Engineering

Metrology and
Instrumentation

Lesson Outcomes
By the end of this lesson, students should be
able to:
Understand what is meant by engineering
metrology and related concepts.
Familiarize with various common
instruments/gauges used in the
measurement of dimensions.
Understand the criteria for choosing the
appropriate instrument/gauge.

( E n g in e e r in g ) M e t r o lo g y
D e f: m e s u r e m e n t o f d im e n s io n s
( e g : l e n g t h , f l a t n e s s , i n t e n s it y , e t c .)

W h y m e a s u r e ? T o in s p e c t

In s p e c t d e f: to c h e ck th e
d im e n s io n o f a p a r t b e in g p r o d u c e d
o r h a s b e en p ro d u c ed

In p ro c e s s
( o n lin e / r e a l t im e )

P o s t p ro c e s s
(a fte r p a rt h a s b e e n p ro d u c e d )

Some definitions

Allowance:

Specified difference in dimensions between mating

parts (eg: phone charger into phone)

Tolerance:
Permissible variation in the dimensions of a part
Reasons:
Manufacturing cost
Proper part functioning

Difference between
allowance and
tolerance?

Some definitions cont.

Sensitivity/resolution:
Smallest difference in dimensions that an instrument can detect

Precision:
Instruments repeatability of measurement

Accuracy:
Degree of agreement between the true value and the measured
dimension

Standard measuring temperature

Important for precision instruments

20oC 0.3 oC
Due to effect of temperature on measurement
Need to have control over measurement

Instrument resolutions

I n s tr u m e n ts / g a g e s
L in e g r a d u a t e d
L in e a r
D ire c t
r e a d in g
R u le

V e r n ie r
c a llip e r

C o m p a r a t iv e le n g th
A n g u la r

In d ir e c t
r e a d in g
M ic r o m e t e r

B evel
p r o tra c to r

D ia l in d ic a t o r s
S in e b a r

G e o m e t r ic f e a t u r e s
S t r a ig h tn e s s

F la t n e s s

S t r a ig h t e d g e

S u r fa c e p la te
& d i a l i n d ic a t o r

G ages

R o un d ne ss
V - b lo c k &
d ia l in d ic a t o r

C e n te rs &
d ia l in d ic a t o r

P r o f i le
D ia l in d ic a t o r
R a d iu s g a g e
F ix e d g a g e

P lu g g a g e

G a g e b lo c k

R in g g a g e

P n e u m a t ic
gage

Common quantities and geometric

features that are measured:
1. Lengthincluding all linear dimensions
of parts.
2. Diameteroutside and inside, including
parts with different outside and inside
diameters (steps) along their length.
3. Roundnessincluding out-of-roundness,
concentricity, and eccentricity.

Common quantities and geometric

features that are measured:
4. Depthsuch as drilled or bored holes and cavities in dies and
molds.
5. Straightnesssuch as shafts, bars, and tubing.
6. Flatnesssuch as machined and ground surfaces.
7. Parallelismsuch as two shafts or slideways in machines.
8. Perpendicularitysuch as a threaded bar inserted into a flat
plate.
9. Anglesincluding internal and external angles.
10. Profilesuch as curvatures in castings, forgings, and on car
bodies.

 Rules: to inspect length

Steel rule, bar, tape
Resolution: 0.5mm

Vernier calliper: to inspect length, diameter

Measure length, inside/outside diameter
Resolution: 25 m

Vernier calliper - cont

1.

Check 0 mark on
vernier scale. Read
from calliper scale.

2.

Check where
vernier scale &
calliper scale
coincide. Read from
vernier scale

3.

Add the two

 Micrometer: to inspect length, diameter

Measure thickness, inside/outside diameter,
depth

 Bevel protractor: to inspect angle

 Dial indicator: to inspect linear displacement

Measure the difference against a reference point
(reference point can be set)
Working principle: converts a linear displacement
rotation of a needle on a dial.

 Sine bar: to inspect angle

1.

Part is placed
on sine bar.

2.

Sine bar is
adjusted until
top surface of
part is
horizontal

3.

Gage blocks
placed under
sie bar

4.

Use dial
indicator to
ensure top of
part is
horizontal

 Dial indicator and surface plate: to inspect

flatness or straightness

 V-block and dial indicator: to inspect roundness

How to measure roundness?

 Centers and dial indicator: to inspect roundness

 Radius gage: to inspect profile

Dial indicator: to inspect profile

 Gage blocks: to inspect length

Blocks of various lengths lapped to very accurate
dimensions.
Combined by wringing to reach desired lengths
Wringing: sliding and twisting blocks together stick due
to moisture and oil

Used as length reference for manufactured parts

Made from hard-wearing materials (eg: alloy steel,
carbide, zirconia)

 Plug gage: to inspect hole diameter

Two types of plug gages: go gage and no go gage
Go gage diameter = min allowable diameter of hole
No go gage diameter= max allowable diameter of
hole

If go gage can pass thru hole hole > min allowable diameter accept
If go gage cannot pass thru hole hole < min allowable diameter reject
If no-go gage can pass thru hole hole > max allowable diameter reject
If no-go gage cannot pass thru hole hole < max allowable diameter accept

 Ring gage: to inspect shaft diameter

Go gage diameter= max allowable diameter of shaft
No go gage diameter= min allowable diameter of
shaft

Which instrument to use? Consider the following

factors when selecting instruments/gages
1. Accuracy, repeat accuracy
2. Amplification or magnification: ratio
(instrument output)/(input dimension)
3. Drift vs. stability: instruments ability to
maintain reading/calibration over time
4. Linearity: Instruments accuracy over its full
working range
5. Precision
6. Resolution

Which instrument to use? Consider the following

factors when selecting instruments/gages (cont)

7. Rule of 10: Instrument must be 10 times

more accurate than the dimensional
tolerance of the part
8. Sensitivity/resolution
9. Response speed: How fast the instrument
registers a reading (i.e. when the
dimension changes)

 Coordinate measuring machine

35.8 Geometric Dimension and Tolerancing

Dimensional tolerance
This is defined as the permissible or acceptable variation
in the dimensions (height, width, depth, diameter, and
angles) of a part.
The root of the word tolerance is the Latin tolerare,
meaning to endure or put up with.
Tolerances are unavoidable, because it is virtually
impossible (and unnecessary) to manufacture two parts
that have precisely the same dimensions.
Furthermore, because close dimensional tolerances can
increase the product cost significantly, a narrow tolerance
range is undesirable economically.

35.8 Geometric Dimension and Tolerancing

Importance of tolerance control

Dimensional tolerances become important
only when a part is to be assembled or
mated with another part.
Surfaces that are free and not functional do
not need close tolerance control.

35.8 Geometric Dimension and Tolerancing

Fig 35.17 shows the basic size, deviation, and tolerance on a shaft, according to
the ISO system.

35.8 Geometric Dimension and Tolerancing

Fig 35.18 shows the various methods of assigning tolerances on a shaft: (a) bilateral
tolerance, (b) unilateral tolerance, and (c) limit dimensions.

Summary
Engineering metrology is the measurement of
dimensions
Various common instruments/gauges used in the
measurement of dimensions were discussed.
Factors relating to instrument/gauge capability
and measurement requirement must be
considered before choosing the appropriate
instrument/gauge

 Dimensional tolerances and their selection are

important factors in manufacturing. Tolerances not
only affect the accuracy and operation of all types
of machinery and equipment but also can
influence product cost significantly
The smaller (tighter) the range of tolerances
specified, the higher is the cost of production.