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MEM560

Manufacturing Processes
Topic 2

Rahani Abdul Rahman


Co-ordinator: PM Yusof Mohd
FKM

Topic 2
2.0 Introduction
2.1 Tolerance, Limits and Fit
2.2 Linear Measurement Using Tools and such
as Digital Gauges, Micrometer and Calipers
2.3 Angular Measurement Using Profile Projector
2.4 Straightness, Flatness, and Roundness
Measurement
2.5 Surface Roughness Measurement
2.6 Measurement Using GO and NO GO Concept

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Introduction to Metrology
and Instrumentation

Science

of measurement
experimental and theoretical with
certain level of uncertainties.
i.e: Length Mass Flatness Profiles
taper
Why is it important?
With a universal
meaning
With
a defined
uncertainties
With a judicious
standardization
With/using
good and correct
technique

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Tolerance, Limits and Fit


2.1 Introduction
2.2 Linear Measurement Using Tools and such
as Digital Gauges, Micrometer and Calipers
2.3 Angular Measurement Using Profile
Projector
2.4 Straightness, Flatness, and Roundness
Measurement
2.5 Surface Roughness Measurement
2.6 Measurement Using GO and NO GO
Concept
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Standards
Who

are the respective parties


responsible to maintain standards of a
universally agreed set of guidelines for
interoperability.
Local
: SIRIM
International
: ISO
Doing an inspection? With/without
Doing a measurement? With
equipment/ apparatus (attributes
Yes/No OR variables dimensional wise)
Differentiate the Metric (SI) and Imperial
System measurement.
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Category

Name

Abbv

Length

Metre

Mass

kilogram

Kg

Time

Second

Electric
current

Ampere

Temperatur Kelvin
e

Amount of
substance

Mole

Mol

Luminous
intensity

Candela

cd

Derivations;
-Farad (F)
-Hertz (Hz)
-Joule (J)
-Newton (N)
-Ohm ()
-Pascal (Pa)
-Volt (V)
-Watt (w)

Accurat
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Allowances

Clearance fit & loose fit / free fit


fit

Tolerances

Interference

4.25 +0.01 / 0.01


(BILATERAL)
4.25 +0.01 /
-0.00
(UNILATERAL)
4.2495 / 4.2505
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LIMIT

Errors
With all dimension inspected, tendency for errors are great
with 3 major categories namely;
1. Systematic error
- Due to quality of equipment: causes consistent signs (+ve
or ve)
- Due to ambient conditions : temperature, humidity, CO2 or
pressure of work piece or instrument
2. Accidental error
- Due to the smallest gradient in equipment or
- Inexperience of equipment user
3. Illegitimate error
Calibration
- Equipment is compared to;
1. primary standard
2. Secondary standard (with higher accuracy than the
equipment itself)
3. Known input source
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2.2 Linear Measurement Using Tools


and such as Digital Gauges,
Micrometer and Calipers

Nibs

Ja
w

Digital Caliper Dial Caliper


Vernier
Caliper
Spindl
Ratchet
Slee
Anvi
l

Fram
e

Point
Micrometer

stop

ve

Thimbl
e

Dual
Point
Micromet
er

Outside
Micromete
r
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2.3 Angular Measurement Using


Main criteria for a PP/optical comparison ;
Profile Projector
-Diascopic (behind) / episcopic (above)
illumination
-Measuring stroke
-Contour illumination system
-Standard equipped turret
-X and Y wheel
-Digital displays
-Focusing (motor-driven or manual)
-Bulbs
-Overlay Charts
-Resolutions
-Data processing unit
Angle measurement;
Protractor : measuring angle via
displacement method in reading of
degrees
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2.4 Straightness, Flatness, and


Roundness
Measurement

Straightness
i.e Laser beam
Flatness
i.e reference of surface (3 points) onto
new reference plane (3 points)
i.e use of calibrated granite table
Roundness
i.e use of dial indicator with object set
on V-block, error in roundness can be
directly known by comparing the
peak height as measured by the dial
gauge.
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2.5 Surface Roughness


Measurement
Characteristic of a surface is its structure, texture

and roughness.
-Structured : microscopic level - effect of
processes that the raw material had gone
through.
-Texture : repetitive and/or random deviations
from the nominal surface of an object (roughness,
waviness, form, lays and flaws).
{surface profile = error of form + waviness +
roughness}
-Roughness : surface profile (peaks and valley)
-Integrity : sub-surface alterations produced due
to manufacturing.
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2.6 Measurement Using GO and


NO GO Concept
Gauges

: device that measures the dimension of an


object or to measure the dimension of
produced part if it is within specified limits.
: gauge of a numeric scale for metal thickness
GO-NO-GO and GO gauges
Gauges that gives categorical data on one or
more dimension of a work piece is within
specification.
Limit Gauges / Attribute gauges
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