University of Engineering and Technology, Lahore

(CEP)
Submitted to:

Eng.Tanveer Mukhtiar

Submitted by:

Awais Wahab 2020-ME-519

Taimoor Aslam 2020-ME-502

Ali Naqi 2020-ME-512

Subject:

Metrology and quality assurance

Metrology plays a vital role in many aspects of modern life, from ensuring the accuracy of medical
equipment to maintaining the quality of consumer products. It includes a wide range of
measurements, from length, mass, and temperature, to more specialized areas such as electrical,
optical, and time and frequency metrology.

One of the fundamental aspects of metrology is the development of international standards for
measurement. These standards help ensure that measurements made in different parts of the
world are consistent and accurate. The International System of Units (SI) is the most widely used
system of measurement, and it is based on the seven base units of measurement, including the
meter for length, the kilogram for mass, and the second for time.

Metrology and quality Assurance

Metrology and quality assurance are closely related. Quality assurance is the process of ensuring
that a product or service meets the required standards of quality. Metrology is an important
aspect of quality assurance, as it involves the measurement of various parameters that determine
the quality of a product or service.

In manufacturing industries, metrology plays a critical role in ensuring that products meet the
required specifications and standards. Accurate and precise measurements are essential for
ensuring that products are consistent, reliable, and safe. Metrology techniques, such as statistical
process control (SPC), are used to monitor the manufacturing process and ensure that it is
producing products within the required tolerance limits.

In addition to manufacturing, metrology is also important in other industries, such as healthcare

and environmental monitoring. In healthcare, metrology is used to ensure the accuracy of
medical devices and instruments, such as blood glucose monitors and blood pressure cuffs. In
environmental monitoring, metrology is used to measure pollutants, radiation levels, and other
environmental factors.

On-Machine Measurement System (OMMS)

On-machine measurement systems (OMMS) are metrology systems that are integrated directly
onto a machine tool, allowing measurements to be taken during the machining process. The
advantage of OMMS is that they can provide real-time feedback to operators, allowing them to
adjust the machining process as needed to improve quality and accuracy.
OMMS typically use non-contact measurement techniques such as laser or vision-based systems
to capture data on the workpiece. This data can be used to measure features such as dimensions,
form, and surface roughness. The measurement data can then be compared to a CAD model or
other reference data to determine if the part is within tolerance.

Figure 1 On-machine surface measurement system configuration on an ultraprecision turning

machine

One advantage of OMMS is that they can reduce the need for off-machine measurements and
inspections, which can save time and reduce the risk of errors. OMMS can also reduce scrap and
rework by catching errors earlier in the process.

However, OMMS do have some limitations. They may not be suitable for all machining operations
or all types of features.

Co-ordinates Measuring Machine (CMMs)

Coordinate measuring machines (CMMs) are metrology systems that use a probe to measure
the physical coordinates of a part. The probe is typically moved across the surface of the part in
a series of predefined paths, and the measurements are recorded and compared to a CAD
model or other reference data to determine if the part is within tolerance.
CMMs are capable of measuring a wide range of features, including dimensions, form, and
surface roughness. They are often used in industries such as aerospace, automotive, and medical
device manufacturing where high accuracy and precision are required. CMMs come in a variety
of sizes and configurations, including bridge, gantry, and portable models. They can use different
types of probes, including touch-trigger, scanning, and optical probes, depending on the specific
application and measurement requirements.
One advantage of CMMs is their high accuracy and precision. They are capable of measuring
features with sub-micron accuracy, making them suitable for applications where tight tolerances
are required. CMMs can also be used to measure complex geometries that may be difficult or
impossible to measure with other types of metrology equipment.

Figure 2 Co-ordinates measuring machine (CMMs)

However, CMMs also have some limitations. They are typically slower and more expensive than
other types of metrology equipment, and they may not be suitable for all types of parts or
features. CMMs also require a controlled environment to maintain their accuracy, which may not
be practical in all manufacturing settings.

When selecting a CMM, it is important to consider factors such as the required accuracy, the size
and complexity of the parts being measured, and the specific features that need to be measured.
It may also be necessary to perform a validation study to ensure that the CMM is providing
accurate and consistent measurements.

Accuracy Demonstration
To demonstrate the accuracy of on-machine measurement systems (OMMS) compared to
coordinate measuring machines (CMMs), it is important to carefully select the measuring
parameters that will be used for the comparison. The measuring parameters should be relevant
to the specific machining operation and part features being measured, and should be chosen
based on their sensitivity to measurement errors.
For example, if the machining operation involves milling a flat surface, the measuring parameters
might include surface flatness, parallelism, and surface roughness. For a cylindrical feature such
as a bore, the measuring parameters might include diameter, cylindricity, and roundness. Other
measuring parameters could include feature position, orientation, and profile. Once the
measuring parameters have been selected, the accuracy of the OMMS and CMM can be
evaluated using a test part or parts with known dimensions and features. The parts should be
measured multiple times using both the OMMS and CMM, and the measurements should be
compared to the known values to determine the accuracy of each system.

It is important to ensure that the measuring parameters are being measured consistently and
accurately by both the OMMS and CMM. This may require calibration of the metrology
equipment, adjustment of the measuring parameters, or modification of the measurement setup
to ensure that the same feature points are being measured by both systems. The results of the
comparison should be analysed to determine the relative accuracy of the OMMS and CMM for
each measuring parameter. This analysis can help identify any limitations of the OMMS, such as
a reduced accuracy for certain types of features or surfaces.

Bevel protector
A bevel protector, also known as a bevel gauge or bevel protractor, is a tool used to measure and
set angles on workpieces in various industries such as metalworking, woodworking, and
construction. It consists of a base plate with a protractor head that pivots on the base plate,
allowing the user to set and measure angle. Bevel protectors come in a range of sizes and styles,
with some having digital readouts for increased accuracy and ease of use. They are used for a
variety of applications such as setting the angle of saw blades, adjusting the angle of meter cuts,
and aligning machines and equipment.

Figure 4 Bevel protector

Workpiece 01
Dimensions
 Figure 6 Work-piece 01

Table 1 Work-piece 01 Dimensions

Length 151 mm

Width 79 mm

Height 37 mm

Thickness 1.75 mm

Workpiece 02
Dimensions

Figure 7 Work-piece 02

Table 2 Work-piece 02 dimensions

 Length 120mm

width 36mm

thickness 5mm

Workpiece 03
Dimensions

Figure 8 Work-piece 03

Table 3 Work-piece 03 dimensions

Length 99mm

width 36mm

thickness 5mm
Solidworks Dimensioning:

Workpiece 1

Comments
o Overall, the study's findings and recommendations can have practical implications for
improving the quality of machining operations, reducing defects, and increasing
productivity in manufacturing processes. However, the execution of the study and the
accuracy of the results will depend on the quality of the data collected, the suitability of
the selected metrology equipment, and the proficiency of the operators conducting the
measurements.
o Based on the problem statement provided, it appears to be a well-defined investigation
into the metrological control of selected surface types of a mechanical part using various
metrology equipment. The objectives of the study are clearly defined, and the proposed
methods of measurement, including assessing the accuracy of dimensions and the derived
deviation, measuring the profile of a given geometrical workpiece, and identifying
features commonly machined and measured by machine tool cycles, are appropriate for
achieving the stated objectives.