MR7002 - MECHATRONICS ELEMENTS

IN METROLOGY AND CNC

UNIT I FUNDAMENTALS CONCEPTS
IN METROLOGY
Introduction to Metrology
NEED FOR MEASUREMENT
To determine the true dimensions of a part.
To increase our knowledge and understanding of the world.
To ensure public health and human safety.
To convert physical parameters into meaningful numbers.
To evaluate the performance of a system.
To study some basic laws of nature.
To check limitations of theory in practical situations.
To establish the validity of design and for finding new data
and new designs.

Functional elements of an instrument
system
Variable
Manipulation
element
Variable
conversion
element
Primary
sensing
element
Data
processing
element
Data
presentation
element
Physical variable
to be measured
Observer
Input
signal
Accuracy vs Precision
Slip Gauges
Slip Gauges
Slip Gauges are used for measuring blocks. It is
also called as precision gauge blocks.
Classification of slip gauges:
o Grade 2
o Grade 1
o Grade 0
o Grade 00
o Calibration Grade

Angular measurements
Sine Bar
VARIOUS TYPES OF SINE BAR
Classification of sine bar:
Acc. to the accuracy of centre distance
(Grade A and Grade B)
Acc. to availability of different designs
(Type 1, Type 2, Type and Type 4)

Principle of Sine Bar
Locating any work to a given height Measurement of unknown angles for heavier components
To check the unknown angles Measurement of unknown angles for heavier components
VERNIER BEVEL PROTRACTOR
Least count= One main scale reading / No. of divisions on vernier scale
= 1
0
/ 12
= 1 / 12 * 60
= 5 min

Universal Bevel Protractor
Optical Bevel Protractor
Applications of Bevel Protractor
Autocollimator
Auto-collimator is an optical instrument used for the
measurement of small angular differences, changes or deflection,
plane surface inspection etc., For small angular measurements,
auto-collimator provides a very sensitive and accurate approach. An
auto-collimator is essentially an infinite telescope and a collimator
combined in to one instrument.
Autocollimator
Angle Dekkor
Angle Dekkor
FORM MEASUREMENT

Form measurement includes screw
thread measurement, gear measurement,
radius measurement, surface finish
measurement, straightness measurement,
flatness and roundness measurements.
MEASUREMENT OF SCREW THREADS
SCREW THREAD TEMINOLOGY
SCREW THREAD TEMINOLOGY
Screw thread
Crest
Flank
Root
Lead
Pitch
Helix angle

Flank angle
Depth of thread
Included angle
Major diameter
Minor diameter
Addendum
Dedendum
Measurement of Various Elements of
Thread
Major diameter
Minor diameter
Effective or Pitch
diameter
Pitch
Thread angle and form

Measurement of major diameter
Ordinary micrometer gauge setting
Bench micrometer
Ordinary micrometer gauge setting
Bench micrometer
Measurement of Minor Diameter
Measurement of minor Diameter of
internal thread

Using Taper parallels
Using Rollers


Taper parallels
Rollers
Measurement of Effective Diameter
One wire Method
Two wire Method
Three wire Method
One wire Method
Two wire Method
Three wire Method
Three wire Method
Thread Measuring Machine
Effective diameter measurement by thread
micrometer
Pitch Measurement
Pitch measuring machine
Tool makers microscope
Pitch Measuring Machine
Tool Makers Microscope
PLUG GAUGE
Gear Terminology
TOOTH MEASUREMENT
PROFILE MEASUREMENT
TOOTH THICKNESS MEASUREMENT
Using Gear tooth vernier
Base Tangent Method
Constant chord Method
GEAR TOOTH VERNIER
Base Tangent Method
Constant chord Method
PARKINSON GEAR TESTER
RADIUS MEASUREMENT
Radius of circle
Radius of concave surface
Radius of circle
RADIUS OF CONCAVE SURFACE
Edges are well defined
Edges are rounded up
Edges are well defined
Edges are rounded up
SURFACE FINISH MEASUREMENT
First order irregularities lack of straightness
of guide ways
Second order irregularities - vibrations
Third order irregularities - machining
Fourth order irregularities improper
handling
Analysis of surface finish
The average roughness method
Peak to valley height method
Form factor
Average roughness measurement
Centre line average (CLA)
Root mean square (RMS)
Ten point method
Centre line average (CLA)
method
Root mean square (RMS)
Ten point method
Peak to valley height method
Form factor
Direct Instrument Measurements
Stylus probe type instruments
Tomlinson surface meter
Profilometer
Taylor-Bobson-Talysurf
Stylus probe type instruments
Tomlinson surface meter
Profilometer
Taylor-Bobson-Talysurf
Profilograph
STRAIGHTNESS MEASUREMENT
Test for straightness - Autocollimator
ROUNDNESS MEASUREMENT
Diametral gauge
Circumferential confining gauge
Rotating on centers
V-block
Three point probe
Accurate spindle
Circumferential confining gauge
Rotating on centers
V-block
Three point probe
Accurate spindle
Tool Wear measurement
The tool wear monitoring methods can be
classified into two categories:
Direct monitoring methods
Indirect monitoring methods

DIRECT MONITORING METHODS

With direct methods it is possible to
determine tool wear directly, which means
that these methods really measure tool wear
as such by means of tool images, computer
vision, etc.. Direct visual inspection of the
cutting edge during machining is not feasible
because the workpiece and chips obstruct the
view.
INDIRECT MONITORING METHODS

Sensors are needed in these systems to identify
unexpected failure. Sensory systems are increasingly
playing a pivotal role in the realization of advanced
automated manufacturing systems. However, it is difficult
to decide on the best parameters to measure and the
analysis methods to adopt for the system are under
investigation. The cost of the sensory system is another
important consideration and should be accounted for
while designing an industrial monitoring system.

Torque, Drift force, and feed force
Vibration and sound
Acoustic emission and ultrasonic vibration
Spindle motor and feed drive current