Engineering Metrology

DPMT III Semester

By Shravan yadav
CAD Department
CIPET JAIPUR
Metrology

Derived from Greek word-

Metro-Measurement
&
Logy-Science
How Metrology relates Day today life
How metrology relates to Industry
What is metrology?

Metrology is Science of measurement which deals with the accuracy of measuring

Instruments, units of measurement & their standards and method of measurement.

Example- Distance, mass , time , temperature, Voltage

Function of metrology

Establishing units of measurement

Reproducing these units as standards
Ensuring the uniformity of measurement
Development of method of measurement
Analysis of accuracy of method related to
errors
Units of mesaurement
Standards of measurement
Uniformity of measurement
Method of Measurement Accuracy of Measurement

Method of measurement-Direct
Method

Method of measurement-
Comparative Method
Measurement standard

Standard is defined as “something that is set up and established by authority as a

rule for the measure quantity , weight, volume.
Objective of Eng. Metrology
To ensure uniformity of measurements
To carry out process capability studies to achieve better component tolerances
To evaluate the newly developed components
To determine the capability of measuring instruments (eg 20+0.01mm)
To enhance the customer satisfaction
To minimize the cost of inspection by effective utilization of instruments and
facilities
To adopt quality control techniques to minimize scrap rate and rework.
To establish inspection procedures from the design stage itself, so that the
measuring methods are standardized
To calibrate measuring instruments regularly in order to maintain accuracy in
measurement.
To resolve the measurement problems that might arise in the shop floor
To design gauges and special fixtures required to carry out inspection.
To investigate and eliminate different sources of measuring errors
It helps in achieving interchangeability of parts.
Category of metrology
Scientific metrology

Industry metrology

Legal metrology
Industrial metrology

It has to ensure the

adequate functioning of
measurement instruments
used in industry as well as
in production and testing
process
Inspection
Inspection is the act
of checking of all
material or products
or components parts
at various stage of
during manufacturing
01 Established desired Coordinate 05
standrad

02 Interchangeability Take decision 06

Need of Inspection

03 Customer good will Promote the spirit of 07

competition

04 Finding out inadequacies

in manufacture Purchase good-quality
raw materials

08
Need of Inspection

Ascertain that component conforms to the established or desired standard.

Accomplish interchangeability of manufacture.
Sustain customer goodwill by ensuring that no defective product reaches the
customers.
Purchase good-quality raw materials, tools, and equipment that govern the quality
of the finished products.
Coordinate the functions of quality control, production, purchasing, and other
departments of the organizations.
Take the decision to perform rework on defective parts, that is, to assess the
possibility of making some of these parts acceptable after minor repairs.
Accuracy and Precision
Accuracy-
Accuracy is the degree of agreement of the measured dimension with its true
magnitude
OR
It can also be defined as the maximum amount by which the result differs from the
true value or as the nearness of the measured value to its true value, often
expressed as a percentage.

Precision-
Precision is the degree of repetitiveness of the measuring process.
It is the degree of agreement of the repeated measurements of a quantity made by
using the same method, under similar conditions
Repeatability-
The ability of the measuring instrument to repeat the same results during the act
of measurements for the same quantity is known as repeatability.
Method of Measurement
Measurements are performed to determine the magnitude of the value and
the unit of the quantity under consideration.
EX-
The choice of the method of measurement depends on the required accuracy and
the amount of permissible error.
The common methods employed for making measurements are as follows:

Direct method:-In this method, the quantity to be measured is directly compared with
the primary or secondary standard without any calculation.
Instruments:-
Scales, vernier
calipers,
micrometers, bevel
protractors
Indirect method :-In this method, the value of a quantity is obtained by measuring
other quantities that are functionally related to the required value.

Instruments:-
Sine bar, measurement of
screw pitch diameter

Sine bar
Strain gauge
Comparative method:-In this method, the quantity to be measured is
compared with the known value of the same quantity.
In this method, only the deviation from a master gauge are determined.

Instruments:-
Dial
indicators, Plug Gauge, Snap
Gauge, Bore Gauge.

Comparators
Transposition method:-This is a differential method of measurement wherein a
very minute difference between the quantity to be measured and the reference is
determined by careful observation of the coincidence of certain lines and signals.

Instruments:-
Vernier caliper, Micrometer
Deflection method:-This method involves the indication of the value of the
quantity to be measured directly by deflection of a pointer on a calibrated scale.

Instruments:-
Pressure measurement
Complementary method:-The value of the quantity to be measured is combined with
a known value of the same quantity. The combination is so adjusted that the sum of
these two values is equal to the predetermined comparison value.

EX-Determination of
the volume of a solid by liquid displacement.
Null measurement method:-In this method, the difference between the value
of the quantity to be measured and the known value of the same quantity with
which comparison is to be made is brought to zero.
Contact method:- In this method the sensor or measuring tip of instrument
actually touches the surface to be measured.

Measurements by Vernier caliper, Micrometer, dial indictors

Contactless method:-There is no direct contact with the surface to be measured.
Instruments:-Optical instruments, tool maker’s
microscope, and profile projector.
Requirements and General care of Instruments
Meteorological instruments are essential for collecting accurate weather data. Proper
handling and maintenance are crucial for ensuring their longevity and reliability. Here’s
a general guide on the requirements and care of these instruments.
General care of Instruments
Calibration:
Regularly calibrate instruments according to manufacturer specifications or standards to maintain accuracy.
Cleaning:
Use appropriate cleaning methods and materials for each instrument to avoid damage.
Avoid harsh chemicals or abrasive materials.
Protection:
Protect instruments from extreme weather conditions, physical damage, and contamination.
Use enclosures or covers where necessary.
Storage:
Store instruments in a dry, stable environment when not in use.
Ensure they are not exposed to extreme temperatures or humidity.
Inspection:
Perform regular inspections for signs of wear and tear, and address any issues promptly.
Check for any loose parts or malfunctioning components.
Documentation:
Maintain records of calibration, maintenance, and repairs.
Document any issues or anomalies and track the performance of each instrument.
Error in measurement
Error:- Error in measurement is the difference between the measured value and
the true value of the measured dimension.

Error = (Measured dimension- True value)

Types of error

Gross error Systematic or Controllable Errors Random Errors

Any measurement cannot be made with perfect accuracy but it is important to find out
what accuracy actually is and how different error have entered into the measurement . Error
may arise from different source.

Gross Error:- The error occurs because of the human mistakes such as careless
reading, making mistake in recording observation, and improper applications of
instruments etc.

Gross error may also be there because of improper setting of zero before the
measurement and this will affect all the reading taken during measurements.

Gross Error will occur in the measurement result if the pointer deflect between
two Scaling point.
These error may be of any magnitude and cannot be subjected to mathematical
treatment.

Gross Error Cab be reduced by:-

Careful reading
Two or three reading should be taken for the quantity under measurement
if the reading differ by an unacceptable large amount, the situation can be
investigated and the more erroneous readings eliminated.
Systematic or Controllable Errors:-A systematic error is a type of error that deviat
by a fixed amount from the true value of measurement.
or

These error the errors that remains constant or change according to a definite law
repeated measurement of the given quantity.

These types of errors are controllable in both their magnitude and their directio
and can be assessed and minimized if efforts are made to analyse them.
Causes of Systematic Errors
Calibration Issues:
If an instrument is not calibrated correctly, all measurements taken with it will be
offset by a constant amount. For example, a scale that is not zeroed properly will
always give a measurement that is off by the same amount.
Instrumental Bias:
Instruments may have inherent biases. For instance, a thermometer might
consistently read a few degrees higher or lower than the actual temperature due to
a manufacturing defect or design flaw. Improper use of instruments.
Environmental Factors:
Conditions such as temperature, humidity, or pressure can affect measurements. If
the instruments or measurement techniques are not adjusted to account for these
factors, systematic errors can occur.
Observational error:
Consistent mistakes made by the experimenter or observer can introduce
systematic errors. For example, always reading a gauge from the same angle might
introduce a bias
Identifying and Correcting Systematic Errors
Calibration:
Regularly calibrate instruments and equipment against known standards to ensure
accuracy.
Cross-Validation:
Use multiple methods or instruments to measure the same quantity and compare
results to identify and correct for biases.
Environmental Controls:
Account for and correct environmental factors that could affect measurements.
Review Procedures:
Analyze and review measurement procedures and techniques to identify any potential
sources of bias.
Training:
Ensure that all personnel involved in measurements are well-trained and follow
standardized procedures to minimize human error.
Random error:-Random errors provide a measure of random deviations when
measurements of a physical quantity are carried out repeatedly. When a series of
repeated measurements are made on a component under similar conditions, the values
measurements vary.

Random errors can be statistically evaluated, and their mean value and standard
deviation can be determined.
The following are the likely sources of random errors:
Presence of transient fluctuations in friction in the measuring instrument
Play in the linkages of the measuring instruments
Error in operator’s judgement in reading the fractional part of engraved scale
divisions
Operator’s inability to note the readings because of fluctuations during
measurement
Positional errors associated with the measured object and standard, arising due to
small variations in setting
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