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INTRODUCTION
Quality Engineering is focusing and highlight to plan, design, conduct and experiments efficiently and effectively. It also exposes the applications of metrology to improve quality, reliability, design and maintain an effective quality management system in manufacturing industry. The metrology as a science of measurement, embracing both experimental and theoretical determinations at any level of uncertainty in any. This help to emphasize towards International Quality Standards. The knowledge and skills covered in Quality Engineering makes route to become valued engineers in industry. This final year is focused on the metrology tools and technique which under the scope of Quality Engineering. Metrology is describe about the science of measurement which deals with theoretical and practical aspects of measurement. Metrology concerns the establishment of quantity systems, unit systems, measurement instrument, and their calibrations. From the metrology scope, mistake cab make measurement and count incorrect. Even if there are no mistakes, nearly all measurements are still inexact. All measurement have to be checked to sufficiently correct. Metrology is science that establishes the correctness of specific measurement situations. This done by anticipating and allowing for both mistakes and error. Calibration is the among the process used to measurement equipment and processes to ensure conformity with know standards of measurement. From this case study and observation, it has been identified that measurement in different temperature condition has affected the temperature.
Based on the observation this final year project is focused on the study of thermal variation effect on height gauge measurement. As in todays Quality Control industry there were rising needed to the outside measurement rather than in controlled temperature environment. In this case, as per theory shows that when 1 increases there will be increase in measurement as 1m. As per theory, it shows that there will be change measurement when there is change in temperature.
The objective of this final year project is to study metrology tools and techniques to identify the thermal variation effect on measurement. Moreover to study the significant effect of measurement on different temperature by using height gauge.
This study will focused on the effect of temperature in measurement, by taking measurement using height gauge. The measurement were taken by different operators. Correlation study method used to analyze and collect data. Moreover the resolution of height gauge used is 0.001mm and the range of height gauge measurement is 0-450mm.
The overall methodology in conducting the project is shown in figure 1 below. It starts with detailed literature review relating to metrology tools and techniques, linear thermal expansions and others. At the same time, attention was given to choose and determine method and tools. Once the supervisor approved, data collection proceeded. If not approved, the method and tools selection will repeated until get suitable method and tools. After select suitable method and tools the data will be collected in the different selected temperature. The data using metrology tools and techniques. The results will be compared and referred with theoretical statement. Lastly, the final year project report is written as the final stage in final year project.
Start
Literature review
Collect the
CHAPTER 2
Analyze the
LITERATURE REVIEW
Metrology is defined by the International Bureau of Weights and Measures (BIPM) as "the science of measurement, embracing both experimental and theoretical determinations at any level of uncertainty in any field of science and technology." The ontology and international Finis vocabulary of metrology (VIM) is maintained by the International Organisation for Standardisation. Figure 1.5 Flowchart of
methodology project
A core concept in metrology is (metrological) traceability, defined as "the property of the result of a measurement or the value of a standard whereby it can be related to stated references, usually national or international standards, through an unbroken chain of comparisons, all having stated uncertainties." The level of traceability establishes the level of comparability of the measurement: whether the result of a measurement can be compared to the previous one, a measurement result a year ago, or to the result of a measurement performed anywhere else in the world. Traceability is most often obtained by calibration, establishing the relation between the indication of a measuring instrument and the value of a measurement standard. These standards are usually coordinated by national metrological institutes. Tracebility, accuracy, precision, systematic bias, evaluation of measurement uncertainty are critical parts of a quality management system.
Metrology has existed in some form or another since antiquity. The earliest forms of metrology were simply arbitrary standards set up by regional or local authorities, often based on practical measures such as the length of an arm. The earliest examples of these standardized measures are length, time, and weight. These standards were established in order to facilitate commerce and record human activity. Little progress was made with regard to proto-metrology until various scientists, chemists, and physicists started making headway during the scientific revolution. With the advances in the sciences, the comparison of experiment to theory required a rational system of units, and something more closely resembling modern metrology began to come into being. The discovery of atoms, electricity, thermodynamics, and other fundamental scientific principles could be applied to standards of measurement, and many inventions made it easier to quantitatively or qualitatively assess physical properties, using the defined units of measurement established by science. Metrology was thus one of the precursors to the Industrial Revolution, and was necessary for the implementation of mass production, equipment commonality, and assembly lines. Modern metrology has its roots in the French Revolution, with the political motivation to harmonize units all over France and the concept of establishing units of measurement based on constants of nature, and thus making measurement units available "for all people, for all time". In this case deriving a unit of length from the dimensions of the Earth, and a unit of mass from a cube of water. The result was platinum standards for the meter and the kilogram established as the basis of the metric system on June 22, 1799. This further led to the creation of the Systeme International d'Unites, or the International System of Units. This system has gained unprecedented worldwide acceptance as definitions and standards of modern measurement units. Though not the official system of units of all nations, the definitions and specifications of SI are globally accepted and recognized. The SI is maintained under the auspices of the Metre Convention and its institutions, the General Conference on Weights and Measures, or CGPM, its executive branch the International Committee for Weights and Measures, or CIPM, and its technical institution the International Bureau of Weights and Measures, or BIPM. As the authorities on SI, these organizations establish and promulgate the SI, with the ambition to be able to service all. This includes introducing new units, such as the relatively new unit, the mole, to encompass metrology in chemistry. These units are then established and maintained through various agencies in each country, and establish a hierarchy of measurement standards that can be traced back to the established standard unit, a concept known as metrological traceability. The U.S. agencies holding this responsibility are the National Institute of Standards and Technology (NIST) and the American National Standards Institute (ANSI).
The development of standards also does involve individual and small group Achievements. In 1893, Edward Weston (chemist) and his company perfected his Saturated Standard Cell design, which allowed the volt to be reproduced to 1 part in ten to the fourth power directly. This advance made a huge practical difference at a critical moment in the development of modern electrical devices. Groupings of saturated cells, called banks, can still be found in some metrology and calibration laboratories today. Edward Weston did not pursue patents for his cell design. By doing this, his superior design quickly replaced similar but inferior patented devices worldwide without much discussion.
Mistakes can make measurements and counts incorrect. Even if there are no mistakes, nearly all measurements are still inexact. The term 'error' is reserved for that inexactness, also called measurement uncertainty. All other measurements either have to be checked to be sufficiently correct or left to chance. Metrology is the science that establishes the correctness of specific measurement situations. This is done by anticipating and allowing for both mistakes and error. The precise distinction between measurement error and mistakes is not settled and varies by country. Repeatability and reproducibility studies help quantify the precision: one common method is an Gauge R&R study. Calibration is the process where metrology is applied to measurement equipment and processes to ensure conformity with a known standard of measurement, usually traceable to a national standards board.
Metrology tools and technique that focusing study of thermal variation towards measurement is important scope that detected to identify and study the theoretical fact. The study important to improve and standardize the measurement process in industries at different environments. Moreover, it also help towards improvement of Quality Standard in industries.
NO.
TITLE
AUTHOR
SCOPE OF STUDY
Thermal error; Realtime thermal error compensation; Thermocouple; Laser interferometer; Thermal deformation
YEAR
R. Ramesh, M.A. Mannan , A.N. Poo Department of Mechanical and Production Engineering, The National University of Singapore, 10 Kent Ridge Crescent, Singapore 119260
Received 7 July 1999; received in revised form 22 December 1999; accepted 14 January 2000
Ted Doiron and John Beers Dimensional Metrology Group Precision Engineering Division National Institute of Standards and Technology
documentation and extended the coverage to completely describe the current gauge block calibration process
S. Kanagaraj, S. Pattanayak Cryogenic Engineering Centre, Indian Institute of Technology, Kharagpur 721 302, India
20 CA Short History of the Standard Reference Temperature for Industrial Dimensional Measurements
Ted Doiron Precision Engineering Division National Institute of Standards and Technology, 100 Bureau Drive, Gaithersburg, MD 20899-8211
One of the basic principles of dimensional metrology is that a part dimension changes with temperature because of thermal expansion. Since 1931 industrial lengths have been defined as the size at 20 C. This paper discusses the variety of
standard temperatures that were in use before that date, the efforts of C.E. Johansson to meet these variations, and the effort by the National Bureau of Standards to bring the United States to the eventual world standard.
Theodore D. Doiron
Ted Doiron and John Stoup National Institute of Standards and Technology, Gaithersburg, MD 20899-0001
The calculation of uncertainty for a measurement is an effort to set reasonable bounds for the measurement result according to standardized rules. Since every measurement produces only an estimate of the answer, the primary requisite of an uncertainty statement is to inform the reader of how sure the writer is that the answer is in a certain range. This report explains how we have implemented these
LINEAR THERMAL EXPANSION OF CALCITE, VAR. ICE LAND SPAR, AND YULE MARBLE
Joseph L. Rosenholtz and Dudley T.Smith, Rensselaer Polytechnic Institute, Troy, New Year.
LINEAR THERMAL EXPANSION OF CALCITE, VAR. ICE LAND SPAR, AND YULE MARBLE
CHAPTER 3
METHODOLOGY
3.1 INTRODUCTION
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This section discusses the methodology of the research. The main purpose of the research is to study the thermal variation effect on height gauge measurement. To study and evaluate the various temperature is set inside the metrology lab of unikl mitec. Data for the study were collected using several tools and technique of metrology.
This research used quantitative method only. Quantitative method used in comparison analysis data after take the readings. We are used different temperature set to take the measurement of our workpiece and we also analyze the and study the result. After analyze the we identify the affect of the temperature in measurement.
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figure 3.2 B temperature and humidity sensor used to check the temperature of lab.
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This method is started with collect data on selected workpiece. The data were collect in 2 methods(refer figure 3.3 and table 3.3a). There were 2 operators used to collect the data, and various selected temperature used to set up the lab( as shown on table 3.3b).
H G
E D C B A Datum
Figure 3.3
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METHOD
DESCRIPTION Datum is set and the measurement is taken as A,B,C,D,E,F,G,H and the set datum again and the step repeated 5 times.
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Data analyzing is done using correlation study method. The correlation study is a statistical measurement of the relationship between two variables. Possible correlations range from +1 to 1. A zero correlation indicates that there is no relationship between the variables. A correlation of 1 indicates a perfect negative correlation, meaning that as one variable goes up, the other goes down. A correlation of +1 indicates a perfect positive correlation, meaning that both variables move in the same direction together. Correlation study r = + 1.0 r = + 0.5 r=0 r =- 0.5 Strong-Positive Weak-Positive No Correlation Weak-Negative As X goes up, Y always also goes up As X goes up, Y tends to usually also go up X and Y are not correlated As X goes up, Y tends to usually go down As X goes up, Y always goes down
r = - 1.0
Strong - Negative
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CHAPTER 4
TEMP:20
HUMIDITY:50 Zainab 16
TEMP:23
HUMIDITY:56 Ashwikumar AVERA 5 GE 11.928 11.953 8 38.535 71.035 105.562 150.343 253.04 328.835 381.233 38.522 71.05 105.55 22 150.32 58 253.02 32 328.79 76 381.21 36
TEMP:23
1 11.884
2 11.917
3 11.919
4 11.944
S.DEVIATI ON 0.023479 17
B C D E F G H
TEMP:25
HUMIDITY:54 Ashwikumar AVERA 5 GE 11.877 38.505 71.041 105.515 150.277 253.06 11.938 38.519 2 71.062 105.55 24 150.31 2 253.05 92
G H
328.827 381.157
328.877 381.259
328.813 381.243
328.843 381.244
328.806 381.188
328.83 32 381.21 82
0.028287 81 0.043597 02
TEMP:25
HUMIDITY:54 Zainab AVERA 5 GE 11.917 11.948 4 38.501 71.065 105.59 150.335 253.074 328.813 381.243 38.363 71.063 2 105.57 2 150.32 84 253.05 36 328.82 58 381.22 76
19
TEMP:27
HUMIDITY:59 Ashwikumar AVERA 5 GE 11.937 11.964 2 38.522 38.56 6 71.084 105.598 150.389 253.065 328.899 381.296 71.072 105.55 64 150.36 74 253.04 6 328.85 6 381.26 2
TEMP:27
HUMIDITY:59 Zainab AVERA 5 GE 11.866 38.491 71 105.521 150.296 253.025 11.911 38.452 4 71.031 8 105.55 34 150.34 18 253.08 1
G H
328.756 381.196
328.897 381.244
328.85 381.269
328.916 381.317
328.787 381.248
328.84 12 381.25 48
0.068889 04 0.043848 6
TEMP:30
HUMIDITY:70 Ashwikumar AVERA 5 GE 11.904 38.515 71.114 105.599 150.324 253.026 328.752 381.162 11.936 38.536 8 71.100 6 105.58 74 150.35 22 253.06 5 328.83 6 381.23 88
TEMP:30
1 A B 11.889 38.337
2 11.939 38.502
3 11.897 38.494
4 11.915 38.487
C D E F G H
20 A B 11.904 38.466
23 0.000 0.001
25 0.001 0.002
27 0.001 0.003
30 0.001 0.004
22
C D E F G H
A B C D E F G H
23
ZAINAB
TEMPERATURE
A B C D E F G H
4.4 DATA BY CORRELATION ANALYSIS ASHWIKUMAR FOR A: X 20 23 25 Y 11.937 11.929 11.938 XY 238.74 274.367 298.45 X2 400 529 625 Y2 142.492 142.301 142.516
24
27 30
X=125
11.937 11.936
Y= 59.677
322.299 358.08
XY=1491.936
729 900
X2 = 3183
142.492 142.468
Y2 = 712.269
FOR B : X 20 23 25 27 30
X=125
FOR C :
25
X 20 23 25 27 30
X= 125
FOR D: X 20 23 25 27 30
X=125
26
FOR E: X 20 23 25 27 30
X=125
FOR F: X 20 23 25 27 30
X=125
320158.355
27
FOR G: X 20 23 25 27 30
X=125
41103.591
540635.325
FOR H: X 20 23 25 27 30
X=125
726690.717
28
29
ZAINAB FOR A: X 20 23 25 27 30
X=125
FOR B : X 20 23 25 27 30
X=125
30
FOR C : X 20 23 25 27 30
X=125
FOR D: X 20 23 25 Y 105.544 105.559 105.572 XY 2110.88 2427.857 2639.3 X2 400 529 625 Y2 11139.536 11142.702 11145.447
31
27 30
X=125
105.553 105.561
Y= 527.789
2849.931 3166.83
XY=13194.798
729 900
X2 = 3183
11141.436 11143.125
Y2=55712.246
FOR E: X 20 23 25 27 30
X=125
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FOR F: X 20 23 25 27 30
X=125
33
FOR G: X 20 23 25 27 30
X=125
FOR H: X 20 23 25 27 30
X=125
Value of (r) r, a A B C D E F G H
r
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Table 4.5 A
1. rmina= 2.988 2.
r=
(figure 4.5A)
rvalue=0.373 Graph
of ra
(figure 4.5B)
Graph of rz
4.6 DISCUSSION
During this final project we use 1 workpiece to take measurement. Moreover, to identify the effect of thermal variation on measurement, we decided to in different temperature, namely at 20,23,25,27, and 30. We have to ensure that our research was gave a successful result. We choose correlation study as our method because it is very much related in identifying relationship between temperature and measurement. Moreover we used 2 methods to take reading of the workpiece, but as for the analysis we choose the 2nd method readings to analyze the data using correlation study.
The correlation shows on the relationship between 2 factors. As the value of r is equal to r=0 there was no correlation happens. As if the r=+0.5 it is weak
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positive, as the x goes up, the y also tends to go up. If the r=+1.0 it is strong positive , when x goes the y also goes up. When there is r= -0.5, it is weak negative, as x goes up, y usually goes down. If the r = -1.0 it is strong negative, as x goes up, y always goes down. As the result, the r value in correlation study shows on how the x and y is related on each other.
Besides that, we decided to use 2 operators to take measurement. This because , we wants to get accurate reading to do analysis. Furthermore, our result from data prove the literature review. As said if 1 increases the dimension also will increases by 1m.
Beside that, we choose different temperature to undergo the experiment. We setup the lab as to standard temperature as 20, other than that to identify the thermal variation effect on measurement, we also used 23,25,27 and 30. We select these temperatures, to study and identify the significant impact of temperature on measurement of the workpiece.
During this experiment, we used height gauge, we used the height gauge to take measurement of workpiece. The height gauge as the measurement range as 0 450mm and the accuracy is 0.001mm. we also use humidifier to control humidity level . the temperature and humidity sensor to read the temperature set is correct and constant. CHAPTER 5
CONCLUSION
5.1 CONCLUSION
As the conclusion, the r value shows how the x and y related to each other. We also use different temperature to study the thermal variation effect on measurement. For this research, we use different temperature setting, which
37
is 20,23,25,27 and 30. We also take the 20 as the reference temperature. Besides that we used 2 operators to take measurement. We conclude that taking measurement using two operator could get 2 set of data, which would give accurate analysis of experiment.
Based on the result that we get the value of r of 2 set of data is r = 0.309. so we can prove that as x goes y also tends to go up (as refer figure 3.4). which x is represent temperature and y represent measurement. It proved the literature review, as 1 increase 1m increase in measurement. But based on our research, the significant relationship between the x and y shows on higher temperature and higher measurement. (refer figure 4.6A and figure 4.6b). Beside that, the effect of thermal variation on measurement is shows the strong and weak relationship (refer table 4.2). as shows on table 4.5a the correlation from A-C is weak as the correlation value is less than zero, but as from D-H the correlation value is strong so it show the relationship between temperature and measurement is significant on the range measurement of 105.000 mm and above. For future research we will be focus on more higher temperature and higher measurement.
REFERENCES Physics seventh edition, Paul E.tippens LINEAR THERMAL EXPANSION OF CALCITE, VAR. ICELAND SPAR, AND YULE MARBLE Josnrn L. Rosnnnolrz AND Duprnv T. Surru, RensselaePr ol'^ ttechnicIn stitute. Trov, New York http://en.wikipedia.org/wiki/Correlation_coefficient http://www.metrology.com.my/english/index.htm International Journal of Machine Tools & Manufacture Error compensation in machine tools a review Part II: thermal errors R. Ramesh, M.A. Mannan *, A.N. Poo The Gauge Block Handbook by Ted Doiron and John Beers, Dimensional Metrology Group Precision Engineering Division National Institute of Standards and Technology
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Measurement of the thermal expansion of metal and FRPs, S. Kanagaraj, S. Pattanayak, Cryogenic Engineering Centre, Indian Institute of Technology, Kharagpur 721 302, India Volume 112, Number 1, January-February 2007, Journal of Research of the National Institute of Standards and Technology Volume 102, Number 6, NovemberDecember 1997,Journal of Research of the National Institute of Standards and Technology, Uncertainty and Dimensional Calibrations
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