Lab Guide 800363
Lab Guide 800363
net/publication/319648634
Metrology laboratory
CITATIONS READS
0 56,064
1 author:
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
Reduction of CO2 emissions and fuel consumption in a heavy duty truck logistics operation by use of a hybrid drive train View project
All content following this page was uploaded by Tumisang Laurel Kalagobe on 12 September 2017.
A project report submitted to the Faculty of Engineering and the Built Environment,
University of the Witwatersrand, Johannesburg, in partial fulfilment of the
requirements for the degree of Bachelor of Science in Engineering.
I am aware that plagiarism (the use of someone else’s work without their permis-
sion and / or without acknowledging the original source) is wrong;
I confirm that the work submitted herewith for assessment in the above course
is my own unaided work except where I have explicitly stated otherwise;
This task has not been submitted before. either individually or jointly, for any
course requirement, examination or degree at this or any other tertiary educa-
tional institution;
I have followed the required conventions in referencing the thoughts and ideas of
others;
i
Abstract
ii
Contents
Declaration i
Abstract ii
Contents iii
List of Figures vi
List of Tables vi
1 Introduction 1
1.2 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Apparatus 2
3 Experimentation 5
iii
3.2 Angular discrepancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4.6 Length of the sample measured with a linear transducer and DTI 8
4 Discussion 8
5 Conclusions 10
A Sample calculations 12
B Uncertainty analysis 14
B.2.1 Vernier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
iv
B.2.3 Dial test indicator . . . . . . . . . . . . . . . . . . . . . . . . . 15
C Tables 16
v
List of Figures
List of Tables
2 Shaft 1 diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
vi
1 Introduction
The National Metrology Institute of South Africa describes metrology as “the process
to establish weights and measures as the basis for accurate measurements worldwide”
[1]. Establishing a standard to which all measurements can adhere to is crucial in
all engineering applications as accurate and precise work ensures good engineering
practise.
1.2 Objectives
1. Determine the least possible number of gauge blocks that can give the most
precise height of a triangular test piece.
1
3. Determine whether 3 hollow cylinders pass a go or no-go plug gauge test.
4. Determine the geometry of a stepped shaft through the use of a vernier calliper.
2 Apparatus
Gauge blocks are precision ground metallic blocks that are often used as a measurement
standard, or means of calibration [4]. These devices are available as sets, typically
ranging from 1.001mm to 100mm. Gauge blocks can have uncertainties ranging from
0.05 microns to 1.00 microns [5], making them extremely precise and a good standard
for measurements. An example of a gauge block set is shown in Figure 2.
Angle gauge blocks are similar to the gauge blocks discussed in subsection 2.1. The
main difference is that they are purposely designed to precise angles. They are also
used as a standard to calibrate equipment.
2
2.3 Vernier calliper
Vernier callipers are precision measurement instruments that can be used to measure
linear widths, depths, external and internal diameters. A vernier calliper is shown in
Figure 3.
DTI’s are used to measure small changes in linear displacements. A DTI is shown
in Figure 4. Each division for this experiment measures a displacement change of 2
microns.
3
2.5 Go or no-go gauges
Go or no-go gauges are used to quickly detect if a component is out of its tolerance
region. The gauge has a large diameter on one side and a small diameter on the other,
representing the upper and lower diameter tolerances for the component. The gauge
is simply inserted into the desired region with either the small or large diameter. A
decision can then be made on whether the component dimensions are satisfactory or
not. Figure 5 shows a go or no-go gauge. There are also 3 hollow cylinders that are
tested with the go or no-go gauge.
4
3 Experimentation
A series of measurements were taken with the various measurement tools mentioned in
section 2 in order to demonstrate their precision and accuracy.
For this measurement a triangular test piece of known hypotenuse length and inclin-
ation angle is used. It has a hypotenuse length and inclination angle of 127mm and
27o ± 300 respectively.
The objective is to determine it’s height, the uncertainty thereof and the combination
of the least number of gauge blocks needed to form that height.
Appendix A.1 shows the calculations for the height of the triangle and Appendix B.1
shows the uncertainty in the aforementioned calculations, opposite to the 27o angle.
The final height of the triangle is 57.657mm ± 1.00mm. This height can be achieved
by a combination of mass pieces as shown in Table 1 in Appendix C.1.
Given a triangular test piece of known base length, the angular discrepancy must be
determined through the use of a dial test indicator. The procedure follows:
2. Place the test piece on a rig that only allows linear motion.
3. Place the sensor button of the DTI on one edge of the test piece.
5. Slowly move the test piece until the sensor button is on the side opposite to that
which it started on.
5
After conducting this experiment it was found that the sensor button had moved 8
microns. This resulted in an angular discrepancy of 0.0001rad. The calculation for
this discrepancy can be found in Appendix A.2. There is no uncertainty in this value.
2. If the gauge slides into the cylinder then it has passed the first part of the test,
otherwise the component is too small and the test may be discontinued.
5. If the gauge does not slide into the cylinder then it passes the Go or No-Go test,
otherwise the component is too wide.
It is found that the first cylinder was too small, the second was the right size and the
third was too large.
2 measurements are taken 90o to each other at the top, middle and bottom of region
1 with the external jaws of the vernier calliper. Table 2 in Appendix C.2 shows the
6
measurements that were taken. The ovality of a shaft is defined as:
ovality = D − d
Where D is the largest diameter measurement and d is the smallest diameter measure-
ment. The ovality of shaft 1 is found to be approximately 0.017mm. All measurements
must be taken by pushing the vernier jaws-first onto the diameter that is being meas-
ured. The vernier must be removed in the same manner.
The stepped shaft is set up on the DTI rig with the sensor button on the outer most
point of the diameter of shaft 2 and calibrated to zero. The shaft is then slowly rotated
360o . The largest deviation is then recorded. The largest deviation is found to be 8
increments, which translates to 16microns.
The length of the shaft is found by use of a digital vernier calliper and measurements are
taken at random locations around the circumference of the shaft. Table 3 in Appendix
C.3 shows the measurements.
The length of shaft 2 is found with the vernier calliper’s external jaws. 3 random
measurements around its circumference are taken. The length of shaft 1 is found
mathematically by subtracting the length of shaft 2 from the total length of the shaft.
Table 4 in Appendix C.4 shows these lengths.
The diameter of shaft 2 is found with the external jaws of a vernier calliper. Only one
measurement is taken and is found to be 74.9mm.
7
The measurement is taken with the vernier at an acute angle with the surface of the
shaft as this ensures that the true maximum external diameter is found.
3.4.6 Length of the sample measured with a linear transducer and DTI
The length of the sample is measured with the use of a linear transducer and a clock
gauge. The same method is used for both measurement devices as they have the same
operating principle.
A 75mm gauge block is used to calibrate the measurement device. The stepped shaft
is then placed under the sensor button and the displacement which is shown of the
measurement device is recorded. The recorded value is subtracted from the 75mm
to which the device was calibrated. The deviations of the transducer and DTI are
0.041mm and 0.02mm respectively. The shaft lengths of the transducer and DTI are
therefore 74.959mm and 74.98mm respectively.
4 Discussion
Measurements of various objects were recorded with the use of a number of different
measurement devices. The precision of these devices vary and are critically evaluated
in this section, along with the deviations from the ideal measurements.
The first measurements taken were done with the objective of demonstrating the use of
gauge blocks as a means of calibrating a measurement (see subsection 3.1). A triangular
test piece of a known hypotenuse length and inclination angle was used. The ideal
height of the side opposite to the inclination angle was found to be 57.657mm by the
sine trigonometry relationship. The uncertainty was found to be ±1.00mm due to an
angular uncertainty of ±300 .
These findings lead to the conclusion that 8 blocks of the dimensions shown in Table 1
are the least number of blocks needed to give the ideal length. The least number of
blocks need to be used in order to reduce the amount of uncertainty in the measure-
ments. Although gauge blocks are made with extreme accuracy and precision, they still
have uncertainties in the region of a few micrometers, as explained in subsection 2.1.
In the process of calibration there must be as little uncertainty as possible because the
8
point of calibration is to conduct measurements with the datum set to a known and
universal standard.
In the second measurement set, a triangular gauge block is assessed for an angular
discrepancy by use of a dial test indicator (see subsection 3.2). Only the base length
of the triangular test piece is known and no uncertainty is given by the manufacturer
for this length. The inclination angle and the uncertainty in the base length of this
test piece are unknown. Measurements showed that there is a 0.0001rad discrepancy
in the inclination angle.
The third measurement involved the use of a go or no-go plug gauge on a series of 3
hollow cylinders (see subsection 3.3). The first cylinder proved too small as the Go
side was unable to enter. The second cylinder was within the tolerance limits of the
plug gauge as the Go side was able to enter while the no-go side was unable to enter.
The final cylinder was too large because both the Go and No-Go sides entered the hole.
The failure of the first and third cylinders to meet the tolerances can be attributed to
machining flaws, assuming that all 3 are from the same production batch.
In order to ensure the first and third cylinders are able to meet the minimum re-
quirements some interventions can be undertaken. The small cylinder’s hole can be
cut slightly larger in order to meet the tolerance requirements. The large cylinder is
slightly more complex to correct as it is much easier to remove material than it is to
add material. The cylinder could be cut even wider and then a bush that meets the
tolerance requirements could be inserted.
The final measurements were of a stepped shaft (see subsection 3.4). The dimensions
were initially unknown and measurements of the diameters and heights were taken
through the use of a vernier calliper, linear transducer and a dial test indicator.
9
The ovality of the small diameter shaft was found to be 0.017mm. This deviation could
be attributed to the machining process used to make the shaft. The process used is
not known so no further conclusions or recommendations can be made. The surface
of shaft 2 was found to have a 16 micron discrepancy with surface of shaft 1. The
discrepancy means that the 2 surfaces are not perfectly perpendicular. Again, this
error can be attributed to the machining process used.
The length of the shaft was found through the use of a vernier calliper, DTI and
linear transducer. The transducer and DTI were calibrated through the use of a 75mm
gauge block. It was found that the transducer and DTI gave measurements that have
a difference of 0.02mm. The difference in these measurements are considered as the
process used to establish these values is the same. The difference could be due to
electrical noise in the transducer. Even though it is more precise, it might not be as
accurate as the DTI since the DTI uses mechanical elements to conduct measurements
and is less likely to have systemic imbalances.
5 Conclusions
Based on the objectives set out in subsection 1.2, the following conclusions can be
made:
3. Of the 3 hollow cylinders that were considered, 1 passed the go or no-go test, 1
was too small and 1 was too large.
4. The stepped shaft lengths, diameters, ovality and perpendicularity were determ-
ined through the use of a vernier calliper.
5. The total length of the haft was also determined through the use of a linear
transducer and a DTI. The DTI is concluded as the most accurate as it has no
threat of electrical noise distorting the measurements taken. The transducer,
however, is the most precise.
10
References
[1] National Metrology Institute of South Africa. (2012). [online] Nmisa.org. Available
at: nmisa.org/theNMISA/Pages/About%20Metrology.aspx [Accessed 18 Mar.
2017].
[2] Howarth, P. and Redgrave, F. (2008). Metrology - in short. 1st ed. Lyngby: [Danish
Fundamental Metrology], p.21.
[3] Math Is Fun, (2013). Accuracy and Precision. [online] Mathsisfun.com. Available
at: mathsisfun.com/accuracy-precision.html [Accessed 18 Mar. 2017].
[5] Mitutoyo, (n.d.). Length Standard Gauge Blocks. [online] Japan: Mitutoyo. Avail-
able at: mitutoyo.co.jp/eng/support/service/catalog/09/E12014.pdf [Accessed 18
Mar. 2017].
[6] Ryan, V. (2004). The Vernier Caliper - Manual Version. [online] Technologystu-
dent.com. Available at: technologystudent.com/equip1/vernier3.htm [Accessed 18
Mar. 2017].
11
A Sample calculations
The following section shows all sample calculations that were undertaken during the
course of the experiment.
The height of the triangle and the angle of inclination are given as 5 inches and 27
degrees respectively, as shown in Figure 7.
The length of the hypotenuse is first converted to millimetres by the following conver-
sion:
25.4mm
5inches = × 5in = 127mm
1in
A conversion from degrees to radians is not necessary, but preferred as that stays
consistent with the use of radians in the uncertainty analysis. A simple trigonometric
manipulation gives the general height of the triangle in terms of θ in Equation 1.
h = r sin θ (1)
The height can now be found, given the hypotenuse and the inclination angle.
o
27 π
∴ h = (127mm) sin = 57.657mm
180o
12
A.2 Angular discrepancy
Since the change in height and the base length of the test piece are known as 8microns
and 75mm respectively, a tangent ratio can be applied:
8 × 10−6 m
tan θ =
75 × 10−3 m
The angular discrepancy of the triangular gauge block in radians is therefore:
∴ θ = 0.0001rad
13
B Uncertainty analysis
The following section gives an uncertainty analysis of all measurements and calculations
shown in Appendix A. Equation 2 is the general uncertainty propagation on which all
of the following uncertainties are based on. In general if f is a function of a, b and z
such that f = f (a, b, ..., z) then the uncertainty in f for any number of variables is:
s 2 2 2
∂f ∂f ∂f
δf = δa + δb + ... + δz (2)
∂a ∂b ∂z
Equation 2 is tailored to the specific needs of each problem, as shown in the following
sections.
The ideal height of the triangle is calculated in Appendix A.1. The uncertainty in the
height can be found through Equation 3 which is a simplification of Equation 1 and
Equation 2.
∂h
δh =δθ (3)
∂θ
The units for the angles are changed to radians because radians represent a ratio
between the arc length and the radius of a circle, which is a dimensionless ratio. The
uncertainty in the height due to the angle uncertainty can now be found:
o o
0.5 π 27 π
∴ δh = o
(127mm) cos = 1.00mm
180 180o
The uncertainty in the measurements of the stepped shaft arises from the u.certainty
in the measurement equipment. The equipment used is the vernier calliper, linear
transducer and the clock gauge.
B.2.1 Vernier
The vernier has an uncertainty of half the smallest increment on the vernier scale,
which is 0.005mm.
14
B.2.2 Linear transducer
The linear transducer uncertainty arises from half the smallest digital reading, which
is 0.0005mm.
The dial test indicator uncertainty is half of an increment, which translates to 1micron
since each incremental movement on the gauge is 2microns.
15
C Tables
The following section contains tables that contain important content, however would
occupy too much space in the main report.
The following table shows the combination of gauge blocks that satisfy the conditions
stipulated in subsection 3.1. The combined height of these blocks is 57.657mm
Table 2 shows the measurements taken in subsubsection 3.4.1. The measurements are
approximated to 4 significant figures as there is no visible difference if measurements
are taken to 3 significant figures.
16
C.3 Total length of stepped shaft
Table 3 shows the random measurements taken around the circumference of the stepped
shaft in subsubsection 3.4.3.
17
D Health and safety risk assessment
Risk Assessment
Activity: Metrology
Risk type Risk description Severity Likelihood Risk score Action type Action Notes
Mechanical Sharp edges on vernier calliper Insignificant Rare 2 Elimination First aid n/a
Version 1.0
Signed: Tumisang Kalagobe Date: 2017-03-19 Revision date: 2017/02/17
18
View publication stats