Metrology
Introduction
• The science of measurement is called as Metrology and when related to practice
of engineering, it is called Engineering Metrology
• The process of expressing anything(object, property, etc) in terms of numbers or
obtaining quantitative information about anything is called as measurement.
• An internationally accepted predefined standard i.e unit is necessary for every
kind of quantity measured
Need for Measurement
• To ensure the interchangeability of the
parts. i.e any two mating parts taken at
random should satisfactorily mate with
each other.
• To ensure the efficient use of resources
• To provide quality products to the end
use
Elements of Measurement
• The sequence of operations necessary for the
execution of measurement is called process of
measurement.
• Measurand - is the physical quantity or property
like length, angle, diameter, thickness etc. to be
measured.
• Reference - It is the physical quantity or property
to which quantitative comparisons are made.
• Comparator - It is the means of comparing
measurand with some reference.
Terminologies in Measurement – Accuracy & Precision
• Accuracy - It is the degree to which the
measured value of the quality characteristic
agree with the true value. The difference
between true value and measured value is
known as error
• Precision - It is the repeatability of the
measuring process. It indicates to what
extent the identically performed
measurements agree with each other
Accuracy and Precision
Accuracy Precision
Measure of reproducibility of the
Closeness with the true value
measurement
Conformity to truth Clearly or sharply defined
Accuracy can be improved Precision cannot be improved
Depends upon many factors and require may
Depends upon simple techniques of analysis
sophisticated techniques of analysis
Terminologies in Measurement – Sensitivity
• It refers to the ability of measuring device to
detect small difference in quantity being
measured
• High sensitivity instruments may lead to drifts
due to thermal or other effects, and the
indications may be less repeatable or less precise
than that of the instrument of lower sensitivity
Terminologies in Measurement – Calibration
• It is the process of establishing the
relationship between a measuring
device and the units of measure
• This is done by comparing a
device or the output of an
instrument to a standard having
known measurement characteristic
Elements of a Measuring System - SWIPE
• Standards – Physical quantity or property relative to which quantitative
comparison is made
• Workpiece – Features of the workpiece to be measured
• Instrument – Instruments need for measurement
• Person – The skill of the human operator
• Environment – The conditions in which measurement are done
Terminologies in Measurement – Standard
• Standard is defined as “something that is
set up and established by authority as a
rule for the measurement of a quantity,
weight, value or quality”. Standard
• Example: A meter is standard established
by an S.I (System International) Line End Wavelength
organization for measure length. Standard Standard Standard
Line Standard
• When length is measured as the
distance between centers of two
engraved lines, its is called Line
Standard
Line Standard - Characteristics
• A scale is quick and easy to use
• The scale markings are subjected to wear.
• The leading ends are subjected to wear and
this may lead to undersize measurements.
• The engraved lines themselves possess
thickness and it is not possible to take
measurement with high accuracy limited to
+0.2 mm.
Line Standard - Characteristics
• Scales are subjected to parallax error
(Reading error).
• Hence it is requires assistance of
magnifying glass or microscope to
achieve sufficient accuracy.
• A scale does not possess “built in” datum.
Therefore it is not possible to align the
scale with the axis of measurement.
End Standard
• When length is expressed as the
distance between centers of two flat
parallel faces, it is called End Standard
End Standard - Characteristics
• They require more time for measurement and
measure only one dimension at a time.
• They are subjected to wear on their measuring faces.
• These standards are highly accurate for
measurement of close tolerance upto + 0.001 mm.
End Standard - Characteristics
• They are not subjected to parallax
error (reading error).
• End standards have “built in”
datum. Hence can be easily
aligned with the axis of
measurement.
• Group of slip gauges can be
wrung together to build up a
given size; fault wringing and
careless use may lead to
inaccurate result.
Line and End Standards – a comparison
Characteristic Line Standard End Standard
Length is expressed as distance Length is expressed as distance
Principle
between two lines between two ends
Highly accurate, Tolerence upto
Accuracy Limited to ±0.2 mm
±0.001 mm
Ease Quick and easy Time consuming and requires skill
Effect of Wear Wear is only at the ends Wear at measuring surfaces
Alignment Cannot be easily aligned Can be easily aligned
Cost Low cost High cost
Parallax Effect Subject to parallax effect Not subjected to parallax effect
Wavelength Standard
• In the 7th General Conference of Weights and Measures in 1927 has
approved, the definition of standard of length relative to the meter is
expressed in terms of wavelength of spectral radiation emitted from
red cadmium as an alternative to the International Prototype Meter.
• Later in 11th General Conference of Weights and Measures in 1960,
Orange radiation of isotope krypton-86 was chosen for new definition
for Length has approved.
• According to this Standard Meter as defined as equal to 1650763.73
Wavelength of the red orange radiation of isotope krypton 86 gas
Wavelength Standard - Characteristics
• Not a material standard and hence it is not
subjected to effects of variation of environmental
conditions like temperature, pressure etc.
• It need not be preserved or stored under security
and thus there is no fear of being destroyed
• It is not subjected to destruction by wear and
tear
Wavelength Standard - Characteristics
• It gives the unit of length which can be
reproduced consistently at all times
• The standard facility can be easily
available in all standard laboratories and
industries
• Can be used for making comparative
measurement of very high accuracy
Errors in Measurement
• No Measurement is exact.
• Necessary to state not only the measured
dimension but also accuracy of determination.
• Errors inherent in the method of measurement
used should be kept to a minimum.
Types of Errors - Controllable Errors
Environmental Conditions
• The international standard temperature of measurement is 20ºC and the ambient temperature should be
maintained at this level.
• Handling a gauge changes its temperature, so it should be handled as little as possible and must give time to
stabilize after use.
Elastic Deformation Due to Loading
• Any elastic body subject to a load will undergo elastic deformation, which is proportional to the applied load
• Elastic deformation occurs when a body sags under its own weight.
• The supports can be arranged to give a minimum error
Types of Errors - Controllable Errors
Alignment Errors
• The scale of a linear measuring system should be collinear
with the spatial dimension or displacement to be measured
Parallax Errors
• The error that occurs when the pointer on a scale is not
observed along a line normal to the scale
Types of Errors - Non-Controllable Errors
Scale Errors
• The scale against which a measurement is made is in error condition
• It can only be overcome by calibrating the instrument scale against known standard
Random Errors
• Imprecise measuring devices may lead to a reading above or below the true value
• The mood of the measuring person can cause fluctuations in the reading
Systematic Error
• It is due to the style of taking dimensions
• Improper measurement can lead to this error
Random Error and Systematic Error
Random Error Systematic Error
Poor precision Poor accuracy
Non-specific causes Definite causes
Not reproducible Reproducible
Metrology - General Terminology
• Basic Size : Exact theoretical size arrived by design. Also called nominal size
• Actual Size : Size of a part as found by measurement
• Zero Line : Straight line corresponding to the basic size. Deviations are measured from this
line
• Limits of Size : Maximum and minimum permissible sizes for a specific dimension
Metrology - General Terminology
• Tolerance : Difference between the maximum and
minimum limits of size
• Allowance : Difference between Lower Limit of Hole(LLH)
and Higher Limit of Shaft (HLS). Allowance = LLH – HLS
• Deviation : Algebraic difference between a size and its
corresponding basic size. It may be positive, negative or
zero
Tolerances and Limits
• It is impossible to produce a part to an
exact size or basic size
• Some variations, known as tolerances,
need to be allowed
• The permissible level of tolerance
depends on the functional requirements,
which cannot be compromised.
Tolerance
• It is a trade-off between the economical production
and the accuracy required for proper functioning of
the product
• It is the algebraic difference (absolute value)
between upper and lower acceptable dimensions
• It is to permit dimensional variations in the
manufacture of components without compromising
performance
Tolerances and Limits
• The dimension of component manufactured
will have an upper limit and a lower limit
• Designer will assign the required tolerance
limits to ensure satisfactory operation
• The difference between upper and lower
limits is termed as permissive tolerance
Tolerance - Classification
Tolerances can be classified into:-
1. Unilateral Tolerance - When the tolerance distribution is only in one side of the basic
size
2. Bilateral Tolerance - When the tolerance distribution lies on either side of the basic size
3. Compound Tolerance - When the tolerance is the combined effects of two dimensions
4. Geometric Tolerance - It is a method of defining parts based on how they function
using standard symbols
Tolerances – Unilateral and Bilateral
Compound Tolerance
Dimension R is determined by the
combined effect of the 40 mm
dimension, the 20 mm dimension and
the angle.
Geometric Tolerance
• Geometric Tolerancing reading helps to understand, to specify and control the
form, location and orientation of the features of components and manufactured
parts.
• Geometric Dimensioning and Tolerancing is an efficient method for describing the
tolerancing mandated by the designer of the part.
• There are several standards available worldwide to describe the symbols and the
rules. These are: The American Society of Mechanical Engineers (ASME) and
International Organization for Standardization (ISO)
Geometric Tolerance
• First Box: Indicates the feature to
be controlled - Represented
symbolically (Here Concentricity)
• Centre Box: Indicates distance
between two cylinders - Centres
cannot be apart by more than 0.01
mm
• Third Box: Indicates that the
datum is with X
Dimensional & Positional Tolerance
Positional Tolerance
Ref:- [Link]
tolerancing_what-is-the-position-tolerance/
Geometric Tolerance
• First Box: Indicates the feature to be controlled -
Represented symbolically (Here Concentricity)
• Centre Box: Indicates distance between two
cylinders - Centres cannot be apart by more than
0.01 mm
• Third Box: Indicates that the datum is with X
Geometric Tolerancing Characteristics
Geometric Tolerance - Modifiers
Limits and Fits
There are three basic types of fits.
1. Clearance fit – The largest permitted shaft diameter is smaller than the
diameter of the smallest hole
2. Interference fit – The minimum permitted diameter of the shaft is larger
than the maximum allowable diameter of the hole
3. Transition fit – The diameter of the largest allowable hole is greater than
that of the smallest shaft but the smallest hole is smaller than the largest
shaft
Clearance Fit
Interference Fit
Transition Fit
Hole & Shaft Basis System
1. Clearance fit – The largest permitted
shaft diameter is smaller than the
diameter of the smallest hole
2. Interference fit – The minimum
permitted diameter of the shaft is
larger than the maximum allowable
diameter of the hole
3. Transition fit – The diameter of the
largest allowable hole is greater than
that of the smallest shaft but the
smallest hole is smaller than the
largest shaft
Upper Deviation
• Upper Deviation : It is the algebraic
difference between the maximum size
and the basic size. The upper deviation
of a hole is represented by a symbol ES
(Ecart Superior) and of a shaft, it is
represented by es.
FOR SHAFT
Lower Deviation
• Lower Deviation : It is the algebraic difference between the minimum size and the
basic size. The lower deviation of a hole is represented by a symbol EI (Ecart
Inferior) and of a shaft, it is represented by ei.
Tolerance, Allowance and Deviation
Fundamental Deviation & Tolerance
• Fundamental Deviation - It is the difference between the zero line and the limit that is nearest to the zero
line (Capital letters denote hole and small letters denote shaft)
• Fundamental Tolerances (Grade Tolerances) – It indicates the degree of accuracy of manufacture. In ISO
system there are 18 Grade Tolerances. It is denoted by IT01,IT0 and IT1, IT2, IT3, …., IT16
IT – International Tolerance grade
Fundamental Deviation & Tolerance
• Fundamental Deviation - It is the difference between the zero line and the limit that is nearest to the zero
line (Capital letters denote hole and small letters denote shaft)
• Fundamental Tolerances (Grade Tolerances) – It indicates the degree of accuracy of manufacture. In ISO
system there are 18 Grade Tolerances. It is denoted by IT01,IT0 and IT1, IT2, IT3, …., IT16
IT – International Tolerance grade
Hole - Deviations
• The term “Hole” is used to describe an internal feature of
a workpiece including features which are not cylindrical
• The fundamental deviations are represented as A, B, C,
CD, E, EF, F, FG, G, H, J, JS, K, M, N, P, R, S, T, U, V, X, Y,
Z, ZA, ZB, ZC. (to avoid confusion I, L, O, Q, W are not
used)
• For shafts ‘A’ to ‘G’ the deviation is above zero line and
for ‘M’ to ‘ZC’ the deviation is below zero line.
Shaft - Deviations
• The term “Shaft” is used to describe an external feature of a
workpiece including features which are not cylindrical
• The fundamental deviations are represented as a, b, c, cd, e, ef,
f, fg, g, h, j, js, k, m, n, p, r, s, t, u, v, x, y, z, za, zb, zc. (to avoid
confusion i, l, o, q, w are not used)
• For shafts ‘a’ to ‘h’ the deviation is below zero line and for ‘m’
to ‘zc’ the deviation is above zero line
Fundamental Deviation & Tolerance
Tolerance Grades
Grades for basic size up to and including 500mm
Grades for basic size up to and including 500mm
• D is the Geometric Mean of the lower and upper diameters
• 𝑫= 𝑫𝒎𝒂𝒙 × 𝑫𝒎𝒊𝒏
Tolerance Grade - Applications
Problem1
Determine limit dimensions for a clearance fit between mating parts
of diameter 40 mm, providing a minimum clearance of 0.10 mm with
a tolerance on the hole equal to 0.025mm and on shaft 0.05mm using
both systems
Hole Basis System
Basic Size = 40 mm
Lower limit of the hole = 40 mm
Upper limit of the hole = 40 + 0.025 =40.025 mm
Lower limit of the shaft = 40 – 0.1 – 0.05 = 39.85 mm
Upper limit of shaft = 40 – 0.1 = 39.9 mm
Problem1 - Answer
Shaft Basis System
Upper limit of shaft = 40 mm
Lower limit of shaft = 40 – 0.05 = 39.95 mm
Lower limit of hole = 40 + 0.1 = 40.1 mm
Upper limit of hole = 40 + 0.1 + 0.025 = 40.125 mm
Problem2
Calculate the limits of tolerance and allowance for a 25mm shaft and hole pair designated as H8d9
From table we get 𝐷 = 18 and 𝐷 = 30
We have
𝑫= 𝑫𝒎𝒂𝒙 × 𝑫𝒎𝒊𝒏 = 𝟑𝟎 × 𝟏𝟖 = 23.2
𝑖 = 0.45 𝐷 + 0.001𝐷 = 0.45 23.2 + 0.001 × 23.2 = 1.308 microns
For ‘H’ hole the Fundamental Deviation = 0
For H8 hole the Fundamental Tolerance (IT8) = 25i (from table) = 25 x 1.3 = 32.5 = 33 microns
Therefore Hole limits are 25 mm and 25.033 mm
For H8 – Hole of 25mm diameter
For d9 – Shaft of 25mm diameter
Problem2 - Answer
For d shaft the Fundamental Deviation = -65 microns (from table)
For d9 shaft Fundamental Tolerance (IT9) = 40i (from table) = 40 x 1.3 = 52 microns
Therefore
The Upper limit of shaft = 25 – 0.065 = 24.935 microns
The Lower limit of shaft = 25 – 0.065 – 0.052 = 24.883 microns
Tolerance = 24.935 – 24.883 = 0.052 = 52 microns
Problem3
Find the Upper and Lower Limit of the shaft and
hole system designated as 25 H7/g6
Basic Size = 25 mm
H7 is the Hole base system with Standard
Tolerance grade IT7
g6 is the Shaft base system with Standard
Tolerance grade IT6
Answer
From table we get the tolerance for hole (H7) = 21µm = 0.021mm (Std. Tolerance
IT7)
The Fundamental Deviation (FD) for hole = 0 mm
The Lower Limit = Basic Size + FD = 25 + 0 = 25 mm
The Upper Limit = Basic Size + FD + Tolerance = 25 + 0 + 0.021 = 25.021 mm
Answer
From table we get the tolerance for shaft (g6) = 13µm = 0.013mm (Std. Tolerance
IT6)
The Fundamental Deviation (FD) for g6 hole = -0.007 mm
The Upper Limit = Basic Size + FD = 25 + -0.007 = 24.993 mm
The Lower Limit = Basic Size + FD - Tolerance = 25 + -0.007 - 0.013 = 24.98 mm
Interchangeability
• In mass production components are manufactured in one or more
batches by different persons, different machines at different locations
and are assembled at one place
• Manufacture of parts under such conditions is called interchangeable
manufacture
• Any one component selected at random should assemble with any other
arbitrarily chosen component. It is called Interchangeability
Selective Assembly
• Sometimes it is not possible to manufacture parts to the required high
degree of accuracy for their correct functioning
• They are made in an economic manner, measured to the required
accuracy and graded or sorted into groups.
• The groups contain parts of which is within close limits
• These are assembled with mating parts which have been similarly graded
Gauges
• A gauge is a tool or instrument to measure
or compare a component
• It is used to determine whether the size of
some component exceeds or is less than the
gauge itself
• It is manufactured & checked with reference
to a standard length.
Gauges
• The true value of a gauge is measured by its accuracy & service
life which in turn depends upon the workmanship & materials
used in its manufacture
• Gauges are continually subject to abrasive wear while in use, so
the selection of proper material is of great importance
• High carbon steel & alloy steels have been the principal materials
for manufacturing gauges
Advantages of Gauges
• Faster checking regarding whether the product is within its specified
limit or not can be done
• Less dependent on operator skill and hence the result are not getting
affected by operator judgement
• More than one dimension of the product can be checked at a time as
well as properties like roundness, taper etc. can be checked at a time
• Gauges are economical than measuring instruments
Limitations of Gauges
• Exact value of product dimension cannot be obtained
• Accuracy of gauges is getting affected due to wear and tear with passage
of time
• It is useful only for smaller products because it is difficult to
manufacture and maintain large size gauges
Classification of Gauges
Gauges
Form of
Type Purpose Design
Tested Surface
Classification of Gauges – According to Type
• If a gauge is an exact copy of
mating part of the component to be
Type of
checked, it is called Standard gauge
Gauges
Standard Limit Indicating
Gauge Gauge Gauge
Limit Gauge
• If a gauge is checking the limit of
dimensions of a part (Lower Limit &
Upper Limit), it is called Limit Gauge (GO Limit
Gauge
& NO-GO Gauge)
• GO gauge should pass through or over a Plug Ring Snap
part while NOT-GO gauge should not Gauge Gauge Gauge
pass through or over the part FOR FOR SHAFTS
HOLES
Limit Gauge
• If a gauge is checking the limit of dimensions of a part (Lower Limit & Upper
Limit), it is called Limit Gauge (GO & NOT-GO Gauge)
• GO gauge should pass through or over a part while NOT-GO gauge should not
pass through or over the part
Limit Gauge
• The Minimum Material Condition is
checked by NOT-GO and Maximum
Material Condition is checked by GO
gauge
PLUG GAUGES
• Plug gauges are limit gauges used
for checking holes
• It consists of two cylindrical wear
resistant plugs
Ring Gauge
• A ring gauge consists of a piece of
metal in which a hole of required size
is bored
• They are used for gauging shafts
• They are used in a similar manner to
that of GO & NO GO plug gauges
Snap Gauge
• It consists of a plate or frame with a parallel
faced gap of the required dimension
• It can be used for both cylindrical as well as
flay surfaces whereas ring gauges can only be
used in cylindrical surfaces
• Double ended snap gauges can be used for
sizes ranging from 3 to 100 mm
• For sizes from 100 mm to 250 mm single
ended progressive type gauge may be used
Feeler Gauge
• It is a tool used to measure gap widths
• It consists of a narrow strip of steel sheet
made to a given thickness
• Work on sense of feel
• It should neither be be forced into nor it
slide freely
• Each blade is marked with the distance
Slip Gauge (Gauge Block)
• Gauge blocks come in sets of blocks of
various lengths, along with two wear
blocks, to allow a wide variety of standard
lengths to be made up by stacking them.
• Each gauge block consists of a block of
metal or ceramic with two opposing faces
precisely flat and parallel, a precise distance
apart.
Slip Gauge (Gauge Block)
• Standard gauge blocks are made of a hardened
steel alloy, while calibration gauge blocks are
often made of tungsten carbide or chromium
carbide because it is harder and wears less.
• Slip Gauges can be classified into:-
1. Grade 2 : It is the workshop grade
2. Grade 1 : It is used for more precise work
3. Grade 0 : It is the inspection grade, which is
used for tool room and machine shop
inspection
4. Grade 00 : It is kept in the Standard Room
and would be kept for highest precision work
only
5. Calibration grade : The slip gauges are
calibrated using this gauges. They are not as
expensive as Grade 00
Slip Gauge - Wringing
• It is the process of sliding two blocks together so that
their faces lightly bond.
• Air pressure applies pressure between the blocks
because the air is squeezed out of the joint.
• Molecular attraction occurs when two very flat surfaces
are brought into contact.
• This force causes gauge blocks to adhere even without
surface lubricants, and in a vacuum.
Wringing – The Process
The process of wringing involves four steps:
1. Wiping a clean gauge block across an oiled pad.
2. Wiping any extra oil off the gauge block using a dry pad.
3. The block is then slid perpendicularly across the other
block while applying moderate pressure until they form a
cruciform.
4. Finally, the block is rotated until it is inline with the other
block.
Dial Indicator
• It is used to measure small linear
distances with high degree of precision
and accuracy
• The side of the indicator probe shaft is
cut with teeth to provide the rack gear.
• When the probe moves, the rack gear
drives a pinion gear to rotate, spinning
the indicator "clock" hand.
Sine Bar
• Used for angular measurement
• It consists of a hardened, precision ground body
with two precision ground cylinders fixed at the
ends.
• The distance between the centres of the cylinders is
precisely controlled, and the top of the bar is
parallel to a line through the centres of the two
rollers
• The hypotenuse is a constant dimension.
• The height is obtained from the dimension between
the bottom of one roller and the table's surface.
Classification of Gauges – According to Purpose
• Workshop - Typical uses include setting up
machine tools, positioning milling cutters and
checking mechanical widths.
Purpose
• Inspection - Its use is confined to toolroom or
machine shop inspection.
• Reference - This grade would be kept in the Reference or
Workshop Inspection
Standard Room and would be kept for work of Master Gauges
the highest precision only.
Classification of Gauges – According to Form of Tested Surface
Form
Plug Snap Ring
Gauges Gauges Gauges
Classification of Gauges – According to their Design
Design
Single Limit & Fixed and
Single Ended &
Double Limit Adjustable
Double Ended
Gauges Gauges
Classification of Gauges – According to Design
• Single Limit & Double Limit Gauges
• Single Ended & Double Ended Gauges
• Fixed & Adjustable Gauges
Gauge Tolerance - Guidelines
• Gauge Tolerance for both GO and NOT GO gauges = 10% of work
tolerance
• 10% of gauge tolerance must be added to GO gauges for wear allowance
for work tolerance greater than 0.0875 mm
• The tolerance zone for the GO gauges should be placed inside the work-
limits and tolerance
• The tolerance zone for NOT GO gauges should be placed outside the
work-limits and tolerance
Wear Allowance
• The GO gauges only are subjected to wear due to rubbing against parts
during inspection and hence provision has to be made for the wear
allowance
• Due to wear the size of GO plug gauges is reduced while that of GO snap
gauges is increased.
• 10% of gauge tolerance must be added to GO gauges for wear allowance
for work tolerance greater than 0.0875 mm
• Wear allowance is taken as 10% of gauge tolerance and allowed between
the tolerance zone of the gauge and the Maximum Material Condition
Taylor Principle
• According to Taylor the GO gauges should be full form gauge and it should
be constructed with reference to the geometrical form of the part being
checked (all dimensions in maximum metal condition)
• For GO gauges consider upper limit of the shaft and lower limit of the hole
• NOT GO gauge shall check only one dimension of the work piece at a time
(one dimension in minimum metal condition)
• For NOT GO consider lower limit of the shaft and upper limit of the hole
Materials for Gauges
• Hardness - To resist wear
• Stability - Its size and shape must not change over a period of time
• Corrosion resistance
• Machinability - It must be easily machined into the required shape and
to the required degree of accuracy and surface finish
• Low coefficient of linear expansion
Materials for Gauges
• Heat treated High carbon steel (0.8 to 1% carbon) is used for making
gauges
• For lower thermal expansion a material called Invar, an alloy containing
36% Nickel may be used
• Nickel alloy Elinvar (42% Nickel) has lower thermal expansion coefficient
• Chromium plated gauges have hard surface and it possess abrasion and
corrosion resistance
Problem
Design a general type GO and NO GO gauges for a 40H7/d8 fit. 40mm lies in the diameter range
30 to 50. Show graphically the disposition of gauge tolerance zones relative to the work tolerance
zones. Standard tolerance for IT7 is 16i and IT8 is 25i, where ‘i’ is the standard tolerance unit. The
upper deviation for d shaft is -16D0.44
𝑫= 𝑫𝒎𝒂𝒙 × 𝑫𝒎𝒊𝒏 = 𝟓𝟎 × 𝟑𝟎 = 38.73
𝑖 = 0.45 𝐷 + 0.001𝐷 = 0.45 38.73 + 0.001 × 38.73 = 1.56 microns
For Hole
Fundamental Deviation for H7 = 0 mm
Fundamental Tolerance = 16i = 16 x 1.56 = 24.96 microns
Hole Lower Limit = 40mm
Hole Upper Limit = 40.025 mm
Problem - Answer
For Shaft
Fundamental Deviation for d8 = -16D0.44 = -16 x 38.730.44 = -80 microns
Fundamental Tolerance = 25i = 25 x 1.56 = 39 microns
Shaft Upper Limit = 40 – 0.08 = 39.92 mm
Shaft Lower Limit = 40 – (0.08 + 0.039) = 39.881 mm
Problem - Answer
Plug Gauge
GO gauges are given 1/10th of work tolerance in the tolerance zone and for NOGO it is
given outside the tolerance zone
GO gauge
Since tolerance (25 microns) is less than 0.0875mm, the effect of wear is not considered
Gauge tolerance = 0.025 x 1/10 = 0.0025 mm
Therefore :-
Lower Limit = 40.000 mm
Upper Limit = 40.000 + 0.0025 = 40.0025 mm
Problem - Answer
Plug Gauge – NO GO gauge
Lower Limit = 40 + 0.025 = 40.025 mm
Upper Limit = 40 + 0.025 + 0.0025 = 40.0275 mm
HOLE TOLERANCE
40.025 40.0275 40.025 HOLE
40 40 40.0025
NOGO PLUG GO PLUG
GAUGE
GAUGE
Problem - Answer
Ring Gauge – GO gauge
Upper Limit = 40 – 0.08 = 39.92 mm SHAFT TOLERANCE
Lower Limit = 40 – (0.08 + 0.0039) = 39.9161 mm
39.92 39.9161 39.881 39.92 39.881
Ring Gauge – NOGO gauge
39.8771
SHAFT
Upper Limit = 40 – (0.08 + 0.039) = 39.881 mm
Lower Limit = 40 – (0.08 + 0.039 + 0.0039) = 39.8771 mm
GO RING NOGO
GAUGE RING
GAUGE
Problem - Plug and Ring Gauges
Basic Size
0.080 mm
NOGO
GO
Tolerance = 0.025 Tolerance = 0.039
GO
Basic Size
NOGO
Plug Gauge Ring Gauge
Assignment - 2
1. Explain Machine Vision used in manufacturing processes
2. Explain various methods of evaluating surface roughness and all terms used in it
3. Explain the terminology of screw threads and explain the measuring technique
4. With the help of a figure explain the working of a CMM. Also explain various probs
used in it
5. Explain the principle of measurement by light wave interference method. Also explain
the working of a Laser Interferometer