S.

Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 1

ME3120: Manufacturing Science -2 (Machining & Metrology)
Metrology: Basics
S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 2
Machining: Principles of Metal cutting: orthogonal and oblique cutting; mechanics
of machining; Machine Tools - turning, milling, shaping, drilling: Construction and
working; Process variables; Cutting tools nomenclature, material and tool life;
Machinability; Abrasive machining processes- grinding, honing, lapping, burnishing
and super finishing: Equipment, process variables and surface features; Surface
integrity concepts.
Introduction to NC and CNC: Concepts and programming Constructional features
of various machine tools; Introduction to computer integrated manufacturing.
Metrology : Fundamentals of measurements: Errors, Length Standards, Gauging,
Comparators, limits & Fits and Tolerances; Role of metrology in quality assurance;
Measurement of geometric forms , Flatness, Straightness, form errors; Slip gauges;
Surface finish measurements; Coordinate measuring machines; Vision applications
in Metrology; Optical metrology and laser interferometry; Nano measurements.
Syllabus
S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 3
Machining: Principles of Metal cutting: orthogonal and oblique cutting; mechanics
of machining; Machine Tools - turning, milling, shaping, drilling: Construction and
working; Process variables; Cutting tools nomenclature, material and tool life;
Machinability; Abrasive machining processes- grinding, honing, lapping, burnishing
and super finishing: Equipment, process variables and surface features; Surface
integrity concepts.
Introduction to NC and CNC: Concepts and programming Constructional features
of various machine tools; Introduction to computer integrated manufacturing.
Metrology : Fundamentals of measurements: Errors, Length Standards, Gauging,
Comparators, limits & Fits and Tolerances; Role of metrology in quality assurance;
Measurement of geometric forms , Flatness, Straightness, form errors; Slip gauges;
Surface finish measurements; Coordinate measuring machines; Vision applications
in Metrology; Optical metrology and laser interferometry; Nano measurements.
Syllabus
S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 4

Why Metrology?
S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 5

Why Metrology?
S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 6
The branch of knowledge concerned with
measurements

The science of measurements

What exactly is Metrology?
S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 7
A procedure in which an unknown quantity is
compared to a known standard using an accepted
and consistent system of units

What is a Measurement ?
S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 8
A procedure in which an unknown quantity is
compared to a known standard using an accepted
and consistent system of units

What is a Measurement ?
Quantity
Numerical
Value
Measurement
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Branches in Metrology
Metrology
Scientific Metrology Legal Metrology Industrial Metrology
R & D work on
measurement
technique and
standards
Units and methods of
measurements and
types of measuring
instruments in
relation to mandatory
technical and legal
requirements
Measurements
related to activities in
industry
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Important parameters for satisfactory performance of engineering components

Terminology
Dimensional
Accuracy
Standardization
Standards of
length
Length
measuring
instruments
Measurements
of angles
Limits and fits
Limit gauges
Geometrical
Accuracy
Measurement
of flatness
Measurement
of parallelism
Measurement
of straightness
Measurement
of roundness
Surface
Accuracy
Measurement
of surface
texture finish
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Accuracy
Precision
Calibration
Magnification
The ratio of instrument output to the input dimension
Linearity
The accuracy of the reading over the instrument's full
working range
Characteristics of Measuring Instruments
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Resolution
Smallest dimension that can be read on the instrument
Sensitivity
Smallest difference in dimension that an instrument can
detect
Speed of response
Stability
An instruments capability to maintain its calibration over
a period of time. Sometimes referred to as Drift



Characteristics of Measuring Instruments
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Apart from the above characteristics, following
factors also should be taken into account when
selecting a measuring instrument for a particular job
Size and type of part being measured
Environment (Temp, humidity etc.,)
Operator skills required
Cost of the instrument


Selection of Measuring Instruments
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Accuracy
Degree to which the measured value agrees with the
actual value
Precision
the repeatability of a measurement
i.e. the closeness of agreement between the results of successive
measurements of the same parameter carried out by the same
observer, with the same measuring instrument, at the same
location at a short interval of time

Accuracy & Precision
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S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 16
Systematic Errors
Random Errors
Operator Errors
Application Errors
Measurement Errors
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Description
An error in which, in the course of the number of measurements of
the same value of a given quantity, made under the same conditions,
with the same measuring instrument, remains constant in absolute
value and sign, or varies according to a known law when the
conditions change.
Cause
Mainly due to instrumental errors such as, zero drift, non-linearity, in
accurate calibration, sensitivity change etc..
Examples
Error which occurs when taking measurements at 25 C from a steel
ruler gauged at 0 C.
Systematic Errors
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S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 19
Description
An error in which, in the course of the number of measurements of
the same value of a given quantity, made under the same conditions,
with the same measuring instrument, varies in an unpredictable
manner both in value and sign of the absolute value.
Cause
Mainly due to unidentified sources, such as changes in environment,
resistance inside measuring instruments etc...
Examples
Error which occurs when taking measurements micro balances in
changing environments
Random Errors
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S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 21
Description
An error in which occurs due to the fault of the operator
Cause
Due to misreading of instrument, lapses in memory, boredom ,
inadequate knowledge in handling the instruments etc
Examples
When taking a same reading over a long period of time.


Operator Errors
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S. Suryakumar, ME, IITH ME3120: Manufacturing Science -2 (Machining & Metrology) 23
Description
An error in which occurs due improper selection and measuring
technique for measurements.
Cause
Lack of knowledge of handing and selecting measuring instruments for
a particular application
Examples
When using a screw gauge to measure the thickness of the soft sheet
of metal strip the force exerted by the anvil on the surface of the
metal may cause faulty reading
Application Errors
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Fundamental quantity
LENGTH

Linear distance between internal or external
surfaces, points etc.


Linear Measurements
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How is it done?
Comparing the unknown quantity with a with a standard
on a appropriate device.

Against what ???

What is the system of units???

Standards of Length
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Hierarchy of Standards
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The Imperial Standard Yard
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The Prototype Meter France
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Line standards
Distance between two engraved/marked points
Steel rulers
Measuring tapes
End standards
Distance between two parallel faces
Slip gauges
Length bars

Working Standards
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Nice
Day
a
Have