AE 224

Metrology and Computer Aided Inspection [CAI] I

AE 224 Metrology and Computer Aided Inspection

Syllabus:
Introduction to Metrology Fundamentals of dimensional Measurement Length Standards Application of light Interference for precision measurements Fits and tolerances Concepts and practice of gauging Comparators and their applications Linear and angular measurements Thread and gear inspection Form, flatness, straightness and alignment measurements Surface metrology Co-ordinate metrology Laser applications in metrology; Vision inspection Micro and nano metrology.

AE 224 Metrology and Computer Aided Inspection

Text Books:
Reference Books
Jain R.K., Engineering Metrology, Khanna Publishers. Busch., Fundamentals of Dimensional Metrology, Delmar Publishers (1998) Shotbolt, C.S. and Galyer. J., Metrology for Engineers, 5th ed., Cassell Publ. (1990).

AE 224 Metrology and Computer Aided Inspection

Reference Books:

Graham T. Smith., Industrial Metrology, Surface and Roundness. D. J. Whitehouse., Handbook of Surface Metrology. Bala Muralikrishnan, Jay Raja., Computational Surface and Roundness Metrology.

Introduction
What is Metrology? Quality in Manufacturing. Why Precision Length Measurements? Need for reliable Standards. Standard of Length. Shop floor standards. Traceability.

What is Metrology ?
Metro - logy

from Greek 'metron' [measure], and logy

Meaning Measurement Science In English, the term Metrology is often used for Linear Measurements Engineering Metrology Industrial Metrology Dimensional Metrology Manufacturing Metrology

Quality in Manufacturing
Changing Concepts on quality and their significance

Inspection Process Control Quality Assurance TQM Strategic Quality Management

Product Process Design People & Systems Product Life

Quality covers all activities from the concept to the final disposal of the product.

Inspection
Passive Active Dynamic Inspect - Accept - Reject Inspect - Infer - Act Inspect Act

All three modes of inspection are still practiced in industries

Tolerance and Inspection

Wide tolerances Medium Tolerances Close Tolerances - Passive Inspection - Active Inspection - Dynamic Inspection

Passive Inspection Sampling Active inspection SQC Dynamic Inspection In-process measurement

Metrology- Applications

Why Precision Length Measurements?

Majority of manufacturing measurements deal with dimensions which are in linear units. Though the dimensions are normally given in mms, the tolerances on these dimensions are given in micrometers and of late even in nanometers. All measurements are comparisons. Comparison with reference to a standard

Measurement Accuracies
Measurement accuracies should be better than the accuracy expected in the measured entity. As a thumb rule, the measurement accuracy should be an order better than the measured value.

Systematic and Random Errors

Systematic errors are caused by assignable factors such as setting errors, temperature, humidity, Random errors are caused by unknown sources, including human errors.

Accuracy and Precision

Measurement Accuracies
Average ------Mean Variation ----- Standard deviation

x
i 1

(x x)
i 1 i

n 1

Precision of a Measurement device

Measurement Accuracies
Take an example of a dimension:10mm + 5 mm
(tolerance 10 mm)

For checking this we need an accuracy of 1 mm. That instrument is to be calibrated to 0. 1 mm That in turn has to be calibrated to 0.01mm That in turn has to be calibrated to 0.001mm And so on . ..Where to stop?

Tolerance Trend

Length Standards
Basic Standards of Length Meter ; Yard Auxiliary Standards Shop floor reference Slip Gauges and accessories

Meter Standard
1889 Physical

Meter Standard
1960 Wavelength
Wavelength of Krypton- 86 was accepted to define the meter.
1 650 763.73 wavelengths in a vacuum of the radiation of krypton-86 is one Meter (m)

Meter Standard
1983 In terms of time. New definition of Meter in Seconds! Meter is the length travelled by light in 1 / 299 792 458 s.

Laser Standard
It was also in 1960 that the first laser was constructed and by the mid 1970s lasers were being used as length standards. This is now realized by iodine-stabilized helium-neon lasers.

Line and End Standards

In line standard, the distance between two lines marked on it, is the specified length. Original meter was a line standard. In End standard, the distance between the ends of a bar or a block is the specified distance. Line standards need auxiliary set ups to measure. End stands need only simple accessories for their applications.

Shop floor measurements

Auxiliary Standards:Length Bars Block or Slip Gauges
Reference Calibration Inspection Workshop (00) (' 0 ') ( I ) (II)

A box of Slip gauges

Shop floor measurements

Slip gauge accessories

Shop floor measurements

Auxiliary Standards:Length Bars

A box of Length Bars

Airy Points
Definition: The best points for supporting a bar horizontally so that the end slopes become zero. If the bar is of length L and there are n supports, the supports should be separated by distance L/sqrt(n2-1). For two support this is 0.5773 L .

Support points

Traceability
For international trade there is the need to adhere to the standard scrupulously especially with diminishing tolerances. This means that all linear measurements done are to be traceable to the standard of length the meter.

Traceability
It is practically impossible to directly refer to the meter for all measurements. So it is done by reference to secondary or auxiliary standards which are calibrated with reference to the standard meter. Like wise all other measuring instruments are to be calibrated with secondary standards, ensuring traceability to the meter. ISO 9000 recommends this.

Light Interference for Precision Measurements

Interference of light. Optical flat. Simple set-up for interference. Measurement of length by comparison. Slip gauge comparison. Distance measurement using interference. Absolute Measurement of Length. Laser Interferometer.

Whitworths flat surface generation

Production of Master Surfaces and Squares

Light Interference

Principle of Distance Measurement

Surface and Form Measurements

Slip Gauge Interferometer

Laser Interferometer

Tolerancing

Fundamental Deviations

Specifying Fits

Quality of fits

Types of Fits

Hole and Shaft Basis System

Preferred Fit Families

For hole tolerances, tolerance zones H7, H8, H9 and H11 are used preferably. For shaft tolerances, tolerance zones h6, h7, h9 and h11 are used preferably. Preferred Fits Clearance fits: H11/c11, H9/d9, H8/f7, H7/g6, H7/h6, C11/h11, D9/h9, F8/h7, G7/h6 Transition fits: H7/k6, H7/n6, K7/h6, N7/h6 Interference fits: H7/p6, H7/s6, H7/u6, P7/h6, S7/h6, U7/h6

Standard Fits
Loose Running H11/ c11 Free Running H9/ d9 Loose Running H11/ c11 Easy Running - Good quality easy to doH8/ f8 Sliding H7/ g6 Close Clearance - Spigots and locations H8 f7 Location/Clearance H7/ h6 Location- slight interference H7/ k6 Location/Transition H7/ n6 Location/Interference- Press fit which can be separated H7/ p6 Medium Drive H7/s6 Force H7/u6

Gauges

Plug Gauge

Gauges

Gauges

Adjustable Gap Gauge

Ring Gauge

Taylors Rules on Gauge Design

Fundamentals of Linear Measurements

Abbe Principle Measuring force and Measurement Environment Contact and Non-contact measurement Measurement and Sensing

Abbe Principle
The scale of a linear measuring system should be co-linear with the spatial dimension or displacement to be measured or else the measurement must be corrected for the associated Abb error.

Abbe Error