QUESTION 1

[CO1 PO3](C3) DK1-DK3

a) A simple rectangular block is going to be made using milling process according to the
following specification:

Material : Mild Steel

Height : 70 mm
Length : 190 mm
Width : 55 mm

State four (4) reasons why specifications are not enough.

(8 marks)
 The specification seems not comprehensive or not completes & may lead to
discrepancies.

 No machine can manufacture to the diameter & length absolutely. Therefore, diameter
& length must be specified together with their working tolerances. If the shaft is
specified with material, length & diameter alone:

 The diameter comply but the shaft may not be round (roundness)

 The length comply but the shaft may not be straight (straightness, parallelism)

 The surface of the shaft may not constant or may be very rough (roughness)

 Overall specification must be as complete as to meet the functions requirements. It may

include flatness of the end faces etc.

b) A vernier caliper is calibrated by using a set of slip gauges within a range of 0 – 100mm. the
experimental data is tabulated as shown in Table Q1(b) below.

Table Q1(b)
Caliper reading (mm) Slip gauge reading (mm)
0.00 0.00
10.00 10.00
20.02 20.00
29.97 30.00
40.00 40.00
50.00 50.00
59.98 60.00
69.99 70.00
80.01 80.00
90.00 90.00
100.02 100.00

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 i. Plot the calibration graph.
(6 marks)
Caliper reading Slip gauge reading Error (mm)
(mm) (mm)
0.00 0.00 0.00
10.00 10.00 0.00
20.02 20.00 0.02
29.97 30.00 -0.03
40.00 40.00 0.00
50.00 50.00 0.00
59.98 60.00 -0.02
69.99 70.00 -0.01
80.01 80.00 0.01
90.00 90.00 0.00
100.02 100.00 0.02

ii. Find the accuracy of the Vernier calliper.

(3 marks)

Accuracy of the Vernier calliper within range 0- 100mm is +0.02mm and -0.03mm

iii. Find the true value when the calliper reads 56.00mm.
(3 marks)
Error when caliper reading 56.00mm is -0.011mm.
True reading = Measured reading – Error = 56.00 – (-0.011) = 56.011mm .

Therefore, true reading is 56.011mm .

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 QUESTION 2

a) Three block gauges A, B and C have same nominal length of 20mm each are being calibrated
using high magnification comparator. As a result, block A is 0.025mm higher than block B and
0.010mm lower than block C. Combination of the three blocks A, B and C is higher 0.010mm
compared to 60mm standard block gauge. Calculate the exact length of each block A, B and
C.
(8 marks

. (
Lstd = LA + LB + LC - x1 …………………..(1) (
LB = LA – x2 ………………………………..…..(2) (
LC = LA + x3 ………………………………….…..(3) (

Subs eqn (2) and (3)into eqn (1)

Lstd = LA + LB + LC - x1
Lstd = LA + (LA – x2 ) + (LA + x3 ) - x1
Lstd = 3LA – x2 + x3 - x1

𝑳𝒔𝒕𝒔𝒅 + 𝒙𝟐 − 𝒙𝟑 + 𝒙𝟏 (
𝑳𝑨 =
𝟑
Given;
Lstd = 60mm, x1 = 0.010mm, x2=0.025mm, x3=0.010mm

𝟔𝟎 + 𝟎. 𝟎𝟐𝟓 − 𝟎. 𝟎𝟏𝟎 + 𝟎. 𝟎𝟏𝟎

𝑳𝑨 =
𝟑
LA = 20.008mm

LB = LA – x2 = 20.008 – 0.025
LB = 19.983mm

Lc = LA + x3 = 20.008 + 0.010
Lc = 20.018mm

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b) A Taper Plug Gauge calibrated using Taper Diameter Measuring Machine as illustrated in
Figure Q2(b).
Firstly, as shown in measurement setting A, two precision rollers with diameter 10mm are
placed on reference surface, touching taper sides. The distance M1 is 40.696mm obtained
from micrometer reading.
Then, at measurement setting B, the two precision rollers are placed on block gauges and
touching taper sides. The distance M2 is 55.513mm obtained from micrometer reading.

Figure Q2(b)
i. If the size of a taper plug gauge is 31mm ±0.3mm and its taper angle is 15°30’.
Calculate the maximum and minimum height of taper gauge.
(
Given;
Dmax = 31.3mm, Dmin=30.7mm,
Taper angle = 15°30’ = 15.5°
Half of taper,θ = 7.75°
M1 = 40.696mm, M2 = 55.513mm, d = 10mm

𝟗𝟎 − 𝜽
𝑫𝒔 = 𝑴𝟏 − 𝒅 [𝟏 + 𝒄𝒐𝒕 ]
𝟐
𝟗𝟎 − 𝟕. 𝟕𝟓
𝑫𝒔 = 𝟒𝟎. 𝟔𝟗𝟔 − 𝟏𝟎 [𝟏 + 𝒄𝒐𝒕 ]
𝟐
𝑫𝒔 = 𝟏𝟗. 𝟐𝟒𝟑𝒎𝒎

𝑫𝒎𝒂𝒙 = 𝑫𝒔 + 𝟐𝑯𝒕𝒂𝒏𝜽 𝑫𝒎𝒊𝒏 = 𝑫𝒔 + 𝟐(𝑯 − 𝒔)𝒕𝒂𝒏𝜽

𝑫𝒎𝒂𝒙 − 𝑫𝒔 𝑫𝒎𝒊𝒏 − 𝑫𝒔
𝑯= 𝑯−𝒔 =
𝟐𝒕𝒂𝒏𝜽 𝟐𝒕𝒂𝒏𝜽
𝟑𝟏. 𝟑 − 𝟏𝟗. 𝟐𝟒𝟑 𝟑𝟎. 𝟕 − 𝟏𝟗. 𝟐𝟒𝟑
𝑯= (𝟒𝟒. 𝟐𝟗𝟕) − 𝒔 =
𝟐𝒕𝒂𝒏𝟕. 𝟕𝟓 𝟐𝒕𝒂𝒏𝟕. 𝟕𝟓

𝑯 = 𝟒𝟒. 𝟐𝟗𝟕𝒎𝒎 ( 𝒔 = 𝟐. 𝟐𝟎𝟓𝒎𝒎

ii. Calculate the smallest diameter Ds for a taper plug gauge.

(2 marks)
𝑫𝒔 = 𝟏𝟗. 𝟐𝟒𝟑𝒎𝒎

5
iii. Calculate the height of block gauge, h.
(2 marks)
𝑴𝟐 − 𝑴𝟏
𝒕𝒂𝒏𝜽 =
𝟐𝒉
𝟓𝟓. 𝟓𝟏𝟑 − 𝟒𝟎. 𝟔𝟗𝟔
𝒕𝒂𝒏𝟕. 𝟕𝟓 =
𝟐𝒉
𝒉 = 𝟓𝟒. 𝟒𝟑𝟕𝒎𝒎

iv. You are given a set slip gauge containing 46 pieces of 2mm base (M46/2). Determine
the number of gauge blocks combination to set the required height of block gauge, h.
(4 marks)

Knowing that, h = 54.437mm

2.007 mm 1 pcs
2.03 mm 1 pcs
2.4 mm 1 pcs
8.0 mm 1 pcs (
40 mm 1 pcs
54.437 – 6.473 = 48mm

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QUESTION 3
[CO1 PO3](C3) DK1-DK3

a) Using appropriate diagram, outline the method and procedure to find the Least Square Center
and the Roundness Error of a roundness profile from roundness measuring machine.
(8 marks)

…………………
i) Draw initial datum/origin point O at any point within the trace/roundness profile.

ii) Draw 12 radial lines at equi-angular spacing, 30°

iii) Intersection of these lines with the trace are measured relative to point O, which
gives the coordinate (x1,y1), (x2,y2) ……..(x12,y12)

iv) Find Ʃx and Ʃy, sum of all values of x and y.

𝒙𝟏 + 𝒙𝟐 + ⋯ 𝒙𝟏𝟐 𝒚𝟏 + 𝒚𝟐 + ⋯ 𝒚𝟏𝟐
Ʃ𝒙 = Ʃ𝒚 =
𝟏𝟐 𝟏𝟐

v) Find least square center (X, Y) coordinate.

𝟐Ʃ𝒙 𝟐Ʃ𝒚
𝑿= 𝒀=
𝒏 𝒏

vi) Find roundness error

𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒊𝒏 𝒓𝒂𝒅𝒊𝒊
𝑹𝒐𝒖𝒏𝒅𝒏𝒆𝒔𝒔 𝑬𝒓𝒓𝒐𝒓 = 𝒙 𝟏𝟎𝟎𝟎µ𝒎
𝒎𝒂𝒈𝒏𝒊𝒇𝒊𝒄𝒂𝒕𝒊𝒐𝒏

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b) The straightness of a linear motion guide was measured using dial gauge on a granite surface
plate. The experimental data is tabulated as shown in Table Q3(b).
Table Q3(b)
Position (mm) 0 10 20 30 40 50 60 70 80 90 100
Dial Gauge Reading (mm) 4.5 4.4 4.3 4.4 4.7 4.9 4.8 5.0 5.1 5.2 5.2

i. Complete the Table Q3(b) by adding three (3) more columns for cumulative height,
adjustment and errors from straight line.
(6 marks)
Position Dial gauge Difference from 1st Cumulative Adjusment Error from straight
(mm) reading (mm) reading (mm) Height (mm) Height (mm) line (mm)
0 4.5 0 0 0 0
10 4.4 -0.1 -0.1 0.3 -0.4
20 4.3 -0.2 -0.3 0.6 -0.9
30 4.4 -0.1 -0.4 0.9 -1.3
40 4.7 0.2 -0.2 1.2 -1.4
50 4.9 0.4 0.2 1.5 -1.3
60 4.8 0.3 0.5 1.8 -1.3
70 5.0 0.5 1.0 2.1 -1.1
80 5.1 0.6 1.6 2.4 -0.8
90 5.2 0.7 2.3 2.7 -0.4
100 5.2 0.7 3.0 3.0 0

ii. Plot graph cumulative height and adjustment versus position.

(2 marks)

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 iii. Plot graph errors from straight line versus position.
(2 marks)

.
iv. Calculate the straightness of the linear motion guide.
(2 marks)
Straightness is 1.4mm .

QUESTION 4
[CO1 PO3](C3) DK1-DK3

a) With the aid of a suitable diagram, briefly describe the principle of interference in an
interferometer.
(8 marks)
Brightness Darkness

When two rays (ray A and ray B) are in When two rays (ray A and ray B) are in
same phase/same wavelength, the different phase/amplitude, the
resulting will be the sum of two intensity. resulting will be zero/very small.
(

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b) By referring to Figure Q4(b), the Effective Diameter of a Screw Plug Gauge (M30 x 3.5 ISO 6H)
was obtained by using Floating Carriage Diameter Measuring Machine, a standard cylinder, and
2 wire cylinders having same diameter, d.
Use 𝑷 = 𝒑 𝒄𝒐𝒕𝜽 − 𝒅(𝒄𝒐𝒔𝒆𝒄𝜽 − 𝟏) (Metric Screw Thread)
𝟐

Metric Screw Thread Standard Cylinder

Figure Q4(b)

i. Referring to Figure Q4(b), derive the expression for P value of metric screw thread.
P = 0.86602p - d
(3 marks)
𝒑
𝑷 = 𝒄𝒐𝒕𝜽 − 𝒅(𝒄𝒐𝒔𝒆𝒄𝜽 − 𝟏)
𝟐
𝒑
𝑷 = 𝒄𝒐𝒕𝟑𝟎° − 𝒅(𝒄𝒐𝒔𝒆𝒄𝟑𝟎° − 𝟏)
𝟐
𝑷 = 𝟎. 𝟖𝟔𝟔𝟎𝟐𝒑 − 𝒅

ii. Prove that the diameter best size of the wire used with a metric thread is given by;
d = 0.577p
p is the pitch and thread angle 60°.
(3 marks)
𝒑
𝒅= 𝒔𝒆𝒄𝜽
𝟐
𝒑
𝒅 = 𝒔𝒆𝒄𝟑𝟎°
𝟐
𝒅 = 𝟎. 𝟓𝟕𝟕𝒑

iii. Calculate the diameter of wire cylinder, d.

(2 marks)
𝒅 = 𝟎. 𝟓𝟕𝟕𝒑
𝒅 = 𝟎. 𝟓𝟕𝟕(𝟑. 𝟓)
𝒅 = 𝟐. 𝟎𝟐𝒎𝒎

10
 iv. Figure Q4(b)(iv) shows a micrometer reading on screw thread and standard cylinder.
Find the value of the Effective Diameter (mm) based on the following experimental
information.

Micrometer Reading on Micrometer Reading on

Screw Thread, R2 Standard Cylinder, R1

Figure Q4(b)(iv)
(4 marks)
Micrometer Reading on Screw Thread, R2
R2 = 4.750mm
Micrometer Reading on Standard Cylinder, R1
R1 =4.803mm
D3 = Dstd + (R2 – R1)
D3 = 30 + (4.750 – 4.803)
D3 = 29.947mm

Deff = D3 + P
Deff = D3 + 0.86602p - d
Deff = 29.947 + [(0.86602 x 3.5) – 2.02]
Deff = 30.958mm

QUESTION 5
[CO1 PO3](C3) DK1-DK3

a) Explain CMM in metrology. State the two (2) benefits and limitations of CMM.
(8 marks)
Advantages (2 points) Disadvantages (2 points)
 CMM can perform complex inspection  Very high cost of CMM and accessories
 Higher productivity of CMM
 Less time than traditional manual methods  CMM are less portable

 Reduce human error  If the operating software cracks down it

is difficult to restart the entire system
 Higher accuracy and precision
 It needs to construct some feature on its
 Flexible – programmable own as some parts of the workpiece are
unreachable by the probe

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b) Using a suitable diagram, explain in detail the three (3) methods of measuring the value of
surface roughness of a machined component.
(12 marks)
Center Line Average method

….

Root Mean Square method

…….

……

Peak to Valley method

…………….

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