Metrology and Quality Control ‘Semester V - Mechanical Engineering / Automobile Engineering (Savitribai Phule Pune University) Dr. R. P. Arora Formerly, Dean Instruction Division BITS Pilani (Rajasthan) and ‘Advisor, Mechanical and Mechatronics Engineering Departments GCET Vallabh Vidya Nagar (Gujarat) 4 ® Tech-Mayrarins re 8 CID | torsion Trout” mi Engineering DivisionMetrology and Quality Control Dr. R. P. Arora 3 i ‘Semester V - Mechanical Engineering, (Savitribai Phule Pune University) (SPPU) Copyright © by Tech-Max Publications. All rights reserved. No part of this publication may be reproduced, copied, or stored in a retrieval system, distibuted or transmitted in any form or by any means, including photocopy, recording, or ‘other electronic or mechanical methods, without the prior writen pemnission ofthe publisher. 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Area Survey No. 2825, Dhayari Near Pari Company, Pune 41, Maharashtra State, India, E-mail : rahlshahimage@ gmail.com ISBN 978-93-5077-642-1 Published by ‘Tech-Max Publications Head Office : B/S, First floor, Maniratna Complex, Taware Colony, Aranyeshwar Comer, Pune - 411 009, Maharashte State, India Ph: 91-20-24225065, 91-20-24217965. Fax 020-24228978. Email: info@techmaxbooks.com, Website: wwrw.techmaxbooks.com [302045] (FID : 1P499) (Book Code : PO283A)Savitribai Phule Pune University, Pune : TE Mechanical and TE Automobile (2015 course) Course Code : 302045 Course Name : Metrology And Quality Control ‘Teaching Scheme : Credits Examination Scheme : ‘TH :03 Hrsiweek TH:03 TH = In-Sem:-+30 —-End-Sem: - 70 PR: 02 Hre/week OR: --25 Course Objectives : Studénits are expected to : Selet suitable instrument gauge / method of inspection for determining geometrical and dimensional measurements. Calibrate measuring instruments and also design inspection gauges. ‘Understand the advances in Metrology such as use of CMM, Laser, Machine Vision System for Metrology etc. Select and apply appropriate Quality Control Technique for given application. Select and Apply appropriate Quality Management Tool and suggest appropiate Quality Management Sytem (Ms). Course Outcomes : ‘The student should be able to Understand the methods of measurement, selection of measuring instruments f standards of measurement carryout: - data collection and its analysis. Explain tolerance, limits of size, fits, geometric and position tolerances and gauge design 3. Understand and use/apply Quality Control Techniques! Statistical Tools appropriately. 1. Develop an ability of problem solving and decision making by identifying and analyzing the cause for variation and recommend suitable corrective actions for quality improvement, ‘Course Contents Unit |- Measurement standards and Design of gauges (06 hrs) Introduction : Principles of Engineering metrology, Measurement standards, Types and sources of errors, Accuracy and Precision, Calibration: Concept and procedure, traceability. Geometric Form Measurement: Straightness, Flatness, Roundness - Straight edge, use of level beam| comparator, autocollimator testing of flatness of surface plate. Design of Gauges : Tolerances, Limits and Fits [IS 919-1993], Taylor’s principle, Types of gauges, Wear| allowance on gauges, Types of gauges-plain plug gauge, ring gauge, snap gauge, limit gauge and gauge materials, Considerations of gauge design (numerical). (Refer Chapters 1, 2 and 3) Unit Il- Comparators, Thread and Gear Metrology, Surface Roughness Measurement (08 hrs) (Comparators : Mechanical, Pneumatic, Optical, Electrical (LVDT). Measurement of Thread form: Thread form errors, Measurement of Minor, Major and Effective diameter (Three Wire Method), Flank angle and Pitch, Floating Carriage Micrometer (Numerical). Gear Metrology: Errors in Spur Gear form, Gear tooth Vernier, Constant chord, Base tangent (Numerical), Gear Rolling Tester. Profile Projector, Tool maker's microscope and ther applications ‘Surface Roughness Measurement: Introduction to Surface texture, Parameters for measuring surface roughness, Surface roughness measuring instrument: TalySurf. (Refer Chapters 4, 5, 6 and 7) Unit Ill - Advances in Metrology (06 hrs) Coordinate Measuring Machine (CMM) : Fundamental features of CMM — development of CMMs ~ role of| CMMs ~ types of CMM and Applications, ~ types of probes Machine Vision Systems: visInterferometer: Principle, NPL Interferometer Laser Metrology: Basic concepts of lasers, advantages of lasers, laser interferometers, types, applications. (Refer Chapter 8) Unit IV - Introduction to Quality and Quality Tools (06 hrs) Concept of Quality: Various Definitions and Quality Statements, Cost of quality & value of quality, Deming's cycles & 14 Points, Juran Trilogy approach, Old New Seven Tools, Quality Circles, Importance of Quality deployment at Design and Manufacturing Engineering: Opportunities for {improvement product design, Importance of-- initia planning for quality, concept of controllability: slf-controls ~ defining quality responsibilities onthe factory flow ~ self inspection, (Refer Chapters 9, 10 and 11) Unit V - Statistical quality control (08 hrs) Statistical quality control : Statistical concept, Frequency diagram, Concept of variance analysis, Control Chart| for Variable (K & R Chart) & Attribute (P & C Chart), Process capability (Indices: cp, epk, ppk), Statistical Process Control (Numerical), Production Part Approval Method (PPAP). Acceptance Sampling : Sampling Inspection, OC Curve and its characteristics, sampling methods, Sampling Plan: Single, Double (Numerical), Multiple, Comparison of Plan, calculation of sample size, AOQ, Probability of| Acceptance (Numerical. (Refer Chapters 12 and 13) Unit VI- Total Quality Management (06 hrs) ‘TQM : Introduction, Quality Function Deployiment, 5S, Kaizen, Poka yoke, Kanban, JIT, FMECA, Zero defects, ‘TPM. Six Sigma- DMAIC - Concept and Applications. (Quality Management System : Need for quality management system ~ design of quality management system - quality management system requirements ~ ISO 9001, TS-16949, ISO-14000, Quality Audit, (Refer Chapters 14 and 15)| goaEP metrology & Quality Contr! (SPU) Table of Contents Syflabus standards, Types and sources of erors, Accuracy and Precision, Calibration: Concept and procedure, traceabilly Chapter 1: Introduction 4-1 to 145 Principles of Engineering ‘metrology, Measurement “ 1 112 12 13 134 132 133 134 135 136 137 138 139 13:10 Maat 14 14a 14a 1412 1413 tata 15 181 15a4 152 1524 153 Syllabus Tope : Principles of Engineering Metrotgy 1-1 Intron (SPPU-May 14, May 15, Oct. 16 (In Sem.) Nocossty and Objectives of Metilogy. Classifications of Meloy. Elomonts ofthe Measuring System... ‘Ciassioaton o Moasuing Instruments (SPPU-- Oot. 16 (In Sem) 12 (Ciassicaon based on Functn.. 12 Dirge and Increct Measuring Instruments. Line’and End Measuring Instruments (Contact and Non-contact Type Measuring Instruments 13 Detlecton Output or Nul Ouput Type. Instruments... 13 ‘Automatic and Manualy Assisted instruments Self Oprated or Power Operated instrument .e 18 Self Contained or Remote lndcating Instruments. Cessation Based on Type of Output Sin Comparison Method of Measurement... Diferential Method of Measurement Syllabus Topic: Measuroment Standards... ‘Standards of Measurement (SPPU-- Dec. 14, Aug, 15(hn Sem). Ciassitcaton of Standards (SPPU- May 14, Aug 15 (In Som,), Dec. 16). Intemational Prototype. Primary Standards. ‘Secondary Standards Working Standards. Length Standards Lin Standards (SPPU - Dec. 18, Dee. 14)... Intemational Standard Meter and Yard. End Standards (SPPU- Dee. 13, DEC. 14) nnn 16 ‘Comparison between Line Standards and End Standards (SPPU- Aug. 15 (n Sem). 6 Disadvantages of Mota Standards 154 Wave Length Standards. 6 1.55. Comparison betweon Metal and Wavelength Standards ~ AB ¥ Syllabus Topic : Precision and Accuracy. a7 1.8 Precision and Accuracy (SPPU - Dee. 13). AT 18.1 Diferentation between Prcision and. Accuracy (SPPU -May 12, Aug. 14(In Sem) ¥—— Syflabus Top 17 Enorsin Measurement... 174 Cassifcation of Erors (SPU ~ Dec. 12, May 13, Dec. 13, Aug. 14 (In Sem), YBP8 Of EMO ‘Aug. 15 (In Sem)... 1.72 Comparison of Systematic and Random Errors (SPPU- May 16) 19 % Syllabus Topie : Sources of Eo... 1-10 17.3 SoU Of EMOF enn et 1-10 1.8 Selection and Care of instruments 181. Selection of Measuring Instruments 182 Care of he instuments 4.83 Carin Use of Instruments ¥ Syllabus Tope: Calration and Tracoablity.n.u. 1-13 1.9 Calibration and Centicaton. set 1.91 Calbration (SPPU - Aug. 16 (In Sem) 192 Cextcation 1.93 Calforation of Some Common Shop Instruments ...1-13 1.94 Traceability (SPPU- Aug. 14 ($2) oon t4 + Review Questions. + University Questions... Chapter 2: Geometric Form Measurement __ 2-1 to 2-22 Syllabus : Straightness, Flatness, Roundness-straight edge, use of level beam comparator, Autocoliimator testing of flatness of surface plate. 2A It O8.C0N nie 2A ¥ Syllabus Topic : Straighiness. 24 22 Measurement of Staighiness..... 24 221 Definition of Stalghthess (SPPU - Dec. 19, May 14, Aug 15 SM) enn24 22.2 Tests for Sraightness (SPPU De. 12) cnn 22 22.2.1 _ Straight Edge Method. 2222 Wedge Method. 2223 Use of Spit Level... 2224 Autocolimator Method ..(BE metrology & Quality Cont (SPPU) 2 Table of Contents = ¥ Syllabus Topic : Autocolimator testing of flatness of 28.11 Sources of Out of Roundness of Machined Parts...214 surface plate. vovmsnnannnsncee®d | 284.2 Types of treguarties. 2225 Autecolimator 28.1.3. Enorof Ckeulary : Definition (SPPU- May 12) (SPPU -May 13, Dec. 14, (Aug 15(In Sem)May 16) 24 | 25.1.4 Circulafly Relerence Circles. ¥ * Syllabus Topic: Flatness v= 25 | 28.15 Gireuarty and Roundness, 23 Measurement of Flan... 25 | 282 Measurement of Cicularty (SPPU- Dec, 12) 23.1 Introduction (SPPU-Dee. 13, May 14). ®5 | 2824 sect V Block and Dial Indicator. 23.2 Flatness Testing (SPPU Dec. 12, May 18)...-.-..28 | 2822 Preision Measuring Machine ~Talyron. 23.21 Using a Surface Plato or Too! Maker's Fa 26 | 283 Measurement of Roundness of Machined Components 2822 Using a Straight £699 oon 26 (SPPU- May 12, Des. 13, May 14, 2923 Usinga Dial Gage... ne) ‘Aug. 15 (in Sem). % Syllabus Topi Use of Level Beam Comparator...246 | 283.1 Eocenticily Tester 2824 Using a Flain@ss Comparattinnnnunnunnnune®6 | 2832 Use of Optical Dividing Head and Cam Shalt Testor.2-18 2925 Spirit Level and Autocolimator Method. 27 | 2833 Usoot Measuring Machine 232.6 Use of Optical Flats (Interference Method). 28 | 29 Indirect Measurement of Sutace Parameters 24 Measurement of Squareness 29.1 Measurement of Linear Dimensions. (SPPU- Dec. 13, Aug. 15 (in. Sem,)... 28. | 292 Measurement of Angles. 24,1 Methods of Sqaureness Testing von 2:6 | 2.9.3 Measurement of Tapers (SPPU - Oct. 16 (In Sem.) 2441 Using a Try Square. eee os se sr BAD 24.1.2 Use of Combination Square sue | 294 — Measuring the Interior Angle of a Profle Gauge when One 2.4.1.3 Indicator Metho 2 arena 24.14 Testing Squareness wih Autocolimator. 29 | 295 — FourBall Method of Measuring Diameter of Bore 24.15 Checking Squareness of Two Planes. 2410 (6PPU- May 12) 24.1.8 Testing Squareness of an Axis of Rotation with a Gen | * Review Questions. Plane 240 + University Questions Chapter: 25 Design of Gauges 251 Testing fr Param... 25.1.1 Paralloism of Two Plans. 2512 _Paralloiom of an Axs toa Piane.. 25.8 Paralloism of Two Axes. 25.1.4 Paraliaism of an Axis tothe Inersection of Two Planes 241 | © Syllabus Topie : Tolerances, Limits and Fits nson 3H 34 2-10 || Syllabus : Tolerances, Limits and Fits (1S-919-1999], Taylor's Principe, Types of gauges, Wear allowance on gauges, Types of gauges plain plug gauge, ring gauge, snap gauge, limit gauge, and ‘gauge materials, consideration of gauge 2545 Parallolsm of Two Straight Lines, each Formed by | 9.1 Tolerances and Fits Intorsecton of Two Planes. sm 2t1 | 3.1.1 Toleranco (SPPU - Dec. 14). 4 252 Motion Peratelsm.. 212 | 312 Methods o Speciying Tolerance 32 252.1 Parallelem botwoen Trajectory and @ Pane een 2442 | 31.3 Maxinum and Minimum Material Conon. 92 2522 _Parallelom of Tajecory to an As. ww 212 | 814 Desivod Condition for a System of Limits and Fis....9-2 2523 Paralosm between Two Traecoies... 242 | 815 Deviation. 26 Funout 2419 | 8.15.1 Fundamental Devaton. 261 Measurement of Runt aia | are Ft, 27 Concentricity (SPPU- May 14). 213 | 31.7 Hole Basis and Shaft Basis System of Fis 28 Measurement of Crcuay (SPPU May 14) 214 (SPPU -Dec. 14, De. 18) 281 Introduction 216 | 3.1.8 Industia Classieation of Fis... 35 36Metrology & Quality Control (SPPU) Table of Contents ths Clewarce Fas a mat 3182 Transition Fis. ~ 38 | Chapter 4: Comparators 41t0 412 2183 neference Fis. uw ‘Syllabus Mechanical, Pnoumati, Optica, Electrical (LVOT). ¥ Syllabus Tope :s 10:08. 41. lnating Gauges and Conparatos 82 indian Sand Speco Lins and Fits qhanienniteinian td = (6PPU Dec. 12, Aug, 14 (In Sem). set ¥ —Sylabus Tope: Mechanical Comparators a“ 321 Methods oinccating Pat Siz and Ft. 38 42 Mechanical Indicating Gauges and Comparator... 44 322 Equivalent Fits in the Hole Bass and Shaft Basis Systems, or) 42.1 Johansson Mikrocator (SPPU - Dec. 12, Dec. 13, Aug, 14(In Sem). 42 323 Calculation of Tolerance and Dimension for Fits... 9-11 422 Sigma Comparator (SPPU - May 13) 43 924 Commonly Usod Holes and Stas een 314 423 Advantages and Disadvantages of Mechanical 325 Selection of Shaft and Hole Tolerances and Fits... 15 coal / 43 328 Other Limit Systems. 318 | 43 Mochanlcal Optica Comparators. “4 33 Goometical Tolerances... S46 | v Syllabus Topic: Optical Comparer nnnnninn de 44 347 | 44 Optical Comparators. ¥ Syllabus Topie : Gauges 34 Gauges. 3.17 | 441 Advantages and Disadvantages of Optical Comparators 341 Measuting and G09 neni SAT oe ‘ Nlabus Topic: Electical Comparats...eon.mm 342 Classification of Gauges. 318 i paced neealemetnepernteagy “ fae ca eeeteee aie | *% — Ehoticaland Eecronicinscaing Gauges and Soares oe Comparators ess 343.1 Footer Gauges. SMB 45.1 Advantages and Disadvantages of Electrical anc 3432 Radius Gauges. Electron Comparators... 3433. Drill and Wire Gauges... a8 |v ‘Syllabus Topic : Pneumatic Comparators... AB 3434 Plate Gauge. 3:19 | 46 Preumatc Compare nee \3435 Standard Gauges 319 | 461. Solex Proumatc Comparator 243.6 Limit Gauges (SPPU- Dee. 14) .ennmennenes 419 (SPPU-May 14, Aug. 15(n Sem), Oct. 16m Sem) 48 3437 Plain Ring Gauge 320 | 462. Dilference between Mecharial an Preumatc 34.38 Position Gauge. 9-20 Comparators bad 8439 Combined Limit Gauge... 329 | 463 Advantages and Disadvantages of Pneumatic. Comparators . 49 ¥ Syllabus Tople : Gouge Design. 3.44 Design of Limit Gauges. 3.4.4.1 Stops in Design of GaUg08 nnnnnn 322 34.42 Taylors Principle of Gauge Design (SPPU-Dec. 13, May 14, Aug. 1419 Sem), ‘May 15, Dec. 15, May 16, Oct. 16(In Sem.) . ¥ Syllabus Topic : Gauge Matera 47 High Magnifeation Gauge Comparator. 48 Mull-check and Automat Comparators ¥ Syllabus Topic = LVDT on 49 Linear Variable Ditferental Transformer (LVDT) (SPPU - May 12, Dec. 16)... ‘+ Review Questions. University Questions. 412 3443 Gauge Materia... 94.4.4 — Advantages and Disadvantages of Gauging. 3.29. | Chapter §; Measurement of Thread Form _ 5-1 to5-18 ‘Syllabus : Thread form errors, Measurement of minor, major and effective diameter (Three wire method), Flank angle and pitch, Freatingcariage micrometer (Numeric). ‘+ University Questions...[BP etrtogy & Quality Control (SPPU) 54 52 53 54 544 55 87 874 572 58 581 582 583 583.1 sa4 585 586 587 59 5:10 5104 5.102 5103 sit IeeodUti0 : st Ctessication of Soon Threads 51 Eloments of @ Ser0W Thad ween SA Details of Common Thread Foms 52 Scrow Thread Stand. on 8S Syllabus Tople : Thread Form Errors, lank angle and Pitch. 55 Errors in Threads (SPPU- Dec. 13, May 14, Aug. 14(In Sem,), (Oct. 16 (In Sem). 55 ‘Screw Thread Inspection. sone ST Syllabus Topic : Measurement of Major and Minor Diameters nnn ST Measurement of Major and Minor Diameter... 7 Measurement of Major Diameter. ST ‘Measurement of Minor Diameter. 58 ‘Syllabus Topic : Etfecive Diametor Measurement... 58 Measurement of Ect Diameter. 58 “Thread Micrometer Method 58 One Wire Method... eee Two Wire Method (SPPU -Oet.16 (In Sem) nce 5-9 Syllabus Tople : Floating Cartiage Micrometer... 5-10 Floating Carriage Micrometer (SPPU- May 1, Dec. 13, May 19).. 510 Syllabus Topic: Three Wie MetNOd nenen SAO Thvee Wire Mathod (SPPU- Dec. 12, Dec. 14, De. 15) 5-10 Bost Wie Size {SPPU-May 18, May 14, Aug. 15 (Sem, Dee. 1) 511 Corrections in Effective Diameter Measurement with Wires 513 Difference Between Two Wire and Three Wie Method a) “Measurement of Thread form and Angle (SPPU- Dee. 12)... Pitch Measurement (SPPU- May 14). Pitch Measurement by Optical Projection lich Measurement by Pich Measuring Machine. Effect of Pitch Error... Measurements of Elemonts ofthe intomal Thread... 5-15 ay Table of Contents 5.11.4 Measuroment ofthe Major Diameter. 515 5.11.2 Measurement of Minor Diameter. 55 5.113 Measurement of Effective Diameters. 516 5.114 Measurement of Pitch. ‘+ Review Questions... + Problems... 6-1 106-19 Syllabus : Erors in spur gear form, Gear tooth vernier, Constant chord, Base tangent (numerical) gear roling tester, Profle projector, Tool Maker's Microscope and their applications. 6.1 oduction. BA 62 Classification of Gears. 62 62.1 Classification Based on Position of Shalt AXES .an.6-2 6.22 Classification According to Peripheral Velocity of Gears eS 62.3 Classtication According to Type of Meshing of Gear Tooth 63 63 GoarTorinology 63 6.3.1. Relaonstp Between Various Elements ofthe Gear..6-4 84 64a 642 643 6.44 Standard Tooth Profle Systons... _,labus Topic: Ero in spur gear for. 65 Enors in Manufactured Gears (SPPU- Aug. 15 (In Sem), Doc. 15, ct 160m Sem) 66 Inspection of Gears... 67 Measurement and Testing of Spur Gears (SPPU - May 14) 68 68 Measurement of Gear Tooth THICKNESS enna 9 ¥ Syllabus Topic : Gear Tooth Vernier. 69 6.8.1 Uso of Gear Tooth Vemier Caliper (SPPU - Dec. 13, May 14, Aug. 15(In Som), Dec. 16). 69 ¥ Syllabus Tople : Base Tangent Method 8410 68.2 Base Tangent Method (SPPU-- May 13, Dec. 13, Dec. 14... 610 ¥ Syllabus Tople : Constant Chord Method rv enneu6A12 6.83 Constant Chord Method (SPPU - May 13, Dee. 14) .6-12,[BF metciogy & Quay Contl(SPPU) 5 68.4 — Measurement Over Rollers... 613 69 Measurement of Baso Pitch ora 6.10 Iavolute Testing... 14 6.11 Measurement of Pitch Diameter sn 618 6.12 Functional Gear Checking = 65, ¥ Syllabus Topie : Gear rong Tester. 6S 6.12.1 Parkinson's Gear Tester (SPPU- May 12, Dee. 12, May 13, Aug. 16 (In Sem.)) 645 ¥ Syllabus Topie : Profile Projector. on B16 6:13 Profile Projector. 616 ¥ Syllabus Topic : Tool Makers Microscope and their Applications. 18 6.14 Tool Maker's Microscope (SPPU- Dec. 15) 618 a7 618 on BB ‘© Roview Questions. © Problems, + University Questions.. Chapter7: Surface Roughness Measurement Tet to7A2 Syllabus : troduction to Surface texture, Parameters for measuring surlace roughness, Surlace roughness measuring Instrument : TalySut Syllabus Tople : Surface Texture and its Parameters 7-1 Te Ito Uet50R nn e 74 TAA Types of Sutface Ire QUlab€S cnr TA \v Syllabus Topic : Parameters of Sirface Roughness e ee m 72 Surface Texture (SPPU-May 14, Aug. 14(In Som,), Aug. 15(In Som), May 16) TA 7.21 Primary and Secondary Texture... sen FB 7.2.1.4 Comparison of Primary and Secondary Textures (SPPU-- May 12, May 13, Dec. 13, May 15). 73 722. Common Types of Lay. 7 7.3 Methods of Assessing Surface Fish. ann TB 74 Comparison Methods a ¥ Syllabus Tople : Sutace Roughness Measuring Instruments nn = 78 75 Direct Roughness Measuring Instruments {SPPU- Aug. 14(In Som.) Oct. 16(In Sem.) 7.5.4 Electical Stylus Protlometer es 752 Piezoelectric ype Roughness Meter... 75 Table of Contents 758. Tominson Surface Tester (SPPU- Dec. 12, May 13, May 14, Aug. 15 (In Sem7-6 © Syllabus Tope: Taysur Roughness Tester. oonon 7-6 78.4 Taylor Hobson-Tlyourt Roughnes8 TSE ronnn 7-6 785 Tracer Type Proftograph.. 7 75.6 Optical Roughness Measuring Instruments, E 7.8 Numerical Spectcation of Surface Roughness (SPPU- May 12, May 14, May 16) 7.7 Incation of Stace Texture on Drawing. 79 78 Sanplng Lengh and Preered Ra Values as Per Indan Standar.. 79 78.1 Sampling Length. 79 782 RaValues 7.10 79 Adverse Elects of Poor Sued Finish nnn 10 + Review Questions. so TAN + Problems. a + University Questions aa ‘Advances in Metrology Chapter 8 : 81 108-21 Syllabue : Coordinate Measuring Machine (CMM) Fundamental features of CMM -development of CMMs, Role of (CMMs, Types of CMM and appfcations-types of probes. Machine Vision Systems, Interferometer: Principle, NPL intererometer. Laser Metrology : Basic concepts of lasers, advantages of lasers, laser interferometers, types, applications. sion system measurement 8.1 Introduction (SPPU - Dec. 19). co ¥ Syllabus Tope: Coordinate Measuring Machine, Role of ‘ous, a4 82 Coordinate Measuring Machine (CMM) (SPPU- Aug. 14 (In Sem), Oct. 16 (In Sem). 821 — Roleof CMMs ¥ Syllabus Tople : Types of CLAM. 822 —Typosof Coordinate Measuring Machines (SPPU-May 14, Aug. 14 (In Sem), Oct. 16 (In Sem.) — sn ¥ Syllabus Topic : Fundamental Features of CM 8.23 Fundamental Features of CMM. ¥. Syllabus Tople : Types of Probes. 824 — Probesused on CMMs. : 82.5 — Computor Controlled ChM (SPPU- May 13, Dec. 12).(BF sowoiogy & Quatty contol SPPU) 6 26 827 83 831 84 84s 42 843 as ass 352 asa 854 8541 85.42 8543 e544 86 861 862 863 86st 8632 8633 86.34 87 ‘Advantages of CMM. Applications of CMM, Universal Measuring Machine (UMM) (SPPU-- May 12, Dec. 12, May 14, May 15, Dec. 16). 85 Comparison of CMM and UMM... 85 Syllabus Topic : Machine Vision systems. Machine Vision (SPPU - May 14, Aug. 14 (In Sem,) 8-5 84 a) Mactine Vision Cameras ‘Advantages of Machin Vision TechngUe uuu 8-7 ‘Applications of Machine Vision System, ‘Syllabus Tope : lertorometer.. Interferometer (SPPU - Dee. 12, May 13, May 15) Interferometry. a Measurement of Height with Optical Fat. Flatness Checking with Optical Fats (SPPU - Dec. 12, May 13, Aug. 15(in Sem), Dec. 16) 840 840 810 10 Bett Syllabus Topic: Principle of interferometer. Intererometers.. Principle of interferometers. Syllabus Topic : NPL interferometer. NPL Fatness intelrometer (SPPU- May 14, Aug. 14 (In Sem), Dec, 15, Mey 16) a 81 ‘The Piter-N.P.L. Gauge Interferometer (SPPU- Oct. 16 (in Sem.) Laser Interferometer. ed ‘Syllabus Topic : Laser Metrology - Basic Concepts of Lasers... 814 Syllabus Topic: Advantages of Lasers Adivatages Of L888 Syllabus Topic: Applications of Laser Laser Applications (SPU - Deo. 12, May 13, Aug. 15n Sem)... Laser Dopplar Velocimetrs (LDV)... Syllabus Topic : Laser interferometer. Laser nterorometer (SPPU- May 12, May 14, Dee. 14, May 1).. Laser Diameter Gauge. Laser Viewer for Product Profile Check Automated Inspection Systems (SPPU- May 12, May 15, Oct. 16 (n Sem) Table of Contents 87.4 Non-Contact Type Automated. inspection 8-17 87.1.1 Machine Vision, 8.7.12 Laser Scanning... “ 87.18 Utrasoni Inspection Technique. 8.7.14 Radiation Technique. 27 87.15 Electric Fil... 818 87.2 Contact Type Automated inspecton.. e18 8.7.2.1. Use of inspection Probe 218 8722 comm e18 87.23 _Flexbo Inepecion Systom 818 87.3 Offine - Ontine Inspection enn 618 87.4 _|sometric Viewing of Surface Defect, 8.19 88 Computer in Metrology... 219 + Review Questions. 820 + University Questions... oa 20 Chapter 9 : Concept of Quality 941 to9-11 aa saa e12 943 a4 92 93 eat 93.11 932 933 94 Syllabus + Various definiéons and qualty statements, Cost of {quality & value of quality, Deming’s cycles and 14 points, Juran trology approach, ‘Syllabus Topic : Quality Definition and Quality Statement. ot ual. ot Quality Statement. sont Importance of Qual. ot Factors Affecting Quay. e2 Quality Spiral 92 uatty Characteristics (SPPU - May 12, May 13, De. 15)) uu. ‘Quality Economics. 92 93 ‘Syllabus Topic Cost of Qual... 98 Cost of Quality (SPPU - May 12, Dec. 12, May 13, May 14, Dec. 14, Dec. 15, Dee. 16). 93 Categories of Costs (SPPU - May 12, May 13, May 14, Dec. 14, May 15, May 16, DeC. 16) nnn Syllabus Topic: Value of Quality Valve of Quality (SPPU- Dec. 12, May 14) 96 ‘Quality Contribution . 96 Syllabus Tople : Deming’s Cycles... 06 Dening's Contbuton 96gl Metrology & Quality Control (SPPU) Table of Contents 941 PDCACycle (SPPU - Dec. 12, May 14, Dec. 14, May 16, Dec. 16) 942 PDSA(Pian-Do-Study-Act) Cycle {SPPU-Dec, 12, May 14, May 16) ¥ Syllabus Topic : Deming’s 14 Point... 1055 Limitations of Qualty Circles (SPPU- May 12, Doc. 12, Dec. 16) 10410 “+ Review Questions ae 10410 + University Questions ~ ron OHO Chapter 11: Quality Deployment at Design and Manufacturing Engineering 11-1 to 11-12 Syllabus: Importance of quality deployment at design and manutacturing engineering: Opportunies for improving product sign, importance of inital planning for qualty, concept of ‘controabiity self controls, defining qualtyresponsbiltes on the 943 Deming’s Fourteen Points (SPPU - Dec. 14, May 18, Dec. 15, Dec. 16) 944 — Deming’s Deadly Sins or Diseases (00) nn 88 ¥——Sylabus Topic: Juran's Trilogy AppFOACR anne 8B 85 Juran's Approach, 8 95.1 Juan's Tiology {SPPU- May 12, May 13, May 14, Dec. 14, Dec. 15, May 16) nn 8 952 Comparison between Deming’ and Juan's Quality Concepts. 910 ‘+ Review Question 910 + University Questions... ee 40 Chapter 10 : Quality Tools 10-4 to 10-11 ‘Syllabus : Old and new quaity tools, Quality circles. % Syllabus Tope: Seven Od Quality TOO! nnnnne 104 10.1 Seven Old Quality Tools (SPPU-- May 12, May 13, May 14, Dec.14, Dec. 16) ~ sa IO ¥ Syllabus Topic : Seven New Quality Tools 105 02 Seven New Qualty Tools (SPPU- May 15, Dec. 15) 105 10.3 Brainstorming (SPPU - Dee. 13).. 105 10.81 Sequence of Operation in Brainstorming Session... 10-6 1032 Etiquettes of Brainstorming 106 10.4 Concurrent Engineering (SPPU- Dec. 12, May 14): 10-7 104.1. Advantages of Concurent Engineering 108 % Syllabus Topie : Quality ices. 108 105 ually Circles (GPPU-May 12, Dec. 12, May 14, Dec. 18, Dec. 16)10-8 105.1 Origin of Quality Circles. 1052 Objectives of Quality Circles 1059 Structure of Qualty Ciclo (SPPU-May 12, Dec. 12, Dec. 16)... 108 1054 Advantages of Quality Circles (SPU - May 12, D66. 12) nnn 10-10 {actor floor - sof inspection ¥__Syflabus Topic : importance of Quality Deployment. 11-1, 11.1 importance of Quality Deployment. sted 11.2 Factors Affecting Quality At “ 11.3 Opportunites for Improvement in Product Design... 11-2 11.3.1 Designing for Basio Functional Requirements.ncou 13 11.32 Selection of Material 0 be USE nnn WB 11.33 Parameter and Tolerance Design.. se ND 11.34 Design for Reliab. 11.35 Designing for Maintainablity and Avellabiy. 11.36 Design for Satety... 11.3.7 Designing for Manufacturabity 11.38 Review of Product Design... ¥ Syllabus Topic: Importance of nia Ptanning for ual. = 115 114 Planning 118 11.4.1 Characteristos of Planning nm 118 11.42 Steps involved in Planing. 116 11.43 Advantages and Limitations of Planning. nennn 16 ¥ Syllabus Topic: Concept of Controtabtty 116 11.5 Concept of Contllaity... 116 1154 Control 116 11.5.1 Need for Conta... 116 1151.2 Charactristies of Control 7 11.5.1.3 Types of Conta. 7 11.544. Steps in Contoling.. "7 11.5.41.5. Advantages and Limitations of Contos 118 11.52 Controlabity Classification 118BF metroogy & Quality Control (SPPU) 8 Table of Contents ¥ Syllabus Tope: Se¥ Cont. 118 1153 Self Cont 118 ¥ Syllabus Topic: Defining Qualty Responsibitis onthe Factory Floor. soe 11.54 Defining Quality Responsibities onthe Factory Foor 7 se HD ¥ Syllabus Topi: Sof inspection... tat 11.55 Solf inspection. wet 11.55:1. Principle ot Sot inspection. tet 11552 Required Condtons for Sof ngpectNeanane M12 11.553 Advantages and Limtatons o Sof Inspection... 1-12 ‘+ Review Questions. 12 Chapter 12 : Statistical Quality Control 12-1 to 12-30 ‘Syllabus : Statistical concept, Frequency dagram, Concept of variance analysis, Control Chart for Vatiable (X & R Chast) & ‘Attibule (P_& Chart, Process capabiyIndices: cy, Gy. Pa) Statstical Process Control (Numerical). Production Part ‘Approval Method (PPAP) ¥ ——Sylabus Tope: Saisical Concepts 12.4 Introduction (SPPU-Dee. 12)... ene OA 12.1.1 Objectives of Stastcal Cont 124.2 Advantages of Stasical Quality Control 122 Statistical Data Handing 122.1 Data Presentation 1221.1 Tabular Presentaton.. 122.12 Data Aranged in Ascending or Descending Order... 122 122.13 Frequency Distbuton . 122 122.14 PiDiagram.. 128 122 122 ¥ —_Sylabus Topic: Frequency Diagram 128 1224.5 Bar Diagram nnn ia 12.218 Frequency Histogram. 123 122.17 Frequency Bar Cha. 123 12.218 Froquancy Polygon. 124 12.22 Mean, Median and Modo. 124 ¥ Syllabus Topic: Concept of Variance Analysis... 124 122.9 Dispersion trom the Mean 124 1224 Bost Valuo From a Sample of Ratings... 125 122.5 Frequency CURE nnn 126 1226 Normal Distribution... 128 122.61 Uso of Normal Probability Distibution Cum nnn. 1257 123 Cont! Chas 127 123.1 Types of Cotol Ona... 128 ¥ Syllabus Topic: Control Chats for Varables(X and R chan). 128 124 Control Charts for Variables (SPPU -May 16) eon. 12-8 12.41 X-char. (SPPU- Dee. 12). son 2B 124.2. Pechart (SPPU- Dee. 12) nu 129 Y Syllabus Topic : Process Capability 124.3 Process Capabilty (SPPU - Dec. 12). 1243.1 Applications of Process Capability Study In Quality Control ve 12.40 ¥ Syllabus Topic: Process Capability indices cy Ge and B 12432 Process Capabity Indices. 1244 Conttol Chart Pattoms (SPPU-May 14)... 12.46 ¥ Syllabus Topic : Contol Chars for Atibutes(P and C Chat). 1217 125 Contol Chats for Atibutes. 125.1 Detects and Detectives. 125.2" chart (SPPU- Dec. 12, 1253 nPChan 1254 Chart (SPPU-Dee. 12), 125.41 Use of C-chat for Quay Rating... a 128 Comparison of Control Chars. 12.25 ¥ —__Syflabus Tope: Production Part Approval Process (ePAP) 1225 127 Production Part Approval Process (PPAP) (SPPU- May 1). 1228 127.1 Objectives of PPAP, 12:72 Advantages of PPAP.. ‘+ Review Questions. + Problems. + University Questions ee Chapter 13 : Acceptance Sampling 13-1 to 13-46 ‘Syllabus : Acceptance sampling: Sampling inspection, OC cure and is charactors, Sampling methods, Samping plan, Single, Double (Numerical) Multiple, Comparison of plan, Calculation of sample size . AOO, Probably of acceptance (Numerical. 13.1 Introduction 132 Types of Acceptance Inspection, 132.1 100 Percent Inspection 134 AB 132 ¥ Syllabus Topie: Samping inspection... eeeMetrology & Quality Control (SPPU) 9 Table of Contents 19322 Sample inspection... 132 | ¥ Syllabus Topic : Quay Function Deployment... 14-3 1323 Inspection by Vaiabies and by Atibutes 132 | 142 Qualty Function Deployment (QD) 133 Analysis of the Samping Inspection Data 193 (SPPU- May 12, May 12, Dec. 14, May 15, Dee, 15)14-3 134 Selection of Samples. 135 | 421 House of Quality (SPPU- Dec. 13). 144 194.1 Principles of Sample Selection. 195 | 1422 Advantages and Lnitaons of OF. “7 Y Syllabus Topic: Samping Methods. 135 | % Syllabus Tope: 5s. “7 13.42 Sampling Methods (SPPU - May 13). 195} 43 5S “ Syllabus Topic : OC Curve and is Characteristics 19-6 (GPPU- May 12, Dec, 12, Dec. $2, Dec. 14, Dec. 16, May 16, Dee. 16) 47 195 Operating Characteristics Cuno(0.C. Curve) + ¥——Sflabus Tope: Kai nner AB {SPPU--May 12, Dec. 12, May 13, May 14, Dec. 14, May 15, Dec. 15, May 16) 195 | 44 Kaizen ;PPU-- May 19, Dec. 12, Dec. 14, Dee. 15, May 16 195.1 Charactoristies of the 0. Cue. ee 1B ane “ {(SPPU- May 13, Dec. 13, May 14, Doc. 14, May 15, ¥ Tople :Poka Yoke. 4 Sapa Syllabus Topi 48 145. Poka Yoke (SPU: Dec. 13, May 14, May 15)... 148 . ‘Syllabus Topic : Sampling Plans. @ ry 14, May 15). ¥ Syllabus Topic: Kanban 186 Commonly Used Samping Plans. 145 Kanban (SPPU-May 12, Dec. 19) (SPPU- May 12, Dec. 12, Dee. 13, May 14, Dec. 14, 136.1 Single Samping Pian (S.SP)(SPPU Mey 16). ane ans ‘49 Y Syllabus Topic: 0, Probably of accptance ry eee oes (SPPU- May 12, May 13, Dec. 13, May 14, Dec. 14, 1282 Double Sampling Plans (0.5.P) eos oate ery (SPPU- May 1). sonmnnnee 340 | y ——— gytbus Tope: FMECA 1363 Multiple Sampling Plan (SPPU-Dec. 14,Dee. 16). 1212 | 149 Faturo Modo Etoct and Ciicalty Analysis (FMECA) 1864 Sequental Samping Plan ~ 1942 (SPPU- May 12, Dec. 12, May 13, Dec. 13, May 14, Dec. / Syllabus Tople: Comparison of Sampling Plane... 13-13 14, Dec. 15, Dac. 16) ttt 1365. Compaston of Various Sampling Plans 149 Fault Tee Anabsis (FTA) ou. : (GPPU- May 13, , May 14, May 15) 4313 | 7 syllabus Topie : Zero Detect 1866 Designing Sampling Pans 1943 | 14:10 Zoro Detect (20) (SPU - Dec. 13). 1419 + Review Questions. 1913 |v _sylabus Tope: TPM... 1444 + Probie su 1944 | 14.11 Total Productive Maintenance (TPM) ‘© University Questions. 13414 Chapter 14: Total Quality Management _ 14-1 to 14-18 Syllabus : Introduction, Qualty Function Deployment, 5S, Kaizen, oka Yoke, Kanban, JIT, FMECA, Zero defect, TPM. Six Sigma: MAIC - Concept and Applications. ¥ Syllabus Topie : Introduction. 141° Introduction 143.1 Phases in Qualiy Management... 141.2 Advantages of Total Qualty Management... 141.3 Barersin TOM Implementation 42 1441.4 TOM Fundaments Concept omens 143 141.5 Tectniques for Total Quay Management nnn 148 {SPPU-May 12, Dec. 12, Dec. 13, May 15, May 16) 414 Plars of TPM (SPU - Dac. 12, May 15, May 16) 14-14 ‘Comparison betwoon TOM and TPM.. 4.15, 415, ‘Syllabus Topic: Six Sigma ‘Six Sigma (60) (SPPU- May 14, Dec. 14, May 15, D6. 18) nun t415 Syflabus Topic : OMAIC. oe AB uae (SPPU- May 12, Dec. 13, Dec. 16) en AB Review Question. ene AB University Questions... 1417Metrology & Quality Control (SPPU) 10 Table of Contents Cone] v ‘Syllabus Topic : Quality Audits. ASAT 158° Quatty Aut Chapter 15 : Quality Management System 15-1 to 1544 (SPPU- May 12,May 13, Dec. 4, Dec. 1). —— 1581 Types of Quay Aud... Syllabus: Need for quality management system, Design of qualty |! as. Objectives of Quality Audit management system, quality management system requirements 1583 Forms of Quality Audit 1809001, 7516049, 8014000, Quay Aust 1584 Elements of Quaity Audit. % —— Srabus Tope: Need trusty Management Sym | 1505 Auat Root... “oo ver 154 | 15.86 Stops in Implementation of Quality Aut 151 Need or Quality Management System SA (3PPU- Dee 12. % —_ Sxlabus Topi: Design ot Quay Management Sytimt |. peview Question. 152 Design ot Guay Management Siem 151 | Unieraty Questions ¥ _—Sylabus Topic: Oat Management System areas Requrements, e182 |. pogo 153 Requirements of he Qalty Management Systm. 152 15.4 Quality Policy...... vse rns gag 154.1 Advantages of Quartatv Spcteaton ct Quality objectives... 159 1642 Documentation of uaty Poy 159 1543. Steps in implementing a Quy Poey (SPPU- May 12, Dee. 13, on tB8 155 Quality Mottin, 4 155.1 improving Motivation 185 155 Qually Sanda... 156 158.1 Intoducton. 156 1862 150.9000 Standois \(SPPU-May 12, May 13, Dee. 13, Dec. 14, Dee 15) : 187 ¥ —Syiabus Tople 50800, 187 1563 150.9001: 2000 andiS0 904 2000, 187 1563.1. Pine of 180 9001-2000 158 15632 Requirements for 180 001200. 158 156.33 Advantages of Registaton or ISO Standards... 158 % —Syisbus Tope :'80 1400. 159 186.4 ISO 14000 (SPPU-- Dec. 12, May 13) we 15D 1564.1. Claseicaton of 0 1400 Standart. 159 1564.2 Advantages o mpementing 0 14000 Envonmental Management System (245). 1510 Sys Tople: TSi6040 1510 1585 15 16949(SPPU- Dec. 12, May 14. 1510 187 Qualy Assurance (SPPU May 13) 161 1574. Responsbites ofthe uatly Assurance Sat... 1611 1872 Diterentation between Quay Assurance and Qualty Control (SPPU - May 16... 1641ray Introduction Syllabus : Principles of Engineering metrology, Measurement standards, Types and sources of errors, Accuracy and Precision, Calibration: Concept and procedure, traceability Syllabus Topic : Principles of Engineering Metrology 1.1__ Introduction SEE Faeeaae : ~The word metrology is derived from two Greek words ‘Metro’ meaning measurements and ‘Logy’ meaning science. = Thus Metrology is the science of measurements In any manufacturing activity the job of a desired accuracy can only be produced if it is possible to check itto the same accuracy. The product designer specifies the material, shape, accuracy, size and finish requirements of the job and it is the responsibility of the manufacturing section to produce the job to these specifications. In doing so it will be necessary to inspect the job at each stage of its, ‘manufacture to make -sure that the job is being produced within acceptable limits. Measuring and ‘gauging are the methods used to cary out these inspections. ~ Measuring may be defined as the process of finding the dimensions of a job and a value of the dimension is obtained. It is done with measuring instruments. Job parameters that are commonly measured include lengths, angles, surface roughness and profile. Other parameters that are measured include temperature, pressure, force, torque, velocity, acceleration, speed and frequency. Gauging is the process of determining whether a given dimension is within specified limits. Gauging is done with gauges and comparators ~ Gauging only determines whether the dimension being checked is oversize or undersize but gives no idea of .the amount by which the gauged dimension differs from the desired value. — Gauging is required with interchangeable part ‘manufacture to cut down inspection time. 1A Necessity and Objectives of Metrology afiee between measuring and advantages ok gauaing ove | Necessity Interchangeable part manufacture calls for fast production of thousands of identical components which can be fitted interchangeably. Individual measurement of each one of the component parameters would be extremely time consuming and costly. Gauges are used in such cases to quickly determine whether the component is to be accepted or not. The inspection becomes extremely fast and even unskilled labour may be used. In order for interchangeable manufacture to be feasible it is necessary that the parts are inspected at various stages during manufacturing. = Metrology is concemed with the establishment, reproduction, conservation and transfer of units of ‘measurement and their standards. = Metrology reduces rework and scrap by providing results of in process inspections for controlling the parameters of production, ~ To be useful, measurement must be done in units that are standardized so that everybody can understand them with the accuracy that is desired and maintainable and the errors that can occur known and rectified. = Its necessary also to know the uncertainty associated with the measurement done.(BF werorogy 8. cuatty Cont PPL) Objectives ‘The objectives of mietrology can thus be summarized as: 1, Establishing the units of measurement, reproducing these units in the form of standards and ensuring the uniformity of measurement. 2. Developing methods of measurement. 3. Analyzing the accuracy of + methods of Measurement, establishing uncertainty of ‘measurement and searching the causes of error and eliminating them. 4. Minimizing cost of inspection by efficient and effective use of available facilities 5. Determining process capabilities to ensure that these are better than the component accuracy requirements. 6. Facilitating comparative evaluation of newly developed products or production methods. 7. Helping in making decision about defective parts in terms of reworking or complete scrapping, 8. Helping in maintenance of customer relations by ensuring that no defective parts reach the customer. Metrology plays a very significant role in every field of investigation and ‘present day scientific and technological progress has depended heavily on the Progress in the field of measurement. 1.1.2 Classifications of Metrology Metrology can be divided into three main classes : \ 1. Scientific metrology 2, Legal metrology 3, Technical metrology Scientific metrology relates to the measurements done to validate the theories of nature and enhance basic knowledge about science and nature. Legal metrology concems the measurements carried out to ensure compliance with, laws and regulations, Such measurements also ensure that established standards are being adhered to so that there is a ‘uniformity of measurement all around. Technical metrology involves the measurement related to the science of measurements i.e. measurements associated with establishment of units, accuracy of ‘measurement and the method of measurement. 1.2 Elements of the Measuring System The elements of the measuring system include : 1. Features of the work piece to be measured. (The measurand) ‘The instruments needed for measurement (Tools) Introduction 3. The standard for comparing the measurand with some reference for judgment (The standard) 4. The physical quantity or property relative to which ‘quantitative comparison is made (Reference). 5. The condition in which measurement is done (Environment) 6. The skill ofthe human operator (The operator). 1.3 Classification of Measuring Instruments EG ‘Measuring instruments can be classified in a number of ‘ways based on theit fiction, design, operation, output etc. Some of the common classification are: 1. Classification based on Function Direct and Indirect Measuring Instruments Une and End Measuring Instruments Contact and Non-contact “Type Measuring Instruments Deflection Output or Null Instruments Automatic and Manually Assisted Instruments Self Operated or Power Operated Instruments Self Contained or Remote Indicating Instruments Classification Based on Type of Output Signal Comparison method of measurement Differential method of measurement, Output. Type 1.3.1 Classification based on Function ‘According to their function, engineering measuring instruments are classified as: Length measuring instruments. 1 2. Angle measuring instruments 3. Instruments for checking geometrical features, 4, Instruments for determining the quality of surface finish, 5. Instruments for miscellaneous measurement like ‘measurement of temperature, pressure, velocity, frequency, vibrations, sound ete.EB metrology & Qualty Control SPPU) 13 1.3.2. Direct and Indirect Measuring Instruments ~The instruments used for measuring can be classified into two types namely direct measuring instruments and indirect measuring instruments. ~ Direct measuring instruments give a measure of the dimension without the help of other measuring instruments. Scale, venire callipers, micrometers and bevel protractors are common examples of direct ‘measuring instruments. Indirect measuring instruments need the help of:other direct measuring instruments to obtain the dimension. ‘These instruments are in fact used to transfer the measurement from the work piece to the direct ‘measuring instrument for reading. Examples of indirect measuring instruments are calipers, adjustable bevels and sine bars. = In general, direct measurement is faster while indirect ‘measurement may be more accurate. 1.3.3 Line and End Measuring Instruments = Measurement of a dimension expressed as a distance between two lines is called line measurement. The common example is.the simple scale in which the distances are marked, in terms of spaces between divisions. Measuring distance by comparing against the space between lines is not very accurate and requires the use of a microscope if accuracy in measurement is desired. = Instruments like callipers, micrometers, slip gauges, measure dimensions in terms of distance between two faces instead of lines. This type of measurement is called end measurement. End measurement is used when more accurate measurement is desired because the instruments can be set more accurately against faces, than against lines. 1.3.4 Contact and Non-contact Type Measuring Instruments - Measuring instruments can also be classification as ‘contact type or noncontact type. With contact type instruments a plunger or sensor of the measuring device comes in contact with the unit being measured as in measurement of length by scale, ‘micrometer ete. Non-contact type instruments are the ‘instruments that work without an actual contact with the work piece. Measurement of temperature with 2 Pyrometer or speed with a stroboscope are typical ‘examples of non-contact type measurements, 1.3.5 Deflection Output or Null Output Type Instruments Deflection output type instruments Deflection output type instruments are the instruments Tike ammeter, voltmeter, dial gauge etc. in which the Introduction magnitude of the physical variable being measured is indicated by deflection of pointer on a scale calibrated in terms of the units of the physical quantity being measured. Null output type instruments In these instruments the deflection or the physical effects caused by the measurement is balanced by an equivalent opposing effect produced by @ known quantity. The magnitude of the opposing quantity is then used to give the magnitude of the quantity being measured. — Examples of this type of instruments are balances, yrometers ete 1.3.6 Automatic and Manually Assisted Instruments. ~ Automatic instruments are the instruments that work without any manual intervention like mercury-in-glass thermometers or pressure gauges. ~ Manually assisted instruments are the instruments like stroboscope o resistance thermometers which need ‘manual assistance for setting and manipulating. 1.3.7 Self Operated or Power Operated Instruments = Self operated instruments are the instruments that operate without any extemal sources of power being attached to them. Examples of such instruments are length measuring instruments like micrometers, and temperature measuring instruments like mercut lass thermometer and bimetallic strips. = Power operated instruments are the instruments like resistance thermometers, thermocouples, comparators that need electrical, mechanical, hydraulic or pneumatic power for operation. 1.3.8 Self Contained or Remote Indicating Instruments = Self contained instruments are the instruments like callipers, manometers, pressure gauges etc. which have all their components enclosed in one physical assembly and provide in situ readings. ~ Remote indicating instruments are the instruments in Which the primary reading elements and the final indicating or recording units are located at different places. This may be done for operating convenience eg, for locating all controls at one central points ot for technological reasons as in space tracking where signals from the space craft have to be monitored by telemetry. 1.3.9. Classification Based on Type of Output Signal Analog type Instruments ‘These are the instruments that indicate the variable being measured in terms of step less or continuous variationev Metrology & Quality Control (SPPU) 14 Introduction with time, Typical examples are fuel gauges, automobile speedometers etc. These instruments give a continuously increasing or decreasing indication and are generally less complicated, cheaper and easier to operate compared 10 digital units. Digital type Instruments In these instruments the variable being measured is presented in discrete steps. These instruments require a convertor to change the sensed data from analog to digital form but are more suitable for modem computer based data handling and control systems. 1.3.10 Comparison Method of Measurement ‘This method involves comparison with either a known value of the same quantity or another quantity which is function of the quantity to be measured Using Tool maker's microscope for checking thread forms is a very common example of comparison measurement. The microscope compares the profile being checked with a standard profile etched on the eyepiece. 1.3.11 Differential Method of Measurement In this method the instrument measures the difference between the given quantity and a known master of near about the same value. Use of comparators to determine the diameter of a workpiece with a master cylinder is a common example ofthis methods. Syliabus Topic : Measurement Standards 14 Standards of Measurement ‘The term standard is used to designate universally accepted specification for a quantity. A standard provides reference for assigning @ numerical value to a ‘measured quantity. For higher overall economy and efficiency of an ‘organization or @ county itis necessary that diversity is minimized and interchangeability encouraged. Standards are means to ensure uniformity and interchangeability throughout a particular industry. Each basic measurable quantity has associated with it an ultimate standard, 1.4.1. Classification of Standards SEE RE PPU. ‘The accepted standards for measurement of physical ‘quantities ae often classified into four categories: International prototype Primary standards Secondary standards Working standards 1.4.1.1 International Prototype International prototypes are the universally accepted physical representations of basic units to which all ‘measurements are attributed. These are maintained in highly controlled conditions so that measurements can be assumed tobe invariable. 1.4.1.2 Primary Standards Primary standards are essentially copies of the international prototypes that are kept in the National Standards Laboratories and institution of similar standing, These standards are quite stable, independent, invariant and finite. Any difference between the primary standards and the international prototypes are known to a great precision. ‘These standards are designed with the following points in mind 1. Rigidity of construction and accuracy of ‘machining. 2, Very low temperature sensitivity and long time stability of the material 3. Noenvironmental effect on their characteristics, ‘The dimensions that determine-the accuracy of the standard are measured with most sophisticated techniques. ‘The primary standards are available for use only in the national laboratories for reference and calibration of secondary standards 1.3 Secondary Standards Secondary standards are reference standards calibrated from the primary standards. These standards are kept as reference in the industrial organizations and ‘measurement laboratories to check and calibrate their ‘measuring instruments, Secondary standards. are periodically sent to the National Standards Laboratories for checking and calibration. ‘The frequency of calibration ofthe secondary standards depends upon the accuracy and type of secondary standards 1.4.1.4 Working Standards ‘These are the standards actually used by the industries. The production measuring instruments used in the factory are checked against these working standards. The accuracy of the working standards is one order lower than that of the secondary standards.EB metrology & Qualty Control (SPPU) 15 Inoduction 1.5 _ Length Standards = Length may be measured between two parallel lines or two surfaces. — When the distance is measured in terms of distance between two lines it is known as line measurement. When ‘measurement is done in terms of distance between two surfaces itis known as end measurement. 1.5.1 Line Standards Lith examples. 1.5.1.1. International Standard Meter and Yard ~The basis of linear measurements is the provision of a fundamental unit together with primary standards from which working standards can be derived. = Two widely used standards internationally are : International standard meter Imperial standard yard 1. International standard meter © The length of one metre is defined as the straight line distance, at 0°C between the centre portions of a pure platinum iridium alloy of 102 em total length with cross section as shown in Fig. 1.5.1. ‘©The graduations are on the upper surface of the web which coincides with the neutral axis of the section. ‘©The sectional shape of the standard is designed to give maximum rigidity forthe amount of costly metal, 402 9 =} 18mm rasustions ons euace trl -£0% platinum 10% aan Fig, 1.5.1 : Details of international standard meter 2. Imperial standard yard 0 The imperial yard (Fig. 1.5.2) is a solid square bronze (82% copper, 13% tin, 5 % zinc) bar 38 inch long and | in? cross section, © A round recess, | inch away from the two ends is cut at both ends up to the’central plan of the bar and at the 1 bottom of this hole gold plug 7g inch diameter is inserted in a smaller hole. 1 (©The surface of each plug is inscribed with thre fine transverse lines, about 75g inch apart and two lines at right angles about 72 inch apart. © Yard is defined as the distance between two central traverse lines of the plug at 62° © The advantages of keeping the gold a 4 plug lines at neutral axis are: Enlarged view 1, The plug is protected from seo ae accidental damage. [essen a 2. Due to bending of the beam the : neutral axis remains unaffected. Gol plug hor Fig, 1.5.2: Imperial standard yardFEF mewoiogy & Qualty Control (SPPU). 16 Introduction 1.5.2 End Standards End standards commonly used include length bars and slip gauges. ‘Length bars are carbon steel bars 10 to 1200 mm in length and 20 mm in diameter. They are suitable for use with large work pieces. Slip gauges or gauge blocks are rectangular or square blocks of metal about 10 mm wide made of high grade cast steel, Two of the parallel faces of each block are ‘manufactured to extremely close tolerance and guaranteed to be flat and parallel within specified limits. Slip gauges are used where high accuracy of measurement is desired for smaller jobs. 1.5.2.1 Comparison between Line Standards and End Standards 1.5.3 Disadvantages of Metal Standards ‘The metal standards described above have the following disadvantages : (1) The lengths are subject to environmental conditions like temperatures, humidity, pressure etc. (2) In case of an accidental damage to these standards, cexact copies cannot be made, (3) Replicas of these standard are not available everywhere, 1.5.4 Wave Length Standards Because of the possibility of variation in iength of ‘metal bars, wave length of light has been considered as a better basic unit as primary standard 1680763.73 tiene — ww 4 meter ——+} Fig. 1.53 : Light standard of length ‘A metre has thus been defined as equal to 1650763.73 wave length of the red orange radiations of Krypton isotope 86 gas as shown in Fig 15.3. ~ Another light wave standard used for metre is defined as: “Length ofthe path travelled by light in vacuum in measured cecxwessod Seppe second.” This standard can be realized in ‘0 mee D970 nen See trasice tough te me of lode sabied hetom — Wark seabshe fooing as — - vantages over 2. | Measurement | Simpleand quick. | Tine for eee aaa mecurenents 1. Tt can be used for making comparative ‘measurements of much higher accuracy. leas eee eres 2. It gives a unit of length which can be produced Doral ene, pea ee consistently at any time in all countries. aa 3. Itdoes not change length. 4 | Acouacy Uptoz02mm | £0001 mm ee ee unless provided ar 7 with maging 5. Iftlestroyed it can easily be replaced. sass. 1.5.5 Comparison between Metal and | Manufacture and | Comparaively | Conplex method Wavelength Standards Cost sinpleto dt manufacturing i. manufac and | andhigher eos factor cheaper. 6 | Etostoruse | Exdottiescale | Duetoconinuos [issubjectio | wemeasung environment environmental wear faces get wor out environmental. | conditions. specie end conditions like ees may be temperature, needed pressure, humidity etc.EF mevoiogy & Quaty Control (SPPU) 17 Invodution ‘measurements, be accurate so that the components fit properly where required. =~ Designing for too much accuracy is difficult and costly and should not be insisted upon unless necessary. 2. | Replacement | 1fdamaged | Can be easily afier damage | exactcopies | reproduced. cannot be ae 1.6.1 Differentiation between Precision and Accuracy 3. | Wearandtear | Affected by | Not subjected ET wwearandtear. | to wear and EES tear. 4, | Availability of | Exact replicas | Identical replicas are not copies can be available eptin all elsewhere. | standard — : eee 1. | Definition 3. | Security Required to be. | No such of ameasuring_| the result of requirement | preserved or | security process. measurement sored under - | requirements. with true value surveillance to cite prevent ee damage or being destruction, ees 2. | Characteristics |1. Aprecise | The difference Syllabus Topic : Precision and Accuracy | measureme | between the a, | ntneed not | measured be accurate | value and true ]2. Whatis | value or error necessary is | should be very that ror | small foreach rmeasureme tbe same, = Precision and accuracy are two import concepts of | | >> | Application | In most poe measurement. Precision is the repeatability of a ‘engineering measurements application | the instrument ‘measuring process or how well identically performed ‘measurements agree with each other. A precise where pats are | has to be ‘measurement need not necessarily be accurate, What is required to fit accurate. An necessary is thatthe eror in each case be same. each other, if | inaccurate Accuracy is the agreement of the result of a both parts are | instrument will tmeasurembat with the true value of the dimension measured with | give wrong being measured. The difference between the measured the same results and will value and the true value, called error, should be very instrument it} need small for an accurate measurement. doesnot matter | calibration to ~ In most manufacturing situations itis enough for an whether the | know the instrument to be precise even though itis not accurate. insrumentis | magnitude of Tn manufacturing a component, for example, to fit in a ee ee required space if both the space and the manufactured elas ea | ee component are measured withthe same instrument it oe ae does not matter whether the instrument is accurate so nation long as it is precise. the dimension being = On the other hand when components are manufactured at one place and are to be fitted elsewhere as happens in most large production jobs, it is necessary that measured.CEE metciogy & Quay Cont (SPPU) 18 Introduction Syllabus Topic : Types of Errors 1.7__Errors in Measurement ~ Accuracy in measurement is a function of both the accuracy of the equipment used and the care and technique used in taking the measurements. In spite of all the care in making a measurement there is always a likelihood of the reading being’ wrong to a small extent due to number of reasons. 1.7.1 Classification of Errors (66,13, sem Errors in measurement can be broadly classified in ‘three groups: 1. Gross errors 2. Systematic errors 3.__ Random errors 1. Gross errors © Gross errors or mistakes are person related errors or human mistakes that occur due to causes like: (Using a wrong instrument. (i) Faulty setting ofthe instrument. ii) Mistake in reading or recording observation (iv) Mistake in applying a correction. (©) Wrong computation and procedure or mistake in computation, It is impossible to correct these errors, ‘mathematically because they cannot be estimated. Some of these errors also cannot be easily detected. The only two ways to avoid these errors me (Taking good care in selecting and setting the instrument and reading and recording the data, (ii) Taking number of readings, preferably at different times. 2. Systematic errors ° These errors have definite magnitude and direction and are repeated consistently every time a reading is repeated. ‘They are generally caused by the following : (Zero offset (i) Change in sensitivity (Gi) Non finearity ‘These errors cannot be detected by taking multiple readings because each time they are repeated in the same magnitude and direction. The only way to detect these errors is to take repeated readings at different times with different instruments and under different conditions, Systematic errors can be further divided into following types Instrument errors Environment errors Observational errors Operational errors System interaction errors Instrument errors Instrument errors arise due to the following reasons : 1. Inherent fault in the design and manufacture ofthe instrument 2. Misuse ofthe instrument 3. Loading effect Inherent faults in the design and manufacture of the instrument include finite width of knife edges, too much friction at sliding surfaces, and clearance between mating parts, non uniform division of the scale and assembly errors like incorrect fitting of patts, zero error, bent or distorted pointer. Some of these errors like assembly errors do not change with time and can be easily set right. rors due to misuse of instruments related to poor maintenance of instruments, wear of parts due to excessive use, loosening of joints, lack of calibration etc. Errors due to loading effect are the errors that occur when the detector or sensor of the instrument utilizes the energy of the medium thereby slightly altering the parameters. of the measurand, Instrument errors can be reduced by : 1. Selecting a proper instrument suitable for the quantity or parameter to be measured, Proper maintenance of instruments. Calibration against standards Mathematically correcting the result by applying correction factors according to the likely instrumental error. Gi) Environment errors Environment errors are the errors caused. by pressure, temperature, humidity, dust, vibrations, ° °EB metroiogy & Quality Conrol (SPPU) 19 Introduction (ii) Observational errors (iv) Operational errors ‘magnetic or electrostatic fields external to the ‘measuring device. ‘Typical examples of this type of error are change in dimensions due to change in temperature, pressure variation due to high pressure of surroundings, radiation effect when an instrument is placed too close to an opening, change in velocity pattem when the instrument is placed close to a fitting etc Environmental errors can be reduced by 1. Using the instrument under environtmental conditions in which it was calibrated. 2. Recalibrating in the existing environmental conditions. 3. Providing suitable shields for the instrument pats Sealing the exposed leads ete. 5. Providing compensating devices against environmental effects Observational errors are the errors that occur due to carelessness or lack of skill of the observer. ‘Typical of these errors ate Parallax error. Mistake in reading the scale. Personal bias or tendency to read too high or too low. 4, Inability to properly estimate the reading between graduations, 5. Impatience in letting a reading stabilizes. 6. Wrong estimation of average reading. ‘Modern digital instruments are quite useful in climinating most ofthese observational errors. ‘© Typical examiples of these types of errors are the change in dimension of a work piece that may ‘occur when too mach pressure is applied between the anvils used for measurement, change in thermal capacity of a fluid system that may occur when a thermometer is immersed, or change in flow pattern when a rota meter is introduced to estimates the flow. © Errors of the first kind are eliminated in many modern instruments by using fiducially indicators ‘or ratchets to limit the maximum pressure applied when taking a reading. The other errors are decided by the design of the instrument used and ‘can only be minimised by proper design. 3, Random errors ‘© Random errors are. small accidental errors that often vary in magnitude and direction in an unpredictable manner. © These errors are caused by following : (Friction and stickiness of surfaces. Gi) Vibrations. (ii) Large tolerances between the mating part. iv) Hysteresis (¥) Backlash in instruments (vi) Variation in supply power. (vii), Elastic deformation’of parts. ‘© Random errors follow laws of probability and can be handled by statistical analysis of test data. By increasing the number of observations the ‘measurements can be judged more precisely. (© A comparison of systematic and random errors ia given in Table 1.7.1 1.7.2. Comparison of Systematic and Random Errors (© Operational errors are the errors caused by misuse of instruments and by poor operational techniques. Examples 4 © Error caused by improper immersion of the’bulb ‘Table 1.7.1 : Comparison of systematic and of a thermometer in the medium whose __fandom errors temperature is to be measured. caeeaoe © Measurement of flow by placing the flow meter SSE close toa valve, joint or bend. 1. | Causes Instumeral errs, | Random dueio © These errors can be eliminated by proper use of evienmental eros, | vation n poston (¥) System interaction errors instruments and care in making the measurement. These are the errors that occur due to interaction between the instrument used for measurement and the body whose parameter is to be measured. observational ror, | of standards, operational eros and | chance a ror in system interacion | operation, ero. isplacement of joints, backash, ose, ction Iysteresis et,140 Introduction sa ‘Always present in |1. Do nothave any ‘the same magnitude | consistent ‘and same sense. pattem, 12 These erors are | agrfude or sense, repeat corsistenly with repeated experiment. 8. | Overaleies 1, Since the sign is [1. Signmaybe same, such errs | _Pasive or add up to a| negaive. There cumulative value eee scarce Hence called ape cumulative eros, called 5 2. The oval etect on | compensating the measured | type eros, wantly is lage |o. Overall efectis since the enos a6 | much ower up. 4 | ior Can be predied ony [1. They are Predton | by repeating the | accidental smal measurement under | and independent. diferent condos, |2. Cannot be with ciferent | preted rom equipment and with & | — th knowiedge of. Bhorent method, ‘measurement system 5. | Control Not controtable tut | Folow laws of ‘can be minimized by | probabilty. Can be ‘suitable rectification of | accounted for by upment or saistzal ana procodres ot the measured ita Syllabus Topic : Sources of Errors ‘The errors of measurement can occur due to the following causes : - Instrument error Environmental effect Flexure at contact surfaces Error in alignment Error of reading or parallax error Elastic deformation or support error Placement or contact error Dirt error 1. Instrument error Instrument error is the error inherent in the instrument due to poor design or manufacture or excessive use, To be working without error all instruments must be periodically checked (and repaired if necessary) against standards . of ‘measurement, 2, Environmental effect © All metals expand or contract with change in temperature, Ifa reading is taken at a temperature different from the one at which the work piece is to be used, there may be an error due to thermal effect © Other than temperature, measurements may also be affected by pressure, humidity, nuclear radiation, vibrations, sound, magnetic fields etc. © Most measurement standards therefore, specify that calibration of measuring instruments and gauges be done in a standard specified environmental conditions Flexure at contact surfaces © Most measurement set ups involve a certain amount of force between contact points of the ‘measuring instrument and the surface of the work piece. © This force produces a contact pressure and if the area of contact during setting of the measuring instrument and that while taking the reading is different, there is a likelihood of an error ‘ecurring due to pressure. Etasicdeformaton at the contac pont Oy Fig. 1.7. : Effect of contact geometry on the accuracy of alinear measurement © As shown in Fig. 1.7.1(a) when the ends of a ‘measuring instrument ot comparator are set by inserting a combination of slip gauge’ between the ends, the contact is over a larger area and the contact stresses are low. © When the same instrument is used to measure a round bar of equal diameter (Fig. 1.7.1(b)) the contact is over a much smaller area and the ‘contact stresses are much higher.FBP metroiogy & Quay Control (SPPU) 41 © Even with the same contact forces, the larger stresses in the second case will lead to larger clastic deformation and hence cause an error in the ‘measurement. This error can be minimized by ensuring that the contact forces and contact area are same during setting and actual measurement. 4, Error of alignment © Error of alignment is illustrated in Fig. 1.7.2. © This error is based on the Abbe’s principle of alignment which states that the line of ‘measurement of the component to be measured should coincide with the measuring scale or axis of the measuring instrument Fig. 1.72: Alignment error with a micrometer © The error occurs when the work piece being measured with a measuring instrument is not held ‘exactly at right angles to the face of the anvils of the instrument. © InFig. 1.7.2 it can be shown thet the true value of the thickness tof the work piece and the measured thickness tare related by the equation t= t cos -d sind (b) Alignment error with dial gauge Fig, 1.7.3 : Cosine errors with scale and dial gauge Introduction o- Fig. 1.7.3 shows two more cases of alignment error when measuring with a scale (a) and dial ‘gauge (b). In both cases the true value 1 =I eos © Because of the geometric terms involved in these equations alignment errors are also_ sometimes called as sine and cosine errors or cosine errors. Error of reading or parallax error © Parallax error occurs when readings are taken by aligning two lines on the measuring instrument. (©The reading taken may be more or less than the actual value depending upon the angle along ‘which the reading is taken, © The error due to parallax falls as the magnification factor of the instrument increases. © One method used for avoiding the parallax error is to use double graticule lines as shown in Fig. 1.7.4, Human eye can estimate distance c or d more accurately than positioning one line directly over another line, Fig. 1.7.4 : Use of double graticule lines to avoid parallax error Elastic deformation or support error (4) Supports too close (©) Supports widly placed Fig, 1.7.5: Elastic deformation or support error © When a heavy work piece is supported as shown in Fig. 1.7.5 it may undergo deflection due to its ‘own weight. The deflection depends on the dimensions, weight and material of the bar and the distance between the supports. (© The error that can occur due to such deflections can be minimized if the distance between the supports is adjusted to 57.7 percent of the length of the bar.PEP wottogy & cual Corot (SPPU, 112 {Introduction 7 Placement or contact error Measurements on curved surfaces like rings, pistons tc. are often found to be erroneous due to the way these members contact the measuring instrument as shown in Fig. 1.76. Fig. 1.7.6 : Contact error Dirt error Presence of any dirt particles, contaminants etc on the surface of the work piece can cause an error Such extraneous substances may come from the shop ‘With the test piece or may enter the test room through doors, windows etc. The Standards Organizations therefore specify the room environment for accurate ‘measurements to be made. Selection and Care of Instruments In order to get correct results from measurements it is necessary to : 18: 1. Select the measuring instruments carefully. 2. Keep the measuring equipment in perfect working order. 3. Take readings with almost care, 1 Selection of Measuring Instruments Selection of the measuring instruments for any particular application is usually done on the basis ofits measuring range, accuracy, precision, sensitivity and readability The range of the instrument selected should be wide enough to completely cover the dimensions to be measured. ' The accuracy of the instrument is usually poor near the end of its scale, When accurate readings are needed throughout the range, its better to use two instruments ‘with different ranges one for the lower range and the other for the higher range. ‘The precision of the instrument is necessary to make sure that the instrument gives the same reading every time itis used to measure a particular parameter. If the instrument is precise its accuracy can be taken care of by calibration against a standard. ‘The sensitivity or resolution of the instrument is ‘important to ensure that even very small changes in the Parameter are indicated by the instrument, ‘The readability of the instrument is required to ensure that changes in the reading can be easily and correctly recorded, 1.8.2 Care of the Instruments. Accurate, precise and sensitive instruments are likely to be easily damaged by even slight mishandling and may lead fo errors in measurement. Following precautions are therefore suggested to ensure that of the chances of currence of such damage to the instrument are minimized. L Highly finished surfaces of measuring instruments should not be touched by hand. The natural acids of the skin are likely to corrode the finished surface and also the temperature of the body may affect the accuracy ofthe instrument. Before touching an instrument, hands should be thoroughly washed and preferably coated with a very thin film of petroleum jelly Very precise instruments like slip gauges should be handled with pieces of chamois leather or tongs made of perspex. ‘The instruments should not be dumped in a bunch or process wok tbe Jere aig 13 | sm | 40] 7a | s70 Paseo | Presswot 08 | 2 | 4 [Prison eppng| Haest qty rar | Ee 4 | a0 | 740] 1150 | 1850 [oecasrg —_|oiecsing, sang 0 3 | 6 | Prionepina|spectan = elie Pees or aie |||_18_| 00 | 0] rm | 20 [Deo apry [sarong a 16 | scoo [1900] 2500 | 000 |Fenecating | sand casing fa 1+ [15 [2] 45] [reciintapn| ox stop cents sionirisand || ~ AS can be seen from this table grades 01, 0, 1 to 4 are a very fine grades and are used for gauges ; grades 5 to " 11 are fine to coarse grades used in machine building 2 [25 | 3 | 7 | 10 |Prisonanig| on aa eee and for general engineering work, while grades 12 to 7 16 ae coarse grades suitable for presswork, rolling, 3 | 4 [5 [10 | 1 [Pmeiiniapin | Good qaity casting, forging ee. cmges — Commonly used tolerance grades for processes 4 [6 [6 |. | a [Peon eppig| cages + le lwlela lew = ~The ISO tolerance grades commonly used for different \ ee eae ‘manufacturing processes are given in Table 3.2.2. bangs || Table 3.2.2: Commonly used tolerance grades for 6 | 8 | 19] 2 | |Lapngand | rrcng 2 ecg honing 7 | a [| 48 | e [rumgon tte | eh ay ast ronrgnd | unig 2 esacting oe 3__| Super finishing 46 @ | 3 |] 2 | o [owsienteet {cone iae 4 | Diamond uking at | ndatonaic | ing vor, 5 Grinding 49 febewok —|reaning, gros é Reaning $9 condtion . hea fl Broaching 59 urea 8 Boring 5.10 9 | se | 4] 15 | 5 foapstnant [Poor uaiy 9 Turing T2 eel 10 Milling 913 59 tert wr, hong 1 | Diilting 1s | mast 12_| Die casting 15, a [3 Forging 13.16kag Metrology & Quality Control (SPPU) 39 Design of Gauges ‘The postion of the tolerance zones with respect to zero line is indicated in terms of 28 types of standard deviations which ar a function ofthe basic size. For holes A to G fundamental deviation is above the | — eto line and for J to ZC it is below the zero line, similarly for shafts a to g fundamental deviation is below the zero line and for shafts jt 2 itis above. For shaft h upper deviation is zero and itis called basic shaft. Similarly for hole Hit lower deviation is zero anditis called abasic hole . - ‘The deviations are specified in microns (10° m) and represent the algebraic diference between a size Gctual, maximum, minimum ete) andthe | — corresponding basic size. Depending upon where a particular dimension is located relative to the basic or ero line the deviation may be positive, zero or | negative, ‘The deviations are given letter symbols both for the holes and shafts, Capital leters A, B, C, CD.D, E, BR, F,FG, G, H, J, 18, K,M,N,P,R,S, 1,0, V, X, YZ, ZA, ZB, and ZC are used for holes and small eters @ to ze for shafts. Letters, LO, Qand W are not used to | — avoid confusion, The deviations are specified foreach hole or shaft, as ‘an upper deviation and a lower deviation, These are called ES and El respectively for the hole and es and ei forthe sha. - Hole basis system is recommended but both hole basis and shaft basis deviations are given, ‘The upper deviation corresponds fo the maximum size Of the part and represents the algebraic difference between the upper limit ofthe part and its basic size 3.21 Similarly lower deviation is the algebraic difference between the lower limit of the part and basic dimension, ‘The upper deviation for the shaft and the lower deviation for the hole correspond to the maximum ‘material condition and thus represent the go limits. Similarly, the lower deviation for shaft and upper deviation for hole represent the minimum material condition and not go limits, ‘When limit gauges are used the go limit is the size checked by the go end and the not go limit isthe size checked by the not go end ofthe gauge Tnnumerable fits ranging from maximum clearance to ‘maximum interference may be obtained by a suitable combination of fundamental tolerances and deviations. Representative deviations for a number of holes and shafts specified by BLLS. for diameter steps up to 500 ‘mm on the hole basis system are given in Appendix A. Methods of Indicating Part Size and Fit ‘The tolerance size of a component is defined by its basic size followed by a letter symbol for tolerance zone and a imumeral indicating the grade. Thus 70 ¢H7 indicates H-hole with a basic size of 70 mm and grade 7. A fits indicated by the basic size common to both hole and shaft followed by symbols corresponding to each component, the hole being given first e.g. 5091167 85,50 9H5— 5 or 509% 3.2.2 Equivalent Fits in the Hole Basis and Shaft Basis Systems ‘Table 3.2.3 gives a set of equivalent fits on the hole basis and shalt basis systems. Table 3.2.3: Equivalent fits in the hole basis and shaft basis systems (Maximum) (Clearance end) H7-c8 C8-h7 | H6-js 16-ns H8-c9 C9-h8 | H7-j6 17-n6 Hil-cll Cl-hil]H8-j7 18-h7 H7-d8 D8-h7 | H6-kS K6-hS H8-d9 D9-h8 | H7-K6 K7-n6 | H6-r5 _R6—nS Hil-d1 Dil-hu/K8-k7 K8-k7 | H7-16 _R7-n6 H6-e7 _E7-h6 | H6-m5_M6-hS |H6-s5 S6-n6Metrology & Quality Control (SPPU) Design of Gauges F6-h6 FI-h7 F8-h8 G6-hs G7-h6 G8-h7 H7-m6 H8-m7 H7-n6 H8-n7 H8-p7 H8-17 (Interference end) M7-h6 |H7-s6 S7-n6 M8-h7 |H8-s7 | S8-h7 N7-h6 |H6-t5 T6-hS N8-h7 | H8-t7 T8-h7 P8-h7 R8-h7 |H7-u6 U7-n6 H6-u5 U6-hS H8-u7 U8-h7 (Maximum) Example 3.2.1 Find the maximum and minimum dimensions of the hole and shaft and the ft produced in the following cases using hole basis system 200 H 7/17, 200 H 7/6, 200 H7 / n6, 200 H 7/86 “The values of deviation in microns for diferent pairs can be found from standard tables. Solution In each case hole used has a dimension 200 H7. From Appendix Upper limit hole = 200 + 46 x 0.001 = 200.046 mm Lower limit hole = 200 + 0 = 200.000 mm Dimensions forthe various shafts can be similarly calculated and the conditions of fit determined as shown below A, the deviations are hole +46 and 0 microns 199.950 199.904 Clearance | Max. clearance 0.142 mm Min, clearance 0.050 mm. 200.016 199.987 Transition | Max. clearance 0.059 mm Min, interference 0.016 mm. 20006 | +60 1 200.081 Transition | Max. clearance 0.015 mm. Min, interference 0.060 mm. 20086 | +151 +122, 200.151 200.122 Interference | Max. interference 0.151 mm, Min, interference 0.076 mm Fig. P. 3.2.1 gives a schematic representation ofthese fits.BF merlogy & Quality Contl (SPPU) 31 Design of Gauges Hole +t 6; +181 +2 +50) sai ° ay =3 HT a 7 6 Zero ine (Basic Sze) 16 $8 (Al doviatons in microns fora 200mm basic ize hole) Fig. P. 3.2.1 : Fits obtained for Example 3.2.1 3.2.3 Calculation of Tolerance and Dimension for Fits A fit specified as 200 H7/s6 can be analyzed in two ways to find the hole and shaft dimensions and the type of fit that ‘will be produced as well as for design of gauges. These are 1, Use of tolerance and deviation tables given in standard data books. 2. By calculation from mathematical formulae given by BIS. ‘The steps are explained below Use of standard table (Refer Ex. 3.2.1) ‘The basic size for both hole and shaft = 200 mm, From Appendix ~ A, Deviation for200 47 = +46 ‘Assuming hole basis system L.LH. = Basic size = 200 mm ULH. asic size + Deviation = 200 +0.046 = 200.046 mm timensions = 290 + 9.045 ie Hole dimensions = 2009.09 Hole tolerance = 200,046~200 = 0.046 mm From Appendix ~ 4, forthe diameter range 180 - 200 ‘mm witha hole H7 the deviations forthe shat 6 are * 15! +51 micron ie, $13) mm ++ Shaft dimensions 200 + 0.151 = 200.151 and 200 +0122 = 200.122 +0151 or 200 4 9.132 mm Shaft tolerance = 0.151 -0.122= 0.029 mm By calculation All standard tolerances for holes and shafts are given as, multiple of a basic tolerance unit also called fundamental tolerance factor ? given by i = 0.454D +0.001 D microns for basic size up 1©500.mm G21) = 0,001 D + 2.1 for basic size above 500 mm up 0 3500 mm Where D is the geometric means ofthe diameter steps in ie D = DD, In Appendix ~ A, 200 man falls inthe range 180-200 mm Thus D = 180%200 = 189.74 mm i = 0459/D +0.001D 0.45 189.74 + 0.001 x.189.74 2.7755 micron ‘The value of standard tolerance for different tolerance grades for ITS onwards are specified in terms of the basic tolerance unit i as given in Table 3.2.4, ‘Table 3.2.4: Tolerance for citferent tolerance grades in microns. T T 57 | a |r |r| free) ria | rts m6 101) | 25 | ft 10 | 1021 40 a | 100 Standard Tolerance forIT7 = 16i= 16%2.7755 : = 44.408 microns 0.044 mm 10 = 102.7755 = 27.165 micron = 0.028 mm The dimensions of the hole and shaft for different fits by calculations are found as follows. = Assuming hole basis system the dimensions of the hole can be found’ directly from the tolerance values calculated above And standard Tolerance for IT6 er ern ener eRLB ntrogy 8 cuaity Cont (SPPU) a2 Dag of Gauges ‘Thus dimension limits for hole are ‘Where IT is the standard tolerance for the given D LLH = Basie size =2000mm For D = 189:74mm ULH = Basic size + Pondamental Deviations for shafts6 ei = IT7+04D deviation + standard tolerance enna ae eee = 16x27755 +0.4% 189.34 Hole tolerance = 200044 -200=0.044 mm aarenenee = Tocalculate the dimensions of the shaft, it is necessary ae to use the formulae given in Table 3.2.5 = The table gives fundamental shaft devitiots for = 148.06 micron = 0.148 mm different shafts. ‘Shaft dimensions = The values are given in terms of upper deviation (es) ULS = Basie size +es =200 + 0.148 for shafts a to h and in terms of lower deviation (ci) for = 200.148 mm shafts jto 2c. Basic size + ei = 200 + 0.120 = The given values can be changed from esto ei and vice versa by using the relationship: es = eitiT 8.2.2) Shaft tolerance 200.120 mm 200.148 — 200,120 = 0.028 mm ‘Table 3.2.5 : Formulae for fundamental shaft deviation for shafts up to $00 mm diameter hs a = (265 +1.3D)forD<120 | 3510/8 : 3.5 Dfor D> 120 k4tok7 kfor grades $3 and 8 \ » = (140 + 0.85 D) for D < 160 m=|+(T7-IT6) +5p™ = 18D forD > 160 +1T7 +0105 + geometric mean of | values ei for p and s values ei for p and s ° = 52D" for D<40 =| +4IT8+1t04 forD<50 : = (95 +08 D) for > 40 +IT7+04D forD>50 4 ~16D™ t=|+1T7+0.63D e -up™ u=|+IT7+D £ 55D" +1T7+1.25D : =25D™ +IT7416D +11 742D +1T7425D +1P743.15D +IT7+4D +IT1045DBF netoogy & ouaty contol (SPPU) 343 Design of Gauges Ir Fors the two deviations are equal tot" Deviations for hole ae identical with shaft deviation of the same grade but disposed on the other side of the zero line ~ In the above example the hole specified was H hole For H-hole the lower limit is at the basic size, The lower deviation is zero. For other holes there may be a deviation from the zero line jus like the deviation for the shaft. Such deviation is to be considered by using the relationship. LLH ULE. = basic size + deviation LLH + tolerance = Basic size + deviation + tolerance G23) Example 3.2.2 Ea Find the shaft and hole cimensions with tolerance for a 90 8 9 pair given the following data: 90 mm les inthe diameter step of 8 to 100 mm Upper deviation for e shaft. Value of tolerance for T8 = 25i and IT9 = 40% Tolerance uniti= 0455 +0.001 D Aso tind the fpe of i produced Solution : D = 80100 = 99.44 mm 04590 +0.001D Basic tolerance unit i = 0.45 89.44 + 0.001 x 89.44 = 2.102 micron = 0.0021 mm Fundamental Tolerance for Hole = IT 8=25xi = 25x 0.0021 = 0.0525 mm Fundamental Tolerance for shaft = 1.9 = 40i = 400.0021 = 0.084 mm Basic size = 90mm ‘Assuming Hole basis, the dimensions of the hole are ULH. = 90+0.0525 = 90.0525 LLH. = 90+0=90.00 Hole dimension or 90 * 2.9525 pum Dimensions forthe shaft : Upper deviation fore shaft = - 11 D™' =~ 11 x 9.44%" = ~69.43 micron =~ 0.0694 mm ULL shaft. = 90 -0,0694 = 89.9306 ei forshaft = es—IT = 0.0694 - 0.084 = -0.1534mm ULS = 90-0.0694 = 89.9306 LLS = 90~0.1534 = 89,8466 ~0.0694, ic. shaft dimensions = 90 ~ 99694 mm Fit ULH = 90.0525; ULS = 89.9306 LLH = 90.00; LS =89.8466 ‘Since both the shaft dimensions are lower than the dimension ofthe hole, the fit produced is a clearance fit. ULH-LLS 90.0525 89.8466 = 0.2059 mm Minimum clearance = LLH-ULS 90.~ 89.931 Example 3.2.3 SLEEP Determine the dimensions and tolerances of shaft and hole Maximum clearance having size of 30 H718 ft. (7 = 16i, ITS = 25i, Dis ina step 18-30 mm, Fundamental deviation fort=—5.5 D°*), Soin. : Shaft and hole = 30 H7f8 TT7= 161; 1T8=25i Diameter isin step 18-30 mm, D = Vi8x30=23.238 Basic tolerance, = 0.45 YD +0.001 D = 045 423238 + 0.001 x 23.238 = 13074 micron Standard tolerance forIT7 = 16 i= 16% 1.3074 micron 1021 mm 251.3074 Standard tolerance forIT8. = 25) == Tyee74 0.033 Assuming hole basis system, lower fundamental deviation =0 LL. = Basic size =30 mm, ULH = Basic size + Fundamental deviation + Standard tolerance Hole “0081 = 30+0+0.021 =30.021 |30 Hole tolerance = 30,021 - 30 = 0.021 mm -ssp! 5x23.238041 = 19.98 micron =~ 0.02 mm mm 000 es for shaftEEF metoiogy & Quatty Control SPPU) 34 Design of Gauges. ULS = 30-0.02=29.98 mm a ei =es-IT = ~002-0.033 shan | Typeot nt = 0053 mm Shaft wpe jee =n en LLS = 30-0053=29947 | 30mm 0033 0 Shaft tolerance = 29.98 - 29.947 = 0.033 mm @ Closrnce 3.2.4 Commonly Used Holes and Shafts 5 ~ Even though a very large number of holes and shafts 5 are given in the standards, for ordinary engineesing ot practice only the holes and shafts shown in Fig. 32.1 Trnation are recommended. ud = Table 3.26 lists the characteristics ofthe fits obtained = | riroenco by various combinations of the recommended holes and 2 shafis and Fig, 322 shows graphically, the fits | Fig, 3.2.1: Possible combinations of recommended holes obtained. and shafts The table and figure have both been prepared fora }— As mentioned earlier, hole basis system is ‘basic size of 50 mm on the hole basis system which is the preferred system. recommended because it is possible to use standard drills and reamers for producing the hole while shaft of ‘any desired dimension can be easily produced by machining. The shaft basis system is preferred very rarely say for example, when a single shaftis carrying a umber of fittings like couplings, bearings collars etc. and it is considered desirable to maintain one constant diameter for the shaft ‘Table 32.6: Characteristics of recommended fits for $0 mm basic size (Hole basis system) +160] — -130] Loose clearance | Farm equipment : | -290 H9—d10 +62] ~80 | Loose running Bearings, gland seals. o| -180 a H9—e9 +62] ~50 | Basy running (Cam shaft bearings o| 12 H8-f7 +39] =25| Normal running | Small shaft bearings, pump or gear 0] 50 box bearings. HT 36 +25], —9) Precision running, | Precision slide ways or bearings 0|' _~25 | Precision location H7-n6 +25 0 | Average location | Location of non running assemblies o| -16 HT -K6 +25] +18 | Basy keying ‘Couplings or pulleys keyed to shaft 0 +2 H7—n6 +25 Push fit ‘Transition fit ao = HT —p6 +25 Press fit ‘Small interference mounting of 0 ears, pulleys et HT-96 +25 Heavy press fit | Permanent assemblies 0EB netciogy & auaty Control (SPPU) 345, Design of Gauges 0h 04 fa10, Fig. 3.22 : Fits obtained for various combinations of recommended holes and shafts for ‘50 mm basic size (Hole basis system) 3.2.5 Selection of Shaft and Hole Tolerances and Fits = According to the principle of statistical probability the fits should be selected such that the clearance or interference of the two parts occurs within the middle ‘to thirds of the tolerance zone. Assuming that the frequency of occurrence of a dimension follows normal distribution, very few dimensions are expected to occur outside the middle two thirds region. Thus even if a wider tolerance is specified for a dimension and the fits are restricted to ‘middle two thirds region very few assembles are likely to fall outside of the specified range and get rejected. Providing a wider tolerance, on the other hand, makes the production easier and less costly. ~The other factors that have to be considered while deciding the shaft and hole dimensions are the allowable stresses in the material, running conditions, ‘nature of lubrication and working temperature. 3.2.6 Other systems for limits that are in use include: 1. American System In this system fits are defined into 8 classes which specify the typical applications as given below : @ w (ii) Class TH: Medium fit (iv) ® Other Limit Systems 1. American National Tolerance System 2. British Standards 1916 or 4900 Standards Association] 3. ISO System 4. The Newall System National Standard Association Class 1: Loose fit (Class I: Force fit Class IV: Snug fit Class V : Wringing fit