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Month Week Date Lecture
October
1 01/10/2015 Lecture 1 Prefix: Dimensioning & Tolerancing
2 08/10/2015 Lecture 2 Introduction to Apparatus and Measurement
3 15/10/2015 Lecture 3 Measurement of Length & Internal Diameters
4 22/10/2015 Lecture 4 Measurement using Optics
5 29/10/2015 Lecture 11 Uncertainty in Measurements
November
6 05/11/2015 Lecture 5 Straightness, Flatness and Perpendicularity
7 12/11/2015 Lecture 6 Angle Measurement
8 19/11/2015 Lecture 7 Taper Measurement & Surface Texture
9 26/11/2015 Lecture 8 Radius Measurement & Roundness
December
10 03/12/2015 Lecture 9 Thread Measurement
11 10/12/2015 Lecture 10 Gear Metrology & CMM
12 17/12/2015 Tutorial 1
Assignment Deadline
13 24/12/2015 CHRISTMAS RECESS
January 14 31/12/2015
15 07/01/2016 Tutorial 2
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• Notes / Tutorial Sheets / Lab Sheets will be
uploaded on VLE
• Books: 1. Fundamentals of Dimensional Metrology by C. Dotson
(ISBN: 978-1-4180-2062-0)
2. Handbook of Dimensional Measurement by Curtis,
Farago
(ISBN: 978-0-8311-0204-3)
MFE 2101 – ENGINEERING METROLOGY
• What is Metrology?
• Why Metrology?
• Manufacturing Process Variation
• The Product Development Cycle and Metrology
• Part Dimensioning and Tolerancing
• Conclusion
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• METROLOGY is the science of measurement, and
measurement is the language of science. It is the
language we use to communicate about size, quantity,
position, condition and time.
Grammar Composition Language
Metrology Techniques
Experience Metrology
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Mass Length Time
Egyptian Jewelers' Balance
(circa. 2000BC)
Egyptian Royal Cubit
(circa. 3000BC)
Greek Sun Dial
(circa. 200BC)
MFE 2101 – ENGINEERING METROLOGY
• Time Measurement:
– Stopwatch on Mobile Phones
• Length Measurement:
– Rulers on your desks
• Weight Measurement:
– Weighing scales in kitchens at home
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In real world
applications an
Engineer is often
confronted with
problems which have to
be investigated.
One of the main
resources in the
engineering toolbox is
the science of
Metrology.
Engineer
Metrology
Tools
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• Pen Production
Bottom Part Top Part
Problem: Parts NOT Fitting
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• Parts and problem report are sent to the
engineer responsible for the product.
• The engineer has then to investigate the
problem or problems with these parts.
• The engineer will issue a measurement report
which identifies a number of dimensions which
might be causing the problem.
• Following the receipt of the report, the engineer
will evaluate the findings and propose a solution
to the problem.
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Raw Material 2
Raw Material 1
Raw Material 3
Raw Material n
.
. Customer
Product
Requirements
and Wishes
Product 2
Product 1
Product 3
Product n
.
.
Value Adding Manufacturing
Processes •Milling
•Turning
•Injection Molding
•Assembly
MFE 2101 – ENGINEERING METROLOGY
Plastic Injection Molding Machine CNC Lathe Machine
VIDEOS
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Overall
Length Dim C8
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Need
Conceptual Design
Embodiment Design
Detailed Design
Production
Feedback
Modified phases of the design
process according to French
Metrology
Metrology
Metrology
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• Concept Development:
– Physical Prototype Stage
MFE 2101 – ENGINEERING METROLOGY
• Parts might need to be used for:
– Customer Evaluation
– Initial Testing
• Before parts can be used they have to be
measured to make sure that they meet the
engineering specifications
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• Detailed Product Design
MFE 2101 – ENGINEERING METROLOGY
• Parts might need to be used for:
– Initial Product Runs
– Final Testing
– Shipping to Customer
– Process Qualification
• Before parts can be used they have to be
measured to make sure that they meet the
engineering specifications
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• Production Environment
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• Parts have to be:
– Under Control
• dimensions have to be monitored to ensure there
are no shifts in the manufacturing process
– Fit for use
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What are you going to
measure?
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• The Engineering Drawing or Model defines
the Specification for the Product
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Nominal
Dimension Tolerance
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Plastic Injection Molding Machine CNC Lathe Machine
MFE 2101 – ENGINEERING METROLOGY
Tighter Tolerances
Hig
her
Co
sts
(mm)
(€)
[Simmons & Maguire, 2004]
Units o
f C
ost
Tolerance (mm)
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Shaft
Bearing
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Shaft
Bearing
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Clearance Size-to-Size Interference
3 types of parts are found in production:
Type 2 Type 1 Type 3
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…After taking a closer look at your drawings
Shaft Bearing
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Tolerance Check (Worst Case Scenario)
1. Nominal Condition: (Nominal Bearing) 50.0 - (Nominal Shaft) 50.0 = 0mm
2. Maximum Clearance: (Maximum Bearing) 50.5 - (Minimum Shaft) 49.5 = 1mm
3. Maximum Interference: (MinimumBearing) 49.5 - (Maximum Shaft) 50.5 = -1mm
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Tolerance Check (Worst Case Scenario)
1. Nominal Condition: (Nominal Bearing) 49.75 - (Nominal Shaft) 50.25 = 0.5mm
2. Maximum Clearance: (Maximum Bearing) 50.5 - (Minimum Shaft) 49.5 = 1mm
3. Maximum Interference: (Minimum Bearing) 50 - (Maximum Shaft) 50 = 0mm
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Hook
Hinge
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y = 75±0.5 - 60±0.5
y = 15±1mm
ymin = 14mm
ymax = 16mm
x = 50±0.5 - 19±0.5 – 15±0.5
x = 16±1.5mm
xmin = 14.5mm
xmax = 17.5mm
Possible Interference of 1.5 mm between X min and Y max
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y = 14±0.5mm
ymin = 13.5mm
ymax = 14.5mm
x = 16±0.5mm
xmin = 15.5mm
xmax = 16.5mm
Minimum Clearance of 1 mm between X min and Y max
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• During this lecture we have seen:
– What is Metrology
– Why Metrology
– Manufacturing Process Variation
– The Product Development Cycle and Metrology
– Part Dimensioning and Tolerancing
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MFE 2101 – ENGINEERING METROLOGY
MFE 2101 – ENGINEERING METROLOGY
• Dr Ing. Paul Refalo
– Room 003
– [email protected]