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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

45 MEASUREMENT AND INSPECTION

Review Questions
45.1

How is measurement distinguished from inspection?

Answer. In measurement, an unknown quantity is compared with a known standard and a value
of the quantity is obtained using an accepted and consistent system of units. In inspection, a
product characteristic is examined to see if it conforms to design specifications.

45.2

How does gaging differ from measuring?

Answer. Gaging determines whether the product characteristic (e.g., dimension) satisfies the
specification or not. Measuring determines the actual value of the characteristic.

45.3

What are the six fundamental quantities in metrology?

Answer. The six quantities are length, mass, time, electric current, temperature, and light
radiation.

45.4

What is accuracy in measurement?

Answer. Accuracy is the degree to which the measured value agrees with the true value of the
quantity of interest. It is a measurement procedure that is absent of systematic errors.

45.5

What is precision in measurement?

Answer. Precision in measurement is the degree to which random errors are minimized.

45.6

What is meant by the term calibration?

Answer. Calibration means checking the measuring instrument against a known standard.

45.7

Besides good accuracy and precision, what are the desirable attributes and features of a
measuring instrument?
Answer. The desirable features include high resolution, ease of calibration, speed of response,
wide operating range, high reliability, and low cost.

45.8

What is the rule of 10?

Answer. The rule of 10 means that the measuring instrument or gage must be ten times more
precise than the object (part) being inspected.

45.9

Automated inspection can be integrated with the manufacturing process to accomplish some
action. What are these possible actions?
Answer. Possible actions discussed in text are (1) parts sortation and (2) feedback of data to
adjust the process.

45.10

Give an example of a non-contact inspection technique.

Answer. Non-contact inspection techniques include machine vision, laser measuring methods,
and electrical field techniques.

45.11

What is meant by the term graduated measuring device?

Answer. A graduated measuring device has markings (called graduations) on a linear or angular
scale to measure an object's feature of interest (e.g., length).

45.12

What are the common methods for assessing surface roughness?

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Answer. Common methods for assessing surface roughness are (1) comparison of the specimen
surface with standard test blocks having known surface roughness values and (2) stylus-type
electronic instruments which measure average roughness.
45.13

What is a coordinate measuring machine?

Answer. A CMM is an automated measuring machine consisting of a contact probe and a means
to position the probe in three dimensions relative to workpart features and surfaces; when the
probe contacts the part, the x-y-z coordinates are recorded.

45.14

Describe a scanning laser system.

Answer. The scanning laser system uses a laser beam deflected by a rotating mirror to produce a
beam of light that sweeps past an object. A photodetector on the far side of the object senses the
light beam during its sweep except for the short time when it is interrupted by the object. This time
period can be measured quickly with great accuracy. A microprocessor system measures the time
interruption that is related to the size of the object in the path of the laser beam, and converts from
time to a linear dimension.

45.15

What is a binary vision system?

Answer. In a binary vision system, the light intensity of each pixel is reduced to either of two
values (black or white, 0 or 1).

45.16

Name some of the non-optical non-contact sensor technologies available for inspection.
Answer. The technologies include electrical fields (capacitance, inductance), radiation (X-ray),
and ultrasonic techniques (high frequency sound).

45.17

(Video) Based on the video about vernier calipers, are the markings on the vernier plate
(moveable scale) the same spacing, slightly closer or slightly further apart compared to the
stationary bar?
Answer: The markings are slightly closer. The 50 markings on the vernier plate fit in place of 49
markings on the stationary bar.

45.18

(Video) Based on the video about vernier calipers, explain how to read the scale on a vernier
caliper.
Answer: The object is inserted between the jaws. The distance between the zero on the stationary
bar and the zero on the vernier plate (moveable scale) is added to the number that corresponds to
the line that exactly lines up on the vernier plate. Only one mark on the veriner plate will line up
with a mark on the stationary bar.

45.19

(Video) Based on the video about micrometers, explain the primary factor that makes an English
micrometer different than a metric micrometer.
Answer: The thread pitch determines the linear motion of the micrometer for each rotation of the
barrel. A metric micrometer will use a different pitch than an English micrometer.

Multiple Choice Quiz

There are a total of 16 correct answers in the following multiple-choice questions (some questions have
multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be given.
Each correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point,
and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage
score on the quiz is based on the total number of correct answers.

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

45.1

Which of the following are attributes of the metric system of linear measurement (two correct
answers): (a) based on astronomical distances, (b) defined in terms of the human body, (c)
originated in Great Britain, (d) rational prefixes for units, and (e) units are subdivided decimally?
Answer. (d) and (e).

45.2

Which one of the following countries does not embrace the International System of units: (a)
China, (b) France, (c) Germany, (d) Japan, (e) Panama, (f) Russia, or (g) United States?
Answer. (g).

45.3

The two basic types of inspection are inspection by variables and inspection by attributes. The
second of these inspections uses which one of the following: (a) destructive testing, (b) gaging,
(c) measuring, or (d) non-destructive testing?
Answer. (b).

45.4

Automated 100% inspection can be integrated with the manufacturing process to accomplish
which of the following (two best answers): (a) better design of products, (b) feedback of data to
adjust the process, (c) 100% perfect quality, and (d) sortation of good parts from defects?
Answer. (b) and (d) are mentioned in the text.

45.5

Which of the following are examples of non-contact inspection (two correct answers): (a)
calipers, (b) coordinate measuring systems, (c) dial indicators, (d) machine vision, (e)
micrometers, (f) scanning laser systems, (g) snap gages, and (h) ultrasonic techniques?
Answer. (d) and (h).

45.6

A surface plate is most typically made of which one of the following materials: (a) aluminum
oxide ceramic, (b) cast iron, (c) granite, (d) hard polymers, or (e) stainless steel?
Answer. (c).

45.7

An outside micrometer would be appropriate for measuring which of the following (two correct
answers): (a) hole depth, (b) hole diameter, (c) part length, (d) shaft diameter, and (e) surface
roughness?
Answer. (c) and (d).

45.8

In a GO/NO-GO gage, which one of the following best describes the function of the GO gage: (a)
checks limit of maximum tolerance, (b) checks maximum material condition, (c) checks
maximum size, (d) checks minimum material condition, or (e) checks minimum size?
Answer. (b).

45.9

Which of the following are likely to be GO/NO-GO gages (three correct answers): (a) gage
blocks, (b) limit gage, (c) master gage, (d) plug gage, and (e) snap gage?
Answer. (b), (d), and (e).

45.10

Which one of the following is the most important application of vision systems: (a) inspection,
(b) object identification, (c) safety monitoring, or (d) visual guidance and control of a robotic
manipulator?
Answer. (a).

Problems
Principles of Measurement
45.1

Two micrometers are used to measure a 1.0000 in gage block. Five measurements are taken with
each micrometer. For micrometer A, the five measurements were 1.0001 in, 1.0003 in, 1.0000 in,

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

1.0001 in, and 1.0003 in. For micrometer B, the five measurements were 1.0002 in, 0.9999 in,
1.0001 in, 1.0000 in, and 0.9999 in. Determine (a) the mean and standard deviation of the error
for each of the micrometers, (b) which micrometer has the better accuracy, and (c) which
micrometer has the better precision.
Solution: (a) x A = (1.0001+1.0003+1.0000+1.0001+1.0003)/5 = 1.00016 in
Astd = (xi x A )2/n = [(1.0001-1.00016)2 + (1.0003-1.00016)2 + + (1.0003-1.00016)2]/5
Astd = 1.44x10-8
Bavg = (1.0002+0.9999+1.0001+1.0000+0.9999)/5 = 1.00002 in
Bstd = (xi x B )2/n = [(1.0002-1.00002)2 + (0.9999-1.00002)2 + + (1.0001-1.00002)2]/5
Bstd = 1.36x10-8
(b) Bavg is closer to the reference value of 1.0000.
(c) Bstd is smaller than Astd so it has better precision.
Note: you would select the same device if you use the formula for std dev = (xi x )2/(n-1). You
could also use this formula for part (a)
45.2

Two vernier calipers are used to measure a 10.000 mm gage block. Five measurements are taken
with each caliper. For caliper A, the five measurements were 10.01 mm, 10.00 mm, 10.02 mm,
10.02 mm, and 10.01 mm. For caliper B, the five measurements were 10.01 mm, 9.98 mm, 9.98
mm, 10.01 mm, and 9.99 mm. Determine (a) the mean and standard deviation of the error for
each of the calipers, (b) which caliper has the better accuracy, and (c) which caliper has the better
precision.
Solution: (a) x A = (10.01+10.00+10.02+10.02+10.01)/5 = 10.012 mm
Astd = (xi x A )2/n = [(10.01-10.012)2 + (10.00-10.012)2 + + (10.01-10.012)2]/5
Astd = 5.60x10-5
Bavg = (10.01+9.98+9.98+10.01+9.98)/5 = 9.994 mm
Bstd = (xi x B )2/n = [(10.01-9.994)2 + (9.998-9.994)2 + + (9.99-9.994)2]/5
Bstd = 1.8x10-4
(b) Bavg is closer to the reference of 10.000.
(c) Astd is smaller than Bstd so it has better precision.
Note: you would select the same device if you use the formula for std dev = (xi x )2/(n-1). You
could also use this formula for part (a)

Measurement and Inspection Devices

45.3

Design the nominal sizes of a GO/NO-GO plug gage to inspect a 1.500 0.030 in. There is a
wear allowance applied only to the GO side of the gage. The wear allowance is 2% of the entire
tolerance band for the inspected feature. Determine (a) the nominal size of the GO gage including
the wear allowance and (b) the nominal size of the NO-GO gage.
Solution: (a) The tolerance band is 0.060 in. Wear allowance = 0.02(0.060) = 0.0012 in.
GO gage will inspect the minimum hole diameter = 1.500 0.030 = 1.470 in.
As the gage wears, the dimension will decrease and allow unacceptable parts, so the wear
allowance is added to it.
Nominal GO Size = 1.470 + 0.0012 = 1.4712 in
(b) NO-GO gage will inspect the maximum hole diameter = 1.500 + 0.030 = 1.530 in.
No wear allowance is added because this gage should not fit in the hole and wear away.

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

45.4

Solve the previous problem except the GO/NO-GO gage is used to inspect the diameter of a shaft
that is 1.500 0.030. A wear allowance is applied to the GO side only.
Solution: (a) The tolerance band is 0.060 in. Wear allowance = 0.02(0.060) = 0.0012 in.
GO gage will inspect the maximum shaft diameter = 1.500 + 0.030 = 1.530 in.
As the gage wears, the dimension will increase allowing unacceptable parts, so the wear
allowance is subtracted from it.
Nominal GO Size = 1.530 0.0012 = 1.5288 in
(b) NO-GO gage will inspect the minimum shaft diameter = 1.500 0.030 = 1.470 in.
No wear allowance is added because this gage should not fit in the hole and wear away.

45.5

Design the nominal sizes of a GO/NO-GO plug gage to inspect a 30.00 0.18 mm. There is a
wear allowance applied only to the GO side of the gage. The wear allowance is 3% of the entire
tolerance band for the inspected feature. Determine (a) the nominal size of the GO gage including
the wear allowance and (b) the nominal size of the NO-GO gage.
Solution: (a) The tolerance band is 0.36 mm. Wear allowance = 0.03(0.36) = 0.0108 mm
GO gage will inspect the minimum hole diameter = 30.00 0.18 = 29.82 mm
As the gage wears, the dimension will decrease and allow unacceptable parts, so the wear
allowance is added to it
Nominal GO Size = 29.82 + 0.0108 = 29.8308 mm
(b) NO-GO gage will inspect the maximum hole diameter = 30.00 + 0.18 = 30.18 mm.
No wear allowance is added because this gage should not fit in the hole and wear away.

45.6

Solve the previous problem except the GO/NO-GO gage is used to inspect the diameter of a shaft
that is 30.00 0.18 mm. A wear allowance is applied to the GO side only.
Solution: (a) The tolerance band is 0.36 mm. Wear allowance = 0.03(0.36) = 0.0108 mm
GO gage will inspect the maximum shaft diameter = 30.00 + 0.18 = 30.18 mm
As the gage wears, the dimension will increase allowing unacceptable parts, so the wear
allowance is subtracted from it.
Nominal GO Size = 30.18 0.0108 = 30.1692 mm
(b) NO-GO gage will inspect the minimum shaft diameter = 30.00 0.18 = 29.82 mm.
No wear allowance is added because this gage should not fit in the hole and wear away.

45.7

A sine bar is used to determine the angle of a part feature. The length of the sine bar is 6.000 in.
The rolls have a diameter of 1.000 in. All inspection is performed on a surface plate. In order for
the sine bar to match the angle of the part, the following gage blocks must be stacked: 2.0000,
0.5000, 0.3550. Determine the angle of the part feature.
Solution: H = 2.0000+0.5000 + 0.3550 = 2.8550 in
A = sin-1 (H/L) = sin-1 (2.8550/6.000 ) = sin-1 ( 0.4758 ) = 28.41

45.8

A 200.00 mm sine bar is used to inspect an angle on a part. The angle has a dimension of 35.0
1.8. The sine bar rolls have a diameter of 30.0 mm. A set of gage blocks is available that can
form any height from 10.0000 to 199.9975 mm in increments of 0.0025 mm. Determine (a) the
height of the gage block stack to inspect the minimum angle, (b) height of the gage block stack to
inspect the maximum angle, and (c) smallest increment of angle that can be setup at the nominal
angle size. All inspection is performed on a surface plate.
Solution: (a) sin A = (H/L); H = L sin A = 200.00 Sin (35.0-1.8)
= 200.00 sin 33.2 = 109.51264 = 109.5150 mm (must round up to insure angle is in
tolerance.
(b) H = L sin A = 200.00 sin (35.0 + 1.8) = 200.00 sin (36.8) = 119.80472 = 119.8025 mm

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(must round down to insure angle within dimensions)

(c) H at nominal angle = L sin A = 200.00 Sin (35.0) = 114.7152 mm
Closest angle to nominal is at H=114.7150; A = sin-1 (H/L) = sin-1 (114.7150/200.000)
A = sin-1 (0.573575) = 34.99989953
At one increment above, H=114.7175; A = sin-1 (H/L) = sin-1 (114.7175/200.000 ) =
A = sin-1 (0.5735875) = 35.00077385
Change in A = 35.00077385 34.9989953 = 0.0008743
45.9

A laser triangulation system has the laser mounted at a 35 angle from the vertical. The distance
between the worktable and the photo-detector is 24.0000 in. Determine (a) the distance between
the laser and the photo-detector when no part is present and (b) the height of a part when the
distance between the laser and photo-detector is 12.0250 in.
Solution: (a) L with no part when D = 0: D=H L cot A;
0 = H L cot A; L = H/cot A = H tan A
L = 24.0000 tan(35) = 16.8050 in
(b) D = H L cot A = 24.0000 12.0250 cot(35)
D = 24.0000 12.0250(1.42815) = 6.8265 in

45.10

A laser triangulation system is used to determine the height of a steel block. The system has a
photo sensitive detector that is located 750.000 mm above the working surface and the laser is
mounted at a 30.00 angle from the vertical. With no part on the worktable, the position of the
laser reflection on the photo sensor is recorded. After a part is placed on the worktable, the laser
reflection shifts 70.000 mm towards the laser. Determine the height of the object.
Solution: Need to find the distance of the reflection from the laser.
L with no part when D=0: D = H L cot A; 0 = H L cot A; L = H/cot A = H tan A
L = 750 tan(30) = 433.0127 mm
L with part = 433.0127 70 = 363.0127 mm
D = H L cot A = 750 363.0127 cot(30) = 750 363.0127(1.732) = 121.262 mm

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301