What is Metrology?

QAS 0313 – ENGINEERING METROLOGY

Science of measurement.
Methods and techniques of measurement
based on agreed units and standards
Concerns in correctness of measurement
 Precision
 Accuracy

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The difference between accuracy and precision is illustrated below by 4
different

QAS 0313 – ENGINEERING METROLOGY

archers… each with varying degree of ability.
The bull's-eye in the target represents the true value of a measurement.
Inaccurate and imprecise (unrepeatable)
Stone age man
missed the bull's-
eye and the 3
attempts were not
near each other.
Precise but inaccurate
Robin Hood's
Merry Man
missed the bull's- 2
eye but the 3
attempts were
near each other.
Accurate but imprecise

QAS 0313 – ENGINEERING METROLOGY

American Indian's
3 attempts are
near the bull's-
eye, but were not
near each other.

Accurate and precise

Olympic archer
hits the bull's-eye
3 times!
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Objectives of Metrology

QAS 0313 – ENGINEERING METROLOGY

1. To minimize the cost of inspection by effective
and efficient use of available facilities, and to
reduce the cost of rejects and rework through
application of Statistical Process Control techniques
2. Standardization of measuring methods: by laying
down the inspection methods for any product right
at the time when the production technology is
prepared
3. Maintenance of the accuracy of measurement: by
periodic calibration of all measuring instruments 4
used in the plant.
Objectives of Metrology

QAS 0313 – ENGINEERING METROLOGY

4. To ensure the products designed are within
the process and measuring instrument
capabilities available in the plant.
5. To determine the process capabilities and
ensure that these are better than the relevant
parts tolerance.
6. To determine the measuring instrument
capabilities and ensure that these are adequate
for their respective measurements 5
Why is Metrology important?

QAS 0313 – ENGINEERING METROLOGY

Standardization in trade
Eliminating technical barriers in trade,
manufacturing industry, construction etc etc.
Promoting awareness to Quality Assurance

What is Inspection?
Formal or Official examination of products with
the use of accurate (calibrated) measuring
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instruments
Needs and Functions of Inspection

QAS 0313 – ENGINEERING METROLOGY

1. To determine good and bad parts
2. To achieve Interchangeability
3. To improve and develop precision measuring
instruments
4. To support the manufacturing department

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1. To determine good and bad parts

Spec in drawing : Diameter 10 mm

Actual size part 1 : 10.01 mm
Actual size part 2 : 9 mm
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2. To achieve Interchangeability

QAS 0313 – ENGINEERING METROLOGY

1. Interchangeability – products should be able
to fit and mate if chosen randomly from
different manufacturers
2. Examples: Screws and threads, nuts and
bolts, pipes and pressure vessels, pnuematic
and hydraulics fittings/valves, etc.
3. Can be achieved by means of measuring and
gauging
1. Calipers, micrometers, thickness gauge, radius 9
gauge etc
2. Plug gauge, pin gauge, ring gauge etc
2. To achieve Interchangeability

Interchangeability -products should be able

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to fit and
mate
3.To improve and develop precision measuring

QAS 0313 – ENGINEERING METROLOGY

instruments
1. Due to demands of high accuracy and
precision works or products
2. Promote spirit of competition between
manufacturers to produce high quality
precision parts

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4.To support the manufacturing department

QAS 0313 – ENGINEERING METROLOGY

1. Functions of inspection in manufacturing
industries
 Comformity of product’s appearance and functions
 Conformity of product’s dimensional specifications
 Conformity of product’s performance
 Providing data for product’s improvement analysis
 Production process
 Manpower skills
 Material analysis
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 Machines accuracy and maintainance
Principles of Metrology

QAS 0313 – ENGINEERING METROLOGY

 Fundamentals Units and Standards
 Language of measurement and must be constant
worldwide
 SI base units:
1. Length : Meter (m)
2. Mass : Kilograms (kg)
3. Time : second (s)
4. Current : Ampere (A)
5. Thermo. Temp : Kelvin (K)
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6. Amount of subs. : Mole (mol)
7. Luminous intensity : Candela (cd)
 QAS 0313 – ENGINEERING METROLOGY
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Principles of Metrology

QAS 0313 – ENGINEERING METROLOGY

 SI derived units:
1. Area : square meter (m2)
2. Volume : cubic meter (m3)
3. Velocity : meter per second (m/s)
4. Acceleration : meter per square sec.
(m/s2)
5. Force : Newton (N)
6. Luminance : candela per square meter (cd/m2)

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Principles of Metrology

QAS 0313 – ENGINEERING METROLOGY

SI Prefixes
Multiplie
Prefixes Symbol Multiplier Prefixes Symbol
r
peta P 1015 deci d 10-1

tera T 1012 centi c 10-2

giga G 109 mili m 10-3

mega M 106 micro µ 10-6

kilo k 103 nano n 10-9

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hecto h 102 pico p 10-12

deka da 101 femto f 10-15

EXAMPLE 1
20 μm = _______________ mm

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18
19
20 μ m = ________ mm 20
 -3 -6
(-6) – (-3) : -3

20 μ m = ________ mm 21
 -3 -6
(-6) – (-3) : -3
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20 μ m = 0.020 mm
EXAMPLE 1
7.6 nm = __________________ cm

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24
25
7.6 nm = ________ cm 26
 -2 -9
DIFFERENCE : -7
7.6 nm = ________ cm
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 -2 -9
DIFFERENCE : 7
7.6 nm = ________ cm 28

= 0.00000076 cm
 QAS 0313 – ENGINEERING METROLOGY
BASIC INSPECTION PROCEDURES
AND MEASUREMENT ERRORS

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Testing and Inspection Procedures

QAS 0313 – ENGINEERING METROLOGY

• A method of inspection by means of
comparing the dimensional characteristics
of products against the scale of a
Measuring measuring instrument.
• Measured value is read off directly from
these instruments

• A method of inspection by means of

comparing the dimensional characteristics
of products against a gauge
Gauging • True dimensional value cannot be obtain
• This method only determine whether the 30
product is within the allowable limits
Measuring

QAS 0313 – ENGINEERING METROLOGY

Measured value
is read off
directly from
the measuring
instrument

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Gauging

QAS 0313 – ENGINEERING METROLOGY

True value is unknown,
only determine ‘good’ 32
or ‘bad’ parts only
33
Types of Measurement

QAS 0313 – ENGINEERING METROLOGY

Direct Indirect Comparative
Measuremen Measuremen Measuremen
t t t
• Compared • Obtained by • Comparison
directly using an between
against the intermediary standards
line of (transfer) blocks or
measuring measuring products
instruments device
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 Direct Measurement

QAS 0313 – ENGINEERING METROLOGY

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Indirect Measurement

QAS 0313 – ENGINEERING METROLOGY

Measure value obtain using intermediary
Measurement directly use instrument, value determine by math (density,
volume)

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Comparative measurement

QAS 0313 – ENGINEERING METROLOGY

 Comparison between standard/either known value.

Dial gauge

Gauge block Measure workpiece

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Factors in selecting Testing Instrument

QAS 0313 – ENGINEERING METROLOGY

1. The Rule of 10
2. Repeat accuracy
3. Stability
4. Magnification
5. Resolution
6. Inspection Cost

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 QAS 0313 – ENGINEERING METROLOGY
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Calibration

QAS 0313 – ENGINEERING METROLOGY

Definition :
a periodical act of
checking/comparing two measuring
instruments, one of which is traceable to
national standards

Purpose :
to detect any discrepancies in accuracy
and adjust it to bring it within its tolerance 40
for accuracy
Calibration

QAS 0313 – ENGINEERING METROLOGY

Inventory and Classification
 Systematic approach of calibration control

1. Calibration Masterlist
2. Record card
3. Equipment Marking with Control number
4. Calibration sticker

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 QAS 0313 – ENGINEERING METROLOGY
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 MEASUREMENT ERRORS

QAS 0313 – ENGINEERING METROLOGY

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44
Measurement error

QAS 0313 – ENGINEERING METROLOGY

• Difference between the unknown actual size of
the products and measured value obtained
• Inaccuracy of measurement

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 Factors Affecting Accuracy of

QAS 0313 – ENGINEERING METROLOGY

Measurement
1. Standards
2. Workpiece
3. Instruments
4. Personal
5. Environment

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 Factors Affecting Accuracy of

QAS 0313 – ENGINEERING METROLOGY

Measurement
Workpiece

 Due to internal and external influences

 Geometrical truth
 Workpiece reference point
 Elastic properties
 Cleanlines
 Surface condition 47
 Factors Affecting Accuracy of

QAS 0313 – ENGINEERING METROLOGY

Measurement
Instrument

 Dent/Wear
 Amplification devices
 Calibration errors

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 Factors Affecting Accuracy of

QAS 0313 – ENGINEERING METROLOGY

Measurement
Personal

 Improper training
 Measuring skills
 Lack of concentration
 Attitudes
 Improper selection of instruments
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 Types of Errors

QAS 0313 – ENGINEERING METROLOGY

1. Systematic Error
○ Occurs constantly under the same measurement
condition
○ Can be detected and further eliminated
○ Ex: thermal expansion
2. Random Error
○ Occurs naturally and is inherent in the measuring
process
○ Difficult to detect and eliminated 50
○ Ex: improper handling
 Source of Measurement Errors

QAS 0313 – ENGINEERING METROLOGY

1. Effects of Heat
2. Parallax Error
3. Positioning or Alignment Errors
4. Reading Errors
5. Instrument Errors
6. Abbe’s Law
7. Error Caused by Force
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8. Airy Points
 Source of Measurement Errors

QAS 0313 – ENGINEERING METROLOGY

Effects of Heat

 Due to expansion properties of metals (measuring

instruments) at different measuring temperatures
 Thus, a temperature of 20C is classified as standard
measuring temperature

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 Source of Measurement Errors

QAS 0313 – ENGINEERING METROLOGY

Parallax Error
 A change in the apparent relative positions of objects
when viewed from different positions

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 Source of Measurement Errors

QAS 0313 – ENGINEERING METROLOGY

Positioning or Alignment Errors
 Caused due to measuring surface of the instrument is
misaligned or tilted at an angle of the workpiece.

Instrument tilted at
an angle

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 Source of Measurement Errors

QAS 0313 – ENGINEERING METROLOGY

Reading Errors
○ Unclear scale mark, line scale thickness, scale
division etc.

Instrument Errors
○ Pitch errors, error of scale division, play, wear and
friction

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 Source of Measurement Errors

QAS 0313 – ENGINEERING METROLOGY

Abbe’s Law

 Abbe’s Law stated that maximum accuracy may be

obtained when the standard is in line with the axis of the
workpiece to be measured

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 Source of Measurement Errors

QAS 0313 – ENGINEERING METROLOGY

Error Caused by Force
 Measuring surface of instrument must be in contact with
workpiece, if pressure too high then instrument will
bend and workpiece may become dented.

Airy Points
 Long bar resting on two points may effect in warping (at
airy points) and causing errors in measurement.
 Thus, the bar should be supported at airy points to kept
both ends parallel 57