UNIT V Advanced Measuring Instruments

• Introduction - Mechanical Measuring Instruments -

Coordinate Measuring Machine (CMM) - Importance -
Types - Application. Roundness test - Importance - 3
Point Method - Rotational drum method.
• Roughness test - Terms of surface texture - Importance -
Roughness tester. 2D Microhite – Applications.
Metallurgical Instruments – Spectrometer. Laser
interferometer - Laser metrology - Laser interferometer.

Dept of MECH Metrology and Measurements 1

 CO5 Explain general measuring instruments for physical parameters

LO 5.1 : Explain Mechanical Measuring Instruments

LO 5.2 : Explain Various types of Mechanical Measuring Instruments

LO 5.3 : Explain CMM

LO 5.4 : Explain Types of CMM

LO 5.5 : Explain Roundness test

LO 5.6 : Explain 3 Point Method

Dept of MECH Metrology and Measurements 2

List various instruments used in day to day life and engineering field

Scale/ Steel rule

Vernier caliper
Micrometer
Bevel Protractor
Weighing Scale
Measuring Jar
Multimeter
Energy meter
Ammeter
Voltmeter
Pressure Gauge
List various mechanical measuring instruments used in engineering field

Flow Measurement,
Sound Measurement,
Light Measurement,
Temperature Measurement,
CMM,
2D Microhite,
Roughness Tester,
Roundness Tester,
Vibration Measurement,
Optical Metrology and
Laser metrology,
Machine Vision
 Types of Measurement and Instruments Used

Dept of MECH Metrology and Measurements 6

Comparison between conventional and coordinate measuring technology

CONVENTIONAL COORDINATE METROLOGY

METROLOGY
Manual, time consuming alignment Alignment of the test piece not
of the test piece necessary

Single purpose and multi-point Simple adaptation to the measuring

measuring instruments making it test by software
hard to adapt to changing
measuring task
Comparison of measurement with Comparison of measurement with
material measures, i.e., gauge mathematical or numerical value
block
Separate determination of size, form, Determination of size, form, location
location and orientation with and orientation in one setup
different machines using one reference system
 QBD
Select an appropriate measurement instrument for measuring the center point of
the cup holder

CMM
 QBD
Select the appropriate measuring instrument to measure all the dimensions of
the part with an accuracy of 0.001mm (1 Micron).

CMM
 What is CMM?

Dept of MECH Metrology and Measurements 9

 CMM Parts

Dept of MECH Metrology and Measurements 10

 Main structure

• The basic version of a CMM has three axes, along three

mutually perpendicular directions. work volume is
cuboidal.
• A carriage is provided for each axis, which is driven by a
separate motor.
• While the straight line motion of the second axis is guided
by the first axis, the third axis in turn is guided by the
second axis.
• Each axis is fitted with a precision measuring system,
which continuously records the displacement of the
carriage from a fixed reference.
• The third axis carries a probe.

Dept of MECH Metrology and Measurements 11

CMM – Co Ordinate Measuring Machine
CMM

Moving
Bridge type

Cantilever
type
Fixed
bridge type

Types of CMM
CMM – Co Ordinate Measuring Machine
CMM

Column
type

Horizontal
Arm type Gantry
type

Types of CMM
Cantilever type

• A vertical probe moves in the z-axis

• Carried by a cantilevered arm that
moves in the y-axis
• This arm also moves laterally through
the x-axis
• Advantage- a fixed table allows good
accessibility to the workpiece
• Disadvantage- the bending caused by
the cantilever design
• The cantilever design offers a long table
with relatively small measuring ranges
in the other two axis.
• Suitable for measuring long, thin part
Moving bridge type

• Most widely used

• Has stationary table to support
workpiece to be measured and a
moving bridge
• Disadvantage- with this design, the
phenomenon of yawing (sometimes
called walking) can occur- affect the
accuracy
• Advantage- reduce bending effect
 Fixed bridge type

• In the fixed bridge configuration, the bridge is rigidly

attached to the machine bed
• This design eliminates the phenomenon of walking and
provides high rigidity
Column type

• Often referred to as universal measuring

machine instead of CMM
• The column type CMM construction
provides exceptional rigidity and accuracy
• These machines are usually reserved for
gage rooms rather than inspection
Horizontal arm type

• Unlike the previous machines, the

basic horizontal arm-type CMM
• Also referred to as layout machine
• Has a moving arm, and the probe is
carried along the y-axis
• Advantage- provides a large area,
unobstructed work area
• Ideal configuration for measurement
of automobile parts
 Gantry type

• The support of workpiece is independent of

the x and y axes, both are overhead,
supported by four vertical columns rising
from the floor
• This setup allows you to walk along the
workpiece with the probe, which is helpful
for extremely large pieces
 Portable CMM

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Gantry configuration with dual linear motor drives, laser scales an online
compensation
Other
configuration
MODES OF OPERATION

• Manual
• Manual computer assisted
• Motorized computer assisted
• Direct computer controlled
 CMM Controller

Dept of MECH Metrology and Measurements 24

 CMM Features

Dept of MECH Metrology and Measurements 25

 CMM Features

Dept of MECH Metrology and Measurements 26

 Probing System

Dept of MECH Metrology and Measurements 27

 Stylus modules

Dept of MECH Metrology and Measurements 28

 Probe tip correction

Dept of MECH Metrology and Measurements 29

TYPES OF PROBES

• Two general categories

1. Contact (see figure)
• Touch-trigger probe
• Analog scanning probe
2. Noncontact
For inspection of printed circuit
board, measuring a clay of wax
model, when the object being
measured would be deformed by
the for of stylus
• laser probes
• video probes
 Contact probes

1. Touch trigger probe

• As the sensor makes contact with the part, the difference in contact
resistance indicates that the probe has been deflected
• The computer records this contact point coordinate space
• An LED light and an audible signal usually indicate contact
• Touch probe assemblies consist of three components; probe head,
probe and stylus
2. Analog scanning probe
• Use to measure contour surfaces, complex, irregular
• Remains in contact with the surface of the part as it moves
• Improve the speed and accuracy
Non-contact probe

1. Laser scanning probe

• Laser probes project a light beam onto the surface of a part
• When the light beam is triggered, the position of beam is read by
triangulation through a lens in the probe receptor
• Laser tool have a high degree of speed and accuracy
2. Video probe
• The feature are measured by computer ‘count’ of the pixels of the
electronic image
• The camera is capable of generating multitude of measurements
points within a single video frame
Probe head, probes and stylus
Multiple shapes of sylus
CMM software

• The programming of the machine or the software of the

system enables the CMM to reach its full potential for
accuracy, precision and speed
• Contour programs allow the CMM to quickly define
detailed, complex non-geometric shapes such as gear,
cams, and injection molds
• These programs also can be used to compare the
measurement data with a computer assisted drafting
(CAD) model
CMM software (cont’)

• Generally software packages contains some or all of the following

capabilities:
• Resolution selection
• Conversion between SI and English (mm and inch)
• Conversion of rectangular coordinates to polar coordinates
• Axis scaling
• Datum selection and reset
• Circle center and diameter solution
• Bolt-circle center and diameter
• Save and recall previous datum
• Nominal and tolerance entry
• Out-of tolerance computation
Coordinate System

• A coordinate allows the CMM to locate features on a

workpiece relative to other features
• The coordinate system is similar to a three-dimensional
map, providing direction and location
• Each machine has a ‘home’ position (an origin) and x, y
and z axes identify location that represents the
machine coordinate system (MCS)
• A manufactured past can also have a part coordinate
system (PCS)
Importance of CMM in metrology
• Co-ordinate Measuring Machines are built rigidly and are very
precise.

• They are linked to computers for online inspection of parts.

• Measurement of diameter, center distances, lengths, geometrical
and form errors in prismatic components, etc.

• Data communications and Interface to CAD software

• They are made more rugged to resist environmental effects in
manufacturing plants such as temperature variations, vibration and
dirt.

• To give maximum rigidity to machines without excessive weight

 CMM Applications

Dept of MECH Metrology and Measurements 39

CO5: Explain advanced measuring instruments

LO 5.4 : Explain Roundness test

SO 5.4.1 : Define Roundness

SO 5.4.2 : Explain the importance of roundness in the

function
of a part/ component

SO 5.4.3 : List the methods of checking the roundness of the

component (3 Point Method, Rotational drum
method, CMM)
Demonstration
Fit and move down the piston
inside the cup (Oval cup) of
sevai m/c assembly.

Roundness

Roundness is the measure

of how closely the shape of
an object approaches that
of a perfect circle
 QBD
Importance of
Roundness
The roundness of a component could have
an effect on
Fuel
leakage
Oil Excessive
retention vibration

Affects many
Oil critical
disbursement functions of the
Friction final assembly
 Measuring Roundness

Dept of MECH Metrology and Measurements 43

 Roundness

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Discussion 3- Point
Roundness checking Method
methods (V Block
Method)
Rotational drum
method

3- Point Method (V Block Method)

Rotational drum method
 Roundness Measurement

Dept of MECH Metrology and Measurements 46

 ways of measuring roundness

Dept of MECH Metrology and Measurements 47

 ways of measuring roundness

for example measurement of a

cylinder bore using this method
would not require rotation of the
complete engine block.

Dept of MECH Metrology and Measurements 48

 V block method
• The set up employed for assessing the circularity error by using
V Block is shown in fig.

• The V block is placed on surface plate and the work to be

checked is placed upon it.
• A diameter indicator is fixed in a stand and its feeler made to
rest against the surface of the work.

Dept of MECH Metrology and Measurements 49

 V block method
• The work is rotated to measure the rise on fall of the workpiece.
• For determining the number of lobes on the work piece, the
work piece is first tested in a 60° V-Block and then in a 90° V-
Block.
• The number of lobes is then equal to the number of times the
indicator pointer deflects through 360° rotation of the work
piece.

Dept of MECH Metrology and Measurements 50

 Rotational Datum Method

• The most accurate method for determining roundness of a

component is to measure the variation of radius from an
accurate rotational datum using a scanning probe (one
that remains in contact with the surface and collects a
high-density of data points).
• A circle can then be fitted to this data and the roundness
calculated from knowledge of the component centre.
• There are many dedicated instruments made for the
measurement of roundness
• The most common configuration is a system that contains
a rotating table onto which the component is mounted.

Dept of MECH Metrology and Measurements 51

 Rotational Datum Method

• A gauge is mounted on a radial arm, which can be

adjusted to bring the gauge into contact with the
component.
• The arm itself is mounted on a column that permits the
height of the measurement plane to be adjusted.
• The linear axes of such instruments are often motorised
and of high form accuracy enabling the instrument to be
used to measure other parameters such as flatness,
straightness and cylindricity.

Dept of MECH Metrology and Measurements 52

 Roundness error

Dept of MECH Metrology and Measurements 53

 Surface texture

• When we are producing components by various

methods of manufacturing process it is not possible to
produce perfectly smooth surface and some irregularities
are formed.

• These irregularities are causes some serious difficulties

in using the components.

• So it is very important to correct the surfaces before use.

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Importance of surface finish

Functioning
Resistance to wear
Load carrying capacity
Tool life(while cutting)
Resistance to corrossion
Resistance to fatigue
Ability to hold pressure
Noise reduction(in gears)

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 Roughness

Roughness is a measurement of the small-scale

variations in the height of a physical surface. It
consists of surface irregularities which result from the
various machining process. These irregularities
combine to form surface texture.
This is in contrast to large-scale variations, which may
be either part of the geometry of the surface or
unwanted 'waviness'.

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 Factors affecting Surface roughness

•The factors which are affecting surface roughness are

•1. Work piece material
•2. Vibrations
•3. Machining type
•4. Tool, and fixtures

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Geometrical Irregularities

The geometrical irregularities can be classified as

1. First order
2.Second order
3 Third order
4.Fourth order

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 Geometrical Irregularities

1. First order irregularities:

These are caused by lack of straightness of guide ways on which tool
must move.
2. Second order irregularities:
These are caused by vibrations
3. Third order irregularities:
These are caused by machining.
4. Fourth order irregularities:
These are caused by improper handling machines and equipments.

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Roughness Parameters

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 •Elements Of Surface Texture
•1.Profile: - Contour of any section through a surface.
•2.Lay: - Direction of the ‘ predominate surface pattern’
produced by scrathes.
•3. Flaws: - Surface irregularities or imperfection, which occur
at infrequent intervals.
•4.Actual surface: - Surface of a part which is actually
obtained,
•5. Roughness: - Finely spaced irregularities. It is also called
primary texture.
•6.Sampling lengths: - Length of profile necessary for the
evaluation of the irregularities.

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7. Waviness: - Surface irregularities which are of greater spacing
than roughness.
8. Roughness height: - Rated as the arithmetical average deviation.
9. Roughness width: - Distance parallel to the normal surface
between successive peaks.

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 Analysis of surface finish

The analysis of surface finish being carried out by

1. The average roughness method.
2. Peak to valley height method
3. Form factor

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1.
Average roughness
measurement:
The assessment of average roughness is carried out by
A) Centre line average (CLA).
B) Root mean square (RMS)
C) Ten point method

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a. C.L.A. method:

The surface roughness is measured as the average deviation from the

nominal surface.

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 b. R.M.S. method:
The roughness is measured as the average deviation from the
nominal surface.
Let, h1,h2, ... are the heights of the ordinates and L is the sampling
length.

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 Ten point height method:
The average difference between five highest peaks and five lowest
valleys of surface is taken and irregularities are calculated by

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 Peak to valley height method:
Peak to valley height measures the maximum depth of the surface
irregularities over a given sample length and largest value of the depth
is accepted for the measurement.
Rmax = Maximum peak to valley height in one sampling
V=Valley
P = Peak
Rt= Peak to valley height with in the assessment length
Here, Rt is the maximum peak to valley height within the assessment
length.

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Peak to valley height method:

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 3. Form factor:
It is obtained by measuring the area of material above the
arbitrarily chosen base line in the section and the area of the
enveloping rectangle.

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Methods of measuring surface finish
The methods used for measuring the surface finish is classified into
1. Inspection by comparison
2. Direct Instrument Measurements

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1. Inspection by comparison methods:
In these methods the surface texture is assessed by observation
of the surface.
The surface to be tested is compared with known value of
roughness specimen and finished by similar machining process.

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• The various methods which are used for
comparison are
•1. Touch Inspection.
•2. Visual Inspection.
•3. Microscopic Inspection.
•4. Scratch Inspection.
•5. Micro Interferometer.
•6. Surface photographs.
•7. Reflected Light Intensity.
•8. Wallace surface Dynamometer.

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Inspection by comparison
methods:
•1. Touch Inspection
•It is used when surface roughness is very high and in this method
the fingertip is moved along the surface at a speed of 25mm/second
and the irregularities as up to 0.0125mm can be detected.
•2. Visual Inspection:
•In this method the surface is inspected by naked eye and this
measurement is limited to rough surfaces.
•3. Microscopic Inspection:
•In this method finished surface is placed under the microscopic and
compared with the surface under inspection. The light beam also
used to check the finished surface by projecting the light about 60°
to the work.

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Inspection by comparison
methods:
•4. Scratch Inspection:
•The materials like lead, plastics rubbed on surface is inspected by this
method. The impression of this scratches on the surface produced is
then visualized.
•5. Micro-Interferometer:
•Optical flat is placed on the surface to be inspected and illuminated
by a monochromatic source of light.
•6. Surface Photographs:
•Magnified photographs of the surface are taken with different types
of illumination. The defects like irregularities are appear as dark spots
and flat portion of the surface appears as bright.

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 Inspection by comparison
methods:
•7. Reflected light Intensity:
•A beam of light is projected on the surface to be inspected and the
light intensity variation on the surface is measured by a photocell and
this measured value is calibrated
•8. Wallace surface Dynamometer:
•It is a sort of friction meter.
•It consists of a pendulum in which the testing shoes are clamped to a
bearing surface and a pre determined spring pressure can be applied
and then,
•The pendulum is lifted to its initial starting position and allowed to
swing over the surface to be tested. If the surface is smooth, then
there will be less friction and pendulum swings for a long period. Thus
time of sing is the direct measure of surface texture

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 Direct instrument measurements

Direct methods enable to determine a numerical value of the surface

finish of any surface.
These methods are quantitative analysis methods and the output is
used to operate recording or indicating instrument.

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Some of the direct measurement
instruments are

1. Stylus probe instruments.

2. Tomlinson surface meter.
3. Profilometer.
4. Taylor-Hobson Talysurf

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 1. Stylus probe type instrument

Principle:
When the stylus be moved over the surface which is to be
measured, the irregularities in the surface texture is measured and
it is used to assess the surface finish of the work piece.

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Working:
• The stylus type instruments consist of skid, stylus, amplifying device
and recording device.
•The skid is slowly moved over the surface by hand or by motor drive.
•The skid follows the irregularities of the surface and the stylus moves
along with skid.
•When the stylus moves vertically up and down and the stylus
movements are magnified, amplified and recorded to produce a trace.
Then it is analyzed by automatic device.
•Advantage:
•Any desired roughness parameter can be recorded.
•Disadvantages:
•1. Fragile material cannot be measured.
•2. High Initial cost.
•3. Skilled operators are needed to operate.

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 2. Tomlinson Surface meter:
•This instrument uses mechanical-cum-optical means for
magnification.
•Construction:
• In this the diamond stylus on the surface finish recorder is held by
spring pressure against the surface of a lapped cylinder.
• The lapped cylinder is supported one side by probe and other side
by rollers.
• The stylus is also attached to the body of the instrument by a leaf
spring and its height is adjustable to enable the diamond to be
positioned and the light spring steel arm is attached to the lapped
cylinder.
• The spring arm has a diamond scriber at the end and smoked
glass is rest on the arm.

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Working:
•When measuring surface finish the body of the instrument is moved
across the Surface by a screw rotation.
•The vertical movement of the probe caused by the surface
irregularities makes the horizontal lapped cylinder to roll.
• This rolling of lapped cylinder causes the movement of the arm. So
this movement is induces the diamond scriber on smoked glass.
•Finally the movement of scriber together with horizontal movement
produces a trace on the smoked glass plate and this trace is magnified
by an optical projector.

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2D-Micro-Hite

This autonomous measuring instrument is designed for

measuring lengths such as external, internal, step, height or
depth dimensions as well as distances. Its concept also enables
measurements of form and orientation tolerances such as
straightness or perpendicularity errors

A cast-iron base (No. 10) including a hardened stainless steel

plate supports the instrument. Three resting points guarantee
the stability of the height gauge The integrated electric pump
(No. 12) generates the air cushion so that your height gauge
can easily be moved across the granite table

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 Video

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The rigid vertical column under the protective housing (No. 17)
includes the guiding part that is rigorously straight and
perpendicular to the base.
A measuring head slides on the guiding element, while the
optoelectronic measuring
system (patented by TESA) measures any head displacement.
Each height gauge is used with a control panel (No. 14) with
numerous calculation possibilities offering a measuring solution
adjusted to each application

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 Automatic procedure:

The measuring system saves automatically the highest and lowest point. By moving the part,
those points are recorded and the calculated difference gives diameter and position of the
bore.
The manual procedure defines the exact position of the lowest or highest point and then
measure without moving the part, diameter and axis position. After go on contact, keep
pressure, a LED appears on the instrument body. Block the slide and move the part over the
minimum point. An acoustic signal confirms the registered reverse value

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 Applications

Manual measuring instrument with 1 or 2 dimension features

on various geometric elements. The measurement of shafts
and bores can be made by automatic or manual process for
reverse point acquisition. The memory features «max.»,
«min.» and «max.- min.» on dynamic and perpendicularity
measurement allows with digital probe calculation of
straightness, parallelism and axial run out.

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