phones

Length Measurement:
Rulers on your desks

Weight Measurement:
Weighing scales in kitchens at home

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Engineering Metrology

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In real world
applications an
Engineer is often
confronted with
problems which have to
be investigated.

Metrology
Tools
Engineer

One of the main

resources in the
engineering toolbox is
the science of
Metrology.
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Pen Production

Top Part

Bottom Part

Problem: Parts NOT Fitting

MFE 2101 ENGINEERING METROLOGY

Parts and problem report are sent to the

engineer responsible for the product.
The engineer has then to investigate the
problem or problems with these parts.
The engineer will issue a measurement report
which identifies a number of dimensions which
might be causing the problem.
Following the receipt of the report, the engineer
will evaluate the findings and propose a solution
to the problem.
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Raw Material 1

Product 1

Raw Material 2

Product 2

Raw Material 3
.
.
Raw Material n

Product 3
.
.

Customer
Product
Requirements
and Wishes

Product n

Value Adding Manufacturing

Processes
Milling
Turning
Injection Molding
Assembly
MFE 2101 ENGINEERING METROLOGY

Plastic Injection Molding Machine

CNC Lathe Machine

VIDEOS
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Overall
Length
Dim C8

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Need

Modified phases of the design

process according to French

Metrology

Embodiment Design

Detailed Design

Production

Feedback

Conceptual Design

Metrology

Metrology

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Concept Development:
Physical Prototype Stage

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Parts might need to be used for:

Customer Evaluation
Initial Testing

Before parts can be used they have to be

measured to make sure that they meet the
engineering specifications

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Detailed Product Design

MFE 2101 ENGINEERING METROLOGY

Parts might need to be used for:

Initial Product Runs
Final Testing
Shipping to Customer
Process Qualification

Before parts can be used they have to be

measured to make sure that they meet the
engineering specifications
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Production Environment

MFE 2101 ENGINEERING METROLOGY

Parts have to be:

Under Control
dimensions have to be monitored to ensure there
are no shifts in the manufacturing process

Fit for use

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What are you going to

measure?

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The Engineering Drawing or Model defines

the Specification for the Product

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Nominal
Dimension

Tolerance

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Plastic Injection Molding Machine

CNC Lathe Machine

MFE 2101 ENGINEERING METROLOGY

Higher Costs

Units of Cost

()

Tolerance (mm)
[Simmons & Maguire, 2004]

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Shaft
Bearing

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Shaft

Bearing

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3 types of parts are found in production:

Clearance

Size-to-Size

Interference

Type 2

Type 1

Type 3

MFE 2101 ENGINEERING METROLOGY

After taking a closer look at your drawings

Shaft

Bearing

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Tolerance Check (Worst Case Scenario)

1. Nominal Condition:
(Nominal Bearing) 50.0 - (Nominal Shaft) 50.0 = 0mm

2. Maximum Clearance:
(Maximum Bearing) 50.5 - (Minimum Shaft) 49.5 = 1mm

3. Maximum Interference:
(MinimumBearing) 49.5 - (Maximum Shaft) 50.5 = -1mm
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Tolerance Check (Worst Case Scenario)

1. Nominal Condition:
(Nominal Bearing) 49.75 - (Nominal Shaft) 50.25 = 0.5mm

2. Maximum Clearance:
(Maximum Bearing) 50.5 - (Minimum Shaft) 49.5 = 1mm

3. Maximum Interference:
(Minimum Bearing) 50 - (Maximum Shaft) 50 = 0mm
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Hook

Hinge

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y = 750.5 - 600.5
y = 151mm
ymin = 14mm
ymax = 16mm

x = 500.5 - 190.5 150.5

x = 161.5mm
xmin = 14.5mm
xmax = 17.5mm

Possible Interference of 1.5 mm between X min and Y max

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MFE 2101 ENGINEERING METROLOGY

y = 140.5mm
ymin = 13.5mm
ymax = 14.5mm

x = 160.5mm
xmin = 15.5mm
xmax = 16.5mm

Minimum Clearance of 1 mm between X min and Y max

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Engineering Metrology

MFE 2101 ENGINEERING METROLOGY

During this lecture we have seen:

What is Metrology
Why Metrology
Manufacturing Process Variation
The Product Development Cycle and Metrology
Part Dimensioning and Tolerancing

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MFE 2101 ENGINEERING METROLOGY

Dr Ing. Paul Refalo

Room 003
paul.refalo@um.edu.mt

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