MODULE- I

Introduction to Metrology:
-Basics of Metrology
-Objectives of Metrology
-process of measurement
-Need of inspection-
-Methods of measurement.
 Introduction to Metrology
• Metrology is a science of measurement. Metrology may be divided depending upon the
quantity under consideration into: metrology of length, metrology of time etc. Depending
upon the field of application it is divided into industrial metrology, medical metrology etc.

• Engineering metrology is restricted to the measurement of length, angles and other

quantities which are expressed in linear or angular terms.

• Definition of Metrology: Metrology is the name given to the science of pure measurements.
For engineering purposes ,it is restricted to measurements of length and angle and quantities
which are expressed in liner or angular terms.

• Definition of measurement: Measurement is a process of comparing quantitatively an

unknown magnitude with a predefined standard.
Objectives of Metrology -
While the basic objective of a measurement is to provide the required accuracy at minimum cost,
metrology would have further objective in a modern engineering plant with different shops like
Tool Room, Machine Shop, Press Shop, Plastic Shop, Pressure Die Casting Shop, Electroplating and
Painting Shop, and Assembly Shop; as also Research, Development and Engineering Department.
In such an engineering organization, the further objectives would be as follows:

1. Thorough evaluation of newly developed products, to ensure that components designed is within
the process and measuring instrument capabilities available in the plant.
2. To determine the process capabilities and ensure that these are better than the relevant
component tolerance.
3. To determine the measuring instrument capabilities and ensure that these are adequate for their
respective measurements.
4. 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 Quality Control Techniques
5. Standardization of measuring methods. This is achieved by laying down inspection methods for
any product right at the time when production technology is prepared.
6. Maintenance of the accuracies of measurement. This is achieved by periodical calibration of the
metrological instruments used in the plant.
7. Arbitration and solution of problems arising on the shop floor regarding methods of
measurement.
8. Preparation of designs for all gauges and special inspection fixtures
[Link] provide the required accuracy at minimum
 Process Of Measurement
• The measurement process in metrology involves several
key stages, including establishing a standard, selecting
appropriate instruments and methods (like direct or
indirect comparison), carefully collecting data,
calibrating instruments, analyzing results, and ensuring
traceability to international standards to maintain
accuracy and reliability.
• This process underpins quality control, supports
manufacturing, and ensures that measurements are
consistent and trustworthy for various applications.
 Need of Inspection-

• Inspection means checking of all materials, products or component

parts at various stages during manufacturing.

• It is the act of comparing materials, products or components with

some established standard. In old days the production was on a
small scale, different component parts were made and assembled
by the same craftsman.

• If the parts did not fit properly at the time of assembly, he used to
make the necessary adjustments in either of the mating parts so
that each assembly functioned properly.

• Therefore, it was not necessary to make similar parts exactly alike

or with same accuracy as there was no need of inspection.
 Thus, the need of inspection can be summarized as:
1. To ensure that the part, material or a component conforms to the established
standard.

2. To meet the interchangeability of manufacture.

3. To maintain customer relation by ensuring that no faulty product reaches the

customers.

4. Provide the means of finding out shortcomings in manufacture. The results of

inspection are not only recorded but forwarded to the manufacturing department for
taking necessary steps, so as to produce acceptable parts and reduce scrap.

5. It also helps to purchase good quality of raw materials, tools, equipment which
governs the quality of the finished products.

6. It also helps to co-ordinate the functions of quality control, production, purchasing

and other departments of the organization.

To take decision on the defective parts i.e., to judge the possibility of making some of
these parts acceptable after minor repairs.
 Methods of Measurement
• These are the methods of comparison used in measurement process. In
precision measurement various methods of measurement are adopted
depending upon the accuracy required and the amount of permissible
error. The methods of measurement can be classified as:
• 1. Direct method
• 2. Indirect method
• 3. Absolute/Fundamental method
• 4. Comparative method
• 5. Transposition method
• 6. Coincidence method
• 7. Deflection method
• 8. Complementary method
• 9. Contact method
• 10. Contactless method etc.
• 1. Direct method of measurement. This is a simple method of measurement, in which the value of
the quantity to be measured is obtained directly without any calculations. For example,
measurements by using scales, vernier calipers, micrometers, bevel protector etc. This method is
most widely used in production. This method is not very accurate because it depends on human
insensitiveness in making judgment.
• 2. Indirect method of measurement. In indirect method the value of quantity to be measured is
obtained by measuring other quantities which are functionally related to the required value. E.g.
angle measurement by sine bar, measurement of screw pitch diameter by three wire method etc.
• 3. Absolute or Fundamental method. It is based on the measurement of the base quantities used
to define the quantity. For example, measuring a quantity directly in accordance with the definition
of that quantity, or measuring a quantity indirectly by direct measurement of the quantities linked
with the definition of the quantity to be measured.
• 4. Comparative method. In this method the value of the quantity to be measured is compared with
known value of the same quantity or other quantity practically related to it. So, in this method only
the deviations from a master gauge are determined, e.g., dial indicators, or other comparators.
• 5. Transposition method. It is a method of measurement by direct comparison in which the value
of the quantity measured is first balanced by an initial known value A of the same quantity, and
then the value of the quantity measured is put in place of this known value and is balanced again
by another known value B. If the position of the element indicating equilibrium is the same in both
cases, the value of the quantity to be measured is√ . For example, determination of a mass by
means of a balance and known weights, using the Gauss double weighing method.
• 6. Coincidence method. It is a differential method of measurement, in which a very small
difference between the value of the quantity to be measured and the reference is determined by
the observation of the coincidence of certain lines or signals. For example, measurement by vernier
caliper micrometer.
7. Deflection method. In this method the value of the quantity to be measured is directly
indicated by a deflection of a pointer on a calibrated scale.

8. Complementary method. In this method the value of the quantity to be measured is combined
with a known value of the same quantity. The combination is so adjusted that the sum of these
two values is equal to predetermined comparison value. For example, determination of the
volume of a solid by liquid displacement.

9. Method of measurement by substitution. It is a method of direct comparison in which the

value of a quantity to be measured is replaced by a known value of the same quantity, so selected
that the effects produced in the indicating device by these two values are the same.

10. Method of null measurement. It is a method of differential measurement. In this method the
difference between the value of the quantity to be measured and the known value of the same
quantity with which it is compared is brought to zero.

11. Contact method. In this method the sensor or measuring tip of the instrument actually
touches the surface to be measured. e.g., measurements by micrometer, vernier caliper, dial
indicators etc. In such cases arrangement for constant contact pressure should be provided to
prevent errors due to excessive contact pressure.

12. Contactless method. In contactless method of measurement, the there is no direct contact
with the surface to be measured. e.g., measurement by optical instruments, such as tool makers
microscope, projection comparator etc.