Powerpoint lectures MECH 213, 2007 edition.

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Powerpoint format lecture © J. Jeswiet 2007

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Professor of Mechanical Engineering.

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University, Kingston, ON, Canada K7L 3N6
Fax: 613-533-6489
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Lecture 4

Topic: Metrology; measurements

Queen’s University, Mechanical Engineering

© J. Jeswiet

MANUFACTURING ENGINEERING
MECH 213

G’day mate.

This lecture is related directly to laboratory 201 - metrology

pp 1085- Kalpakjian & Schmidt 5th ed; see p 1101 for dimensioning & tolerancing

1
Machinery’
Machinery’s Handbook

Geometric Tolerances
See p 1106 5th ed

Geometric tolerancing is a
method of constraining the
deviation in shape to what is
functionally allowable for a part.

•Shape Deviations
• cylindricity
• circularity
• flatness
• concentricity
• parallelism
• perpendicularity
• symmetry
• etc...

2
 METROLOGY
Definition: Science of physical measurement,
applied to variables such as dimension , surface finish,
and mechanical and electrical properties.
• Measurements require precision and accuracy.
accuracy
• A group of measurements when plotted will usually
follow a normal distribution or bell curve.
• The centre of the curve is the mean (x ),
and it’s proximity to the true value is accuracy.

x =
∑x
n −1
• The repeatability of this
mean value is the precision. precision

accuracy

Standard ( )
Deviation: σ= ∑ x − x
2

n −1
‰ Standard deviation (σ) is common measure of
precision.
‰ ± σ, covers 68% of measurements
‰ ± 2σ covers 95% of measurements
‰ ± 3σ covers 99.73% of measurements
‰ The Industry standard once was,
27 in 10,000 parts can be defective;
this is not acceptable anymore.
‰ Sigma 6 is now claimed by many industries
- this translates to 2 defects per billion parts made.

3
 Measurement Instruments
Attributes of Measuring Instruments
• Sensitivity or Resolution,
Resolution must be fine*.
Rough rule of thumb: instrument sensitivity must be 10 times the
precision of the measurement.
• Linearity
• Repeatability:
Repeatability the instrument must be capable of repeating readings
to the same accuracy to which it can be read.
• Stability,
Stability is the resistance to drift after calibration.
• Speed of Response
• Feasibility of Automation

* Fine: capable of delicate perception; perceptible only with difficulty

Gauges
• Gauge Blocks:
Blocks blocks are manufactured to standard lengths
and tolerances, for use in calibration.
– Available in several grades: 3 (production) +0.15, to .05 μm; 2
(inspection) +0.10, to 0.05 μm; 1 (laboratory) +0.05, to 0.05 μm; 0.5
(reference) +0.03, to 0.03 μm
• Angle Blocks:
Blocks same principal as above except for angles
• Plug and Ring Gauges:
Gauges for measurement of diameters,
usually of the go, no go type.

4
 Graduated Measuring Devices
• Line-Graduated Rules and Tapes
• Vernier Calipers
• Diffraction Gratings: by counting interference fringes
a sensitivity of 5 μm or 0.0002 in can be achieved
• Linear Digital Transducers: photoelectric, magnetic,
pulses are measured, and provide resolution of 4 μm
• Numerical Encoding Discs
• Solid-State Photodetector diodes and Charge-C Coupled
Devices provide resolution of 3 μm
• Toolmaker’s Microscopes equipped with micrometer
driven cross slide stages.

Standard measurement devices found in any manufacturing facility:

Standard measurement devices found in any manufacturing facility:

Vernier calipers

See p 1088

micrometer

5
The
Thesine
sinebar
bar

6
 Measuring“straightness”
Measuring “straightness”

Point: At some stage of manufacturing,

some precision measurements must be made.

• either an intermediate stage,
• or at the end of the machining process
• or for reverse engineering

A CMM,
CMM coordinate measurement machine is often
used to do this.

7
 CMM’s: coordinate measurement machines

Measuring the accuracy is a time consuming

operation.
Increased accuracy, at high rates,
can now be achieved with CMM’s

Renishaw probe
MME CMM

Probes can be very long

Probes can measure hole

roundness & location

CMM systems come

in many varieties

8
 CMM’s are often used to
measure large structures

Measurement of
roundness of a ring

Measurement of a thruster
cone for the Arianne rocket

Applying some of the stuff we have seen to information given on drawings:

Recall these symbols See p 1106

and what do we do with them?

9
Geometric call
out notation
format

10
Thank
Thank you
you for
for your
your attention
attention

11
Probe tips come in different
shapes and sizes

12
 Probes can now be mounted in milling
machines with telemetry systems.

try
me
tele

Measuring a
part on a lathe
after machining

CNC lathe

Grin
ding

13
 CMM probes can be used to measure
cutting tool position & configuration.

Cutting insert

14