ME5350 METROLOGY AND COMPUTER AIDED INSPECTION

END SEMESTER EXAMINATION (ONLINE PROCTORED)

ANSWER ALL THE QUESTIONS

Date: 9/05/2022 Time: 1.30 – 4.30 pm
PART-A (10 X 2 =20 MARKS)
1. Identify and describe a method for measuring the diameter of a human hair [2]

2. Explain the procedure to calibrate the precision polygon using the autocollimator setup
shown in Fig.1. If R1 and R2 are the readings on autocollimators 1 and 2 respectively, S is
the angle between the normal to faces A and B, and T is the angle between the
autocollimators. [10]

Fig.1. Autocollimator Arrangement

𝑃𝑏 𝐴
3. Plot the relationship between the ratios of = 𝐴2 and estabilish the working
𝑃𝑠 1
range of the back pressure sensor. Express the pneumatic magnification as a
function of input pressure and control orifice size (Refer.Fig.2.) [2]

Fig.2. Backpressure pneumatic gauge-Principle

4. Explain the procedure of checking the flatness of a surface plate size (300mm x 300 mm)
using a optical flat, laser light source and a microscope attached with a camera. [2]
5. Explain the procedure of PSI and VSI mode of surface measurement using optical
profiler?. [2]

6. Define circularity error and explain various reference circles that can be used for
evaluation of circularity. [2]

7. Explain the use of these 3-D parameters for functional characterization of

surfaces. 1.Areal Material Ratio, Smr(c) 2. Inverse Areal Material Ratio, Sdc(mr) 3.
Spk (Reduced Peak Height) 4. Sk (Core Roughness Depth) [2]

8. Compare M-System with E- system for functional surface roughness

characterization? [2]

9. The dial indicator shows (Fig.3.) a reading of 0.5 mm when inclined at 15° to the
perpendicular.
a) Calculate the reading on the dial indicator, if it is set perpendicular to the
component surface
b) What is the numerical value of the cosine error for the inclined dial indicator?
[2]

Fig.3. Dial Gauge setup

10. Explain the method half bore measurement using a dial gauge and fixture setup as given
in below Fig.4. [2]

Fig.4. Half bore measurement

Part-B (6 x 5 =30 Marks)

1. Estimate the flatness Error for the following data set. ( Consider your last digit of your
registration number twice in the Zi ‘ (column)
 2. Estimate the roundness error by fitting a least square limacon. ( Consider your last digit
of your registration number twice in the ri ( at an angle of 60 ° & 120 °column)

Table 11: Form Dataset

Angle
Angle (in Angle (in Angle (in
ri (in ri ri ri
degree) degree) degree)
degree)
0 8.979319 90 6.176784 180 5.725835 270 9.701958
5 10.31817 95 5.665064 185 6.261023 275 10.74702
10 8.701716 100 5.641435 190 4.277557 280 11.10627
15 10.04676 105 4.675655 195 4.222749 285 10.49725
20 11.80136 110 5.250032 200 6.297341 290 11.57606
25 11.10921 115 4.73883 205 6.001016 295 13.08467
30 10.16666 120 3.296095 210 6.849424 300 10.78331
35 9.345438 125 4.845863 215 6.844435 305 9.887203
40 9.407119 130 4.542595 220 5.943132 310 9.22579
45 8.014596 135 4.063757 225 10.50547 315 10.13485
50 9.656457 140 3.996656 230 8.286487 320 8.413668
55 6.422552 145 5.122405 235 7.243835 325 9.173569
60 7.101779 150 4.145838 240 7.997563 330 9.216067
65 8.17345 155 4.809759 245 8.906573 335 10.15234
70 8.69508 160 4.98127 250 9.129903 340 11.13211
75 8.433978 165 4.631294 255 10.4024 345 8.069267
80 9.48249 170 4.776244 260 8.803206 350 7.681097
85 7.920962 175 4.463179 265 11.11965 355 9.177779

3. Evaluate the surface roughness parameters Ra, Rq and Rz and Rt for the following
triangular profile (Fig.5) Also construct the bearing area ratio curve for the profile.
Calculate the Ra, Rq parameters for the theoretical parameters for the profile (Fig.6).

Fig.5. Triangular Profile

i) ii)

Fig.6. Theoretical Profile

4. Please refer the wire drawing process (Fig.7). The wire diameter to be measured in-
process using an optical inspection system. Please propose a suitable method and
explain the procedure [10 marks]

Fig.7. Wire drawing Principle (Source: internet)

5. Identify the features (Fig.8 ) and its mathematical minimum points required to evaluate
it [3 marks]

Fig.8. Geometrical shapes

A CMM measures 3 points on surface A and 3 points on surface B of a rectangular cuboid (Fig.9).
The coordinates are shown in the table below. Determine the distance L – between surfaces A and
B. Surface A is to be considered as the datum.[7]

Fig.9. CMM Data

6. Develop a machine vision based inspection plan for the following product layout shown in
Fig.10 To inspect bottles in a full 360-degree view to ensure that products are placed in the
correct packaging and is also able to inspect other critical attributes of packaged products such
as:
1 Cap closure/seal, 2. Position, 3. Label 4. Print quality

Fig.10. Plastic Bottle Product layout