DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY

UNIVERSITY EXAMINATIONS 2021/2022

THIRD YEAR SPECIAL/SUPPLEMENTARY EXAMINATION FOR THE DEGREES

OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING AND BACHELOR
OF EDUCATION TECHNOLOGY (MECHANICAL ENGINEERING)

EMG 3212 METROLOGY

DATE: April, 2022 TIME: Two Hours

Instructions:

This paper contains FIVE questions.

Question one is compulsory.
Attempt Question one and any other two questions.

QUESTION ONE (Thirty marks)

a) (i) Define metrology (1mark)

(ii) With the aid of a sketch, differentiate between end standards and line standards
(3 marks)
(iii) With an appropriate example, differentiate between precision and accuracy (3 marks)
(iv) State two advantages of micrometer screw gauges over vernier calipers (2 marks)
(v) Using a sketch, differentiate between unitary and bilateral tolerances tolerance as
applied to metrology (5 marks)
b) State any three functional parameters of a screw thread that a metrologist would be interested
in establishing (3 marks)
d) With the aid of sketches, describe the following fits, stating a typical application for each
(i) Clearance fit (3 marks)
(ii) Interference fit (3 marks)
e) (i) With the aid of a plot, describe the Root Mean Square method, as applied to surface
roughness measurement (3 marks)
(ii) Using a sketch, describe how a skid type (surface datum)surface roughness measuring
instrument works (4 marks)
QUESTION TWO (Twenty marks)
a) (i) Using sketches, describe the principle of operation of micrometer screw gauge (5 marks)
(ii) With the aid of a sketch, describe how misalignment can affect the accuracy of the
reading of a vernier caliper (3 marks)

b) (i) With the aid of a sketch, differentiate between a continuous clockwise dial and a
continuous anti-clockwise dial indicator (2 marks)
(ii) Using a sketch, describe how a dial indicator can be used to determine if a shaft is
running true when mounted between centers (3 marks)
c) (i) A hole has a diameter of 30±0.05 mm. Without considering wear, design a GO NO GO
gauge, using a unilateral tolerance system, that can be used in gauging the hole
(5 marks)
(ii) Design the GO gauge in c)(ii) above, while compensating 5% for wear (2 marks)

QUESTION THREE (Twenty marks)

(a) With the aid of a sketch, describe how a square can be calibrated using a cylindrical
square and a surface plate (3 marks)

(b) i) Using sketches, describe how two angle gage blocks, 1 0 and 1.50can be used in an
additive and subtractive manner (4 marks)
ii) A six(6) gauge block set is available in a workshop. The pieces are 1 0, 30, 50, 150, 300 and
450. Using the gauge blocks given, combine them to obtain an angle of 32 0 and sketch
the arrangement (3 marks)

(iii) The part shown in figQ3 is to be milled. A 300 mm sine bar, a dial indicator, a surface
plate and a gauge block set are available in the inspection room. Using an appropriate
sketch, describe how the angle on the part can be genearated. (The 47 pieces gauge
block set has the sizes as tabulated in table Q3). (7 marks)
Size (mm) Step (mm)
1 Block 1.005 -
9 Blocks 1.01 – 1.09 0.01
9 Blocks 1.1 – 1.9 0.1
24 Blocks 1 - 24 1
4 Blocks 25 - 100 25

Table Q3
 19.47220

FigQ3

c) Using a sketch describe one method of determining the pitch angle of a screw thread. (3 marks)

QUESTION FOUR (Twenty marks)

(a) In the component shown in figQ4a, dimension h is 50±0.5 mm. Using sketches, describe how a
dial indicator can be used a comparator for gauging the dimension. (4 marks)

Fig Q4a

(b) i) Define collimation of light (1 mark)

ii) Using a sketch, describe how collimation of light is obtained (3 marks)

(c) A hole is required with a diameter of 20 ± 0.01 mm.

 i) Ignoring wear, design and sketch GO NO GO gauge for inspecting the hole, using a
bilateral tolerance approach (7 marks)
ii) Determine the dimensions and tolerances of the GO gauge in c(i) above while
compensating for wear. (2 marks)
(d) A surface plate is required to have a flatness of 0.01 mm. With the aid of a sketch, show the
tolerance zone and how this can be specified in the production drawing (3 marks)

QUESTION FIVE (Twenty marks)

a) (i) Using a sketch describe how the minor diameter of a screw thread can be measured
using a micrometer screw gauge (3 marks)
(ii) State any two methods of measuring the pitch of an external thread (1 mark)
b) (i) Using an appropriate sketch, describe how the three wire method is used in determining
the pitch circle diameter of an external screw thread (4 marks)
(ii) ISO metric threads have a thread angle of 600. An ISO metric power screw has a pitch of
5 mm. Determine the diameter of the wire that can be used in determining the pitch
circle diameter (3 marks)
c) With the aid of a sketch, describe the working principle of a pneumatic back pressure
comparator (5 marks)
d) With the aid of a sketch (graph), differentiate between the root mean square method (RMS) and
the ten point height