Professional Documents
Culture Documents
ENGINEERING METROLOGY
IN MECHANICAL ENGINEERING
Linguistic Advisor
Manager of the
Department for Academic Affairs of the Institute of Cybernetics, TPU
E.A. Panasenko
Reviewers
4
CONTENTS
Preface .......................................................................................................... 3
CONTENTS ................................................................................................. 5
1. General Concepts. Legal Basis of Metrology.......................................... 7
2. Types and Methods of Measurements .................................................... 9
3. International System of Units ................................................................ 14
3.1. SI base units ..................................................................................... 14
3.2. SI derived units ................................................................................ 15
4. Objects of Measurement ........................................................................ 17
4.1. Measurands ...................................................................................... 17
4.2. Dimension of a measurand .............................................................. 18
5. Standard Conditions for Linear and Angular Measurements ............ 20
6. Means of Measurement ......................................................................... 22
6.1 Measurement Standards .................................................................. 22
6.2 Measures and Reference Measuring Instruments .......................... 25
6.3 Gauge Blocks..................................................................................... 27
6.4 Angle Gauge Blocks .......................................................................... 40
6.5 Transfer of Physical Quantity .......................................................... 47
6.6 Measuring Instruments and Devices ............................................... 49
6.7 Metrological Parameters and Characteristics of Measuring
Instruments ............................................................................................. 50
7. Measurement Errors and Causes of the Errors ................................... 53
8. Measurement Traceability Assurance .................................................. 56
8.1 Verification, Inspection and Expertise of Measuring Instruments 58
8.2 State Testing of Measuring Instruments ......................................... 59
9. Product Quality Control ........................................................................ 61
9.1 Types of Inspection ........................................................................... 61
10. Measurement and Inspection of the Product Parameters ................. 64
10.1 Measurement and Inspection ......................................................... 64
10.2 Selection of Means of Measurement and Inspection ..................... 65
10.3 Accuracy of Means of Measurement and Inspection .................... 66
10.4 Measurement Results Analysis ...................................................... 70
10.5 Examples of Measurement Results Analysis ................................. 77
5
10.6 Example of Creating Frequency Polygon and Histogram in Excel
2007 ......................................................................................................... 84
10.7 Example of Creating Histogram, Polygon and Curve of Normal
Distribution in Statistica 7.0 .................................................................. 87
Conclusion .................................................................................................. 92
Index ........................................................................................................... 93
References .................................................................................................. 97
6
1. General Concepts. Legal Basis of Metrology
Metrology is the science of measurements, methods and means to ensure
traceability and achieve required accuracy.
Thus, metrology includes three interrelated problems: implementation of
measurement processes, measurement traceability assurance, methods and
means of measurement.
The main tasks of metrology according to RMG 29-99 are:
establishment of physical units;
establishment of state standards and reference measuring instruments;
development of the theory, methods and means of measurement and
inspection;
measurement traceability assurance;
development of methods for assessing errors and condition of the
means of measurement and inspection;
development of methods of transferring units from standards or refer-
ence measurement means to the working measurements means.
The legal framework of metrology includes the following general doc-
uments:
RF Law On ensuring the traceability of measurements;
RMG 29-99 State system for ensuring the traceability of measure-
ments. Metrology. Key Terms and Definitions;
MI 2247-93 GSI Metrology. Key Terms and Definitions;
GOST 8.417-2002 GSI. Physical units;
PR 50.2.006-94 GSI. Verification of measurement tools. Organiza-
tion and procedure of verification;
PR 50.2.009-94 GSI. Procedure of testing and approval of the
measuring instruments type;
PR 50.2.014-94 GSI. Accreditation of metrological services of legal
entities for the right for verification of measuring means;
MI 2277-94 GSI. System of certification of measurements means.
The fundamentals and procedures of the certification;
PR 50.2.002-94 GSI. Procedure of the state metrological supervision of
release, condition and use of measuring instruments; supervision of certified
methods of measurement, measurement standards and compliance with met-
rological rules and norms.
The law On ensuring the traceability of measurements regulates the
relations in the field of ensuring the traceability of measurements in the Rus-
7
sian Federation in accordance with the Constitution of the Russian Federa-
tion. The law establishes the following: the basic concepts, such as: organiza-
tion of governmental control of measurement traceability; regulations on
measurements traceability, units and national standards of units; the means
and methods of measurement. The law establishes the National service of le-
gal metrology and other services aimed at ensuring traceability of measure-
ments, metrology services of public authorities and legal entities, as well as
the types and area of distribution of governmental metrological control and
supervision. The law reflects the establishment of market relations in the
Russian Federation, defining the basis of metrological services of the public
authorities and legal entities. The activity of the metrological departments of
the enterprises is beyond the legal metrology and is regulated by the econom-
ic methods.
The activities that are not directly controlled by the government are sub-
jected to the Russian Calibration System, which is aimed at ensuring the
traceability of measurements too. The Calibration System is a system of
agents and calibration activities aimed at ensuring the traceability of meas-
urements in areas that are not subjected to the governmental metrological
control and supervision, which act on the basis of the established require-
ments for the organization and implementation of the process of calibration.
The law provides for cooperation between the international and national sys-
tems of measurement. This allows for the mutual recognition of the results of
tests, calibration and certification, and to use international experience and
trends of modern metrology. There are other laws, regulations and standardi-
zation documents relating to the legal basis of metrology.
8
2. Types and Methods of Measurements
Measurement is the process of empirical finding the physical quantity
value by measuring means.
The result of the measuring process is the value of a physical quantity:
Q qU ,
where q the numerical value of a physical quantity in the adopted unified
units; U the unit of a physical quantity. The value of the physical quantity
Q, found in the measurement is called actual value.
Principle of measurement is a physical phenomenon or a combination
of physical phenomena underlying the measurement. For example, measure-
ment of the mass of a body by weighing it with gravity proportional to the
mass, or temperature measurement using the thermoelectric effect.
Measurement method is a set of principles and means of measuring.
Means of measurement are the means with specified metrological
characteristics used to perform measurements.
There are various types of measurements. Classification of the meas-
urements is made on the basis of the measurand dependence on the time, type
of measurement equation, conditions that determine accuracy of the meas-
urement results and ways of expressing these results.
Depending on the nature of the measurand dependence on the time, all
measurements are divided into static and dynamic measurements.
Static measurement is the measurement when the measurand remains
constant over time. Examples of static measurements are the measurements
of product dimensions, static pressure, temperature and other quantities.
Dynamic measurement is a measurement, during which the measurand
varies with time, for example, measurement of pressure and temperature of
gas being compressed in the engine cylinder.
Depending on the way of obtaining measurement result, which is deter-
mined by the type of measurement equation, measurements are classified as
direct, indirect, transposition and joint measurements.
Direct measurement is the measurement in which the value of the
physical quantity is obtained directly from experimental data without any
calculations. Direct measurements can be expressed by the following equa-
tion:
Q x,
where Q the desired value of the quantity to be measured, and x the value
obtained directly from the experimental data. Examples of such measure-
9
ments are measurement of the length by a ruler or tape-measure, measure-
ment of the diameter by a vernier caliper or micrometer, measurement of the
angle by a protractor, measurement of the temperature by a thermometer, etc.
Indirect measurement is the measurement in which the value of the
quantity is determined on the basis of the known relationship between the de-
sired value and quantities, the values of which are obtained through direct
measurements. Thus, the quantity value is calculated according to the follow-
ing equation:
Q F ( x1, x2 ,..., xn ) ,
where Q the required value of the quantity; F known functional depend-
ence; x1 , x2 ,..., xn - the values obtained by direct measurements.
Examples of indirect measurements: calculation of the body volume
from direct measurements of its geometrical dimensions, finding the specific
electrical resistance of the conductor by measuring its resistance, length and
cross-section area, measurement of the screw pitch diameter by three-wire
method, etc. Indirect measurements are common in the cases when the de-
sired value is impossible or too difficult to measure by the direct measure-
ment. There are cases when the value can only be measured indirectly, e.g.,
sizes of the intra-atomic or astronomical order.
Transposition measurements are the measurements in which the val-
ues of the measurands are determined from results of repeated measurements
of one or more quantities of the same kind with different combinations of the
measures or the quantities. Value of the desired quantity is determined by
solving the set of equations formulated by the results of several direct meas-
urements.
An example of the transposition measurements is finding of the mass of
weights from a set, i.e. calibration by the known mass of one of the weight
and by the results of direct measurements and comparison of masses of dif-
ferent combinations of weights. Consider an example of transposition meas-
urements which is the calibration of weights, consisting of weights of 1, 2,
2*, 5, 10 and 20 kg. Several weights (except 2*) represent standard measures
of mass. An asterisk indicates a weight that has a value other than the exact
value of 2 kg. The calibration is to determine the mass of each weight with
the help of the standard measure, such as weight with mass of 1 kg. The
measurements are performed by changing the combination of weights. We
form the equations, where the numbers denote the mass of the weights, e.g., a
1ref denotes the mass of the standard weight of 1 kg weight, then:
1 1ref a ; 1 1ref 2 b ; 2* 2 c ; 1 2 2* 5 d and so on.
Additional weights, which must be added to the mass of the weight indi-
cated on the right side of the equation, or subtracted from it to balance the
10
scales, are indicated as a , b , c , d . Solving this system of equations, we can
determine the mass of each weight.
Joint measurement is the measurement, performed simultaneously for
two or more unlike values for finding the functional dependence between
them. Examples of joint measurements are finding of the length of a rod, de-
pending on its temperature or finding of the electrical resistance of a conduc-
tor depending on pressure and temperature.
On the basis of accuracy the measurements are divided into three clas-
ses.
1. Measurements of the maximum possible accuracy are the measure-
ments that can be achieved with the state-of-the-art engineering. This class
includes all the high-precision measurements and, in the first place, the refer-
ence measurements associated with the highest possible accuracy reproduc-
tion of the physical quantities. This also includes measurement of physical
constants, especially universal, such as measurement of the absolute value of
the acceleration of free fall.
2. Testing-calibrating measurements are the measurements, which error
has a defined probability not to exceed a predetermined value. This class in-
cludes measurements performed by laboratories of state supervision on tech-
nical regulations, measuring equipment condition and plant measurement la-
boratories. These measurements ensure that with a certain probability the
measurement error is not exceeding a certain specified value.
3. Engineering measurements are the measurements in which the error
of the result is determined by the characteristics of the measuring instru-
ments. Examples of engineering measurements are measurements performed
in manufacturing processes in industry, in service sector etc.
On the basis of measurement result expression, the measurements are
divided into absolute and comparison measurements.
Absolute measurements are the measurements based on direct meas-
urements of one or more base quantities or on the use of values of the physi-
cal constants. Examples of absolute measurements include measurements of
length in meters, electric current in amperes and acceleration of free fall in
m/s2.
Comparison measurements are the measurements in which the un-
known quantity is compared with a known value of the same quantity, which
plays the role of a unit or reference quantity. Examples of comparison meas-
urements are: measurement of the shell diameter by measuring number of
revolutions of the measuring wheel, measurement of the air relative humidity
defined as the ratio of the amount of water vapor in 1 m3 of air to the amount
of water vapour in 1 m3 of air at a given temperature.
11
Depending on the method of determining values of the quantities to be
measured two basic methods of measurement are distinguished: method of
direct evaluation and method of comparison with the measure.
The method of direct evaluation is a method of measurement in which
the value of the quantity is determined directly from the reading device of the
measuring instrument of direct action. Examples of such measurements are as
follows: length measurement with a ruler, micrometer or protractor, pressure
measurement with a manometer and so on.
The method of comparison with a standard measure is a method of
measurement, in which the quantities to be measured are compared with the
value reproduced by the standard measure. For example, to measure diameter
of the limit gauge the optimeter is set to zero with the help of the stack of
gauge blocks, and the measurement result is indicated by the deflection of the
pointer optimeter from zero. Thus, the quantity to be measured is compared
with the size of the gauge block stack. There are several types of the compar-
ison method:
a) method of opposition, in which the quantity to be measured and the
standard measure simultaneously act on the comparator, allowing to establish
relationship between these variables, e.g., measurement of the resistance with
a bridge circuit when the indicating device is in the diagonal of the bridge
circuit;
b) differential method, in which the quantity to be measured is compared
with a known quantity reproduced by a reference measure. This method, for
example, is used for determining the deviation of the part diameter by an op-
timeter after setting it to zero with the help of a stack of gauge blocks;
c) method of null measurement is also a method of comparison with a
standard measure in which the resulting effect of the values on the instrument
is brought to zero. This method of measurement is used to determine electri-
cal resistance with the balanced bridge circuit;
g) with the coincidence method the difference between the quantity to be
measured and a quantity reproduced by a reference measure, is determined by
identifying coincidence of the scale marks or periodic signals. For example,
measurements with a vernier caliper are based on observation of the match-
ing marks of the main and vernier scales.
Depending on the method of obtaining measurement data the measure-
ments are divided into contact and non-contact.
Depending on the type of the measuring means, there are instrumental,
expert, heuristic and organoleptic methods of measurement.
The instrumental method is based on the use of special means of meas-
urement, including automated and automatic.
The expert method is based on the judgments of the group of experts.
12
Heuristic methods are based on intuition.
Organoleptic methods are based on the use of the human senses.
Assessment of the state of an object can also be performed with ele-
ment-by-element and complex measurements. Element-by-element method is
characterized by measurements of each parameter of the product separately.
For example, eccentricity, ellipticity, faceting of a cylindrical shaft. The
complex method is characterized by measuring the total quality parameter,
which is influenced by its individual components. For example, the meas-
urement of radial run-out of a shaft, which is affected by eccentricity, ellipti-
city and other parameters; inspection of the profile position by the limiting
contours etc.
13
3. International System of Units
Metre is equal to the length of the path travelled by light in vacuum dur-
ing a time interval of 1/299792458 of a second.
Table 1
SI base and supplementary units
SI base units
Quantity Unit Symbol
Name Russian international
Length L metre m
Mass M kilogram kg
Time T second s
Electric current I ampere A
Thermodynamic temper-
kelvin K
ature
Luminous intensity candela cd
Amount of substance mole mol
SI supplementary units
Quantity Unit Symbol
Name Russian international
Plane angle radian rad
Solid angle steradian sr
14
Kilogram is equal to the mass of the International Prototype of the Kilo-
gram.
Second is defined as the duration of 9192631770 periods of the radiation
corresponding to the transition between the two hyperfine levels of the
ground state of the caesium 133 atom.
Ampere is constant current which, if maintained in two straight parallel
conductors of infinite length, of negligible circular, and placed one metre
apart in vacuum, would produce between these conductors a force equal to
2 10 7 newton per metre of length.
Kelvin is defined as the fraction 1273.16 of the thermodynamic tempera-
ture of the triple point of water.
Mole is the amount of substance that contains as many elementary entities
as there are atoms in 12 grams of pure carbon 12.
Candela is equal to the luminous intensity, in a given direction, of a source
that emits monochromatic radiation of frequency 540 1012 hertz and that has
a radiant intensity in that direction of 1683 watt per steradian.
The SI derived units are formed with the help of simplest equations be-
tween quantities with numeric coefficient, equivalent to 1. For example, in
order to define dimension of linear speed we use the expression for uniform
linear speed. If the length of the distance travelled is l v t (m) and the trav-
el time t (s), then speed is measured in metres per second (m/s). Therefore, SI
speed unit is a metre per second that is speed of uniformly moving point
that travels the distance of 1 m over the time of 1 s. Other units have the same
methods of formation including coefficient not equal to 1 (Table 2).
15
Table 2
Units derived from SI base units
Electrical capaci-
farad F C/V m-2kg-1s42
tance
Electrical resistance ohm V/ m2kgs-3-2
Electrical conduct-
siemens S /V m-2kg-1s32
ance
Magnetic flux weber Wb Vs m2kgs-2-1
Magnetic flux densi-
tesla T Wb/m2 kgs-2-1
ty
Inductance henry H Wb/ m2kgs-2-2
Luminous flux lumen lm cdsr
Luminous flux lux lx m2cdsr
Radioactivity becquerel Bq s-1 s-1
Absorbed dose gray Gy J/kg m2s-2
16
4. Objects of Measurement
4.1. Measurands
18
ture can be different and unknown on different parts of the scale. The hard-
ness measurements, for example, are expressed in Vickers hardness numbers,
Rockwell hardness numbers, Brinell numbers, Shore numbers and not in
units of measurement. Ordinal scales allow monotonic transformation, they
can have or not a zero value.
Interval scales (difference) differ from ordinal scales in that they pro-
vide both relation of equivalence and order and summation of interval values
(differences) between different quantitative demonstrations of properties. The
typical example is a time scale.
The time intervals (for example, working periods and study periods) can
be added and subtracted but it is senseless to summarize the dates of some
events.
Another example, a length (distance) scale of space intervals is applied
by fixing of zero mark of the scale at one point and making the reading at the
second point. This type of scales includes the centigrade Celsius scale, Fahr-
enheit temperature scale, Reaumur temperature scale.
Interval scales have standard (agreed) units of measurement and zeros,
based on reference elements or data.
These scales allow linear transformations; procedures for finding of
mathematical expectation, standard deviation, skewness and displaced mo-
ments are applicable for them.
Ratio scales have natural zero, and the unit of measurement is deter-
mined by agreement. For example, mass scales starting with zero can be
graded differently in accordance with required weight accuracy. Just compare
chemical balance and household scales. These scales apply relations of
equivalency and order operations of subtraction and multiplication (ratio
scales of the 1st type proportional scales) and in many cases the sum opera-
tions (ratio scales of the 2nd type additive scales).
The masses of different objects can be summarized but it is no use in
summarizing temperatures of different bodies, though we can estimate the
difference and relation of their thermodynamic temperatures. The examples
of ratio scales include mass scales (2nd type), thermodynamic temperature
scale (1st type).
The ratio scales are widely used in physics and engineering allowing all
arithmetic and statistic operations.
Absolute scales possess all the characteristics of ratio scales but they
additionally have natural unambiguous determination of unit of measure-
ment. Such scales are used to measure relative quantities (relations of similar
quantities: magnitude ratio, attenuation ratio, efficiency coefficient, reflection
and absorption coefficients, amplitude modulation index and so on).
19
5. Standard Conditions for Linear and Angular Measurements
Parameter Value
Environmental temperature, C 20
Atmosphere pressure, kPa (mmHg) 101.3 (760)
Relative humidity, % 58
Acceleration of free fall, m/s2 9.8
Table 4
21
6. Means of Measurement
22
The standard of the mass unit (1 kg) is a cylinder made from an alloy of
platinum (90%) and iridium (10%) with diameter and height being approxi-
mately the same (about 30 mm).
The mole was recognised as a unit of amount of substance. The mole is
the amount of substance of a system which contains as many elementary enti-
ties as there are atoms in 12.000 grams of carbon-12.
As a standard unit of luminous intensity the candela was adopted, which
is the luminous intensity, in a given direction, of a source that emits mono-
chromatic radiation of frequency 540x1012 Hz and radiant intensity in that di-
rection of 1/683 watt per steradian.
As a standard unit of current the ampere was adopted, which is the con-
stant electric current which, flowing in two parallel straight conductors of in-
finite length, of negligible circular cross-sectional area, located one metre
apart in vacuum, produces between these conductors an interaction force
equal to 2x10-7 newtons per metre of length.
The standard unit of thermodynamic temperature is Kelvin, constituting
the fraction 1/273.16 of the thermodynamic temperature of the triple point of
water.
If the direct transfer of the unit value from the existing etalons with the
required accuracy is not technically feasible in view of the special conditions,
then the special standards are produced for the unit reproduction. Such condi-
tions may include: high or low pressure, high humidity, measurements at ex-
treme boundaries of the range of values of the measured quantity.
In metrological practice secondary standards, working standards and
reference standards are widely used. These standards are produced and ap-
proved for organization of verification procedures, as well as to ensure safety
and minimize wear of the state primary standard.
The following categories of standards are also used:
transfer standard is the secondary standard used to compare stand-
ards, which for some reason cannot be checked against each other;
duplicate standard is the secondary standard used to test the integri-
ty of the state standard or to replace it in case of damage or loss;
reference standard is the secondary standard to transfer unit value
to the working standards. It may not always be an exact physical
copy of the state standard;
working standard is the secondary standard that is used to store the
unit and transfer it to the reference measuring instruments or to the
most accurate working measuring instruments.
23
The working standards can be implemented as a single standard (or sin-
gle material measure), as a collective standard, as a complex of measuring
instruments and as a group standard.
An example of a single standard is the standard of mass in the form of
platinum-iridium weight. An example of a collective standard is the reference
standard of volt, consisting of 20 normal cells. An example of a measuring
instruments complex is the standard unit of the molar fraction of the concen-
tration of components in gas mixtures. In this case the different components,
different concentration ranges and different diluent gases create a large num-
ber of measurement tasks with the general formulation. Therefore, in this
case a standard consists of several tens of measuring instruments. An exam-
ple of a group standard is a set of instruments for measuring density of liq-
uids in different parts of the density range.
Such a wide range of varieties of standards is not specified in the inter-
national metrological documents. International standards stored at the Inter-
national Bureau of Weights and Measures reproduce a limited number of
physical units. Typically, this is either the basic units of the SI system or
units which can be reproduced at accuracy equal to or exceeding the accuracy
of the standard of basic unit. An example of such a standard is the standard of
volt based on the Josephson effect, which consists in the flow of direct cur-
rent across the junction formed by two superconductors separated by a thin
dielectric layer (stationary effect), or in the flow of alternating current across
the junction of two superconductors, to which direct voltage is applied (non-
stationary effect).
The number of international standards is small in comparison with Rus-
sian standards due to the fact that the concept of standards and reference
measuring instrument does not have a clear distinction in many countries.
There is a vast concept a standard, which can be applied to the secondary
standard (reference measuring instrument) or an etalon (original reference
measuring instrument).
24
6.2 Measures and Reference Measuring Instruments
25
silver, 444.6 C the melting point of sulphur, 100 C boiling point of wa-
ter, 182.97 C the boiling point of oxygen etc.
Another example of the certified reference material, which uses the
properties of matter, is folic acid. The combustion of a certain mass of folic
acid in a closed volume generates a fixed quantity of heat. According to the
results of preliminary tests the certificate is issued on the certified reference
material, and the material is registered in the State Register of certified refer-
ence materials. Certified reference material, as well as other measures are pe-
riodically compared and stored in the metrological organizations.
In the Russian Federation, the State Register of certified reference mate-
rials is kept in a special institute in Yekaterinburg. A special place in the sys-
tem of measures is occupied by the certified reference materials of composi-
tion reference gas mixtures. These reference materials have features that
distinguish them from reference materials made in the form of liquids or sol-
ids. The main difference is that the reference gas mixture is consumed in the
process of measurement, which may lead to changes in gas composition. It is
also impossible to store the reference gas mixture that is being analysed.
Therefore, a batch of vessels with mixtures is prepared for analysis.
The measures are divided into single-valued and multi-valued.
Single-value measures are measures that reproduce constant value of
the physical quantity. It can be a unit or a multiple or a sub-multiple value
(weights, gauge blocks, receiving flasks, standard cells of electromotive
force, electrical resistance coils etc.). For convenience of use the sets of
measures (weights, gauge blocks and other measures) are manufactured. A
set of measures combined in one mechanical unit with a device is called a
measure box (resistance box, capacitance box, and so on).
Multi-valued measures reproduce not one, but several sub-multiple or
multiple values of units. Such measures are, for example, a millimeter ruler
and other graduated measures, graduated variable capacitors, variometer and
so on. To reproduce a length the line gauge blocks and end gauge blocks are
widely used in the industry. The line gauge blocks are made in the form of
samples, rulers, tape measures and scales with the indicating elements.
26
6.3 Gauge Blocks
27
individual gauge block of the set. Gauge block of 1.005 mm available in sets
1, 2, 3, 12, and 15 of the third accuracy grade, should have accuracy grade
not lower than 2nd.
Table 5
Cross section dimensions of gauge blocks (a, b) must meet the require-
ments specified in the Table 6.
Table 6
Cross section dimensions of gauge blocks
Table 7
Permissible deviations
Nominal length
from nominal length, m, from flatness and parallelism,
of a gauge
related to the accuracy grade m, related to the accuracy grade
block, mm
00 01 0 1 2 3 00 01 0 1 2 3
To 0.29 - - - 0.20 0.40 0.80 - - - 0.16 0.30 0.30
Over 0.29 to
- - 0.12 0.20 0.40 0.80 - - 0.10 0.16 0.30 0.30
0.9
Over 0.9 to 10 0.06 0.20 0.12 0.20 0.40 0.80 0.05 0.05 0.10 0.16 0.30 0.30
Over 10 to 25 0.07 0.30 0.14 0.30 0.60 1.20 0.05 0.05 0.10 0.16 0.30 0.30
Over 25 to 50 0.10 0.40 0.20 0.40 0.80 1.60 0.06 0.06 0.10 0.18 0.30 0.30
Over 50 to 75 0.12 0.50 0.25 0.50 1.00 2.00 0.06 0.06 0.12 0.18 0.35 0.40
Over 75 to 100 0.14 0.60 0.30 0.60 1.20 2.50 0.07 0.07 0.12 0.20 0.35 0.40
Over 100 to
0.20 0.80 0.40 0.80 1.60 3.00 0.08 0.08 0.14 0.20 0.40 0.40
150
Over 150 to 0.25 1.00 0.50 1.00 2.00 4.00 0.09 0.09 0.16 0.25 0.40 0.40
29
Permissible deviations
Nominal length
from nominal length, m, from flatness and parallelism,
of a gauge
related to the accuracy grade m, related to the accuracy grade
block, mm
00 01 0 1 2 3 00 01 0 1 2 3
200
250 0.30 1.20 0.60 1.20 2.40 5.00 0.10 0.10 0.16 0.25 0.45 0.50
300 0.35 1.40 0.70 1.40 2.80 6.00 0.10 0.10 0.18 0.25 0.50 0.50
400 0.45 1.80 0.90 1.80 3.60 7.00 0.12 0.12 0.20 0.30 0.50 0.50
500 0.50 2.00 1.00 2.00 4.00 8.00 0.14 0.14 0.25 0.35 0.60 0.60
600 0.60 2.50 1.30 2.50 5.00 10.0 0.16 0.16 0.25 0.40 0.70 0.70
700 0.70 3.00 1.50 3.00 6.00 11.0 0.18 0.18 0.30 0.45 0.70 0.80
800 0.80 3.20 1.60 3.20 6.50 13.0 0.20 0.20 0.30 0.50 0.80 0.80
900 0.90 3.60 1.80 3.60 7.00 14.0 0.20 0.20 0.35 0.50 0.90 0.90
1000 1.00 4.00 2.00 4.00 8.00 16.0 0.25 0.25 0.40 0.60 1.00 1.00
These requirements are not applied to the zone adjacent to the edges of
the measuring surfaces; the zone is 0.5 mm wide for gauge blocks of nominal
length up to 0.29 mm and 0.8 mm wide for gauge blocks of nominal length of
more than 0.29 mm.
Deviations from flatness of the measuring surfaces of gauge blocks with
the nominal length from 0.9 to 3 mm in free state (not wrung) should not ex-
ceed 2 m.
Wringability of the gauge block measuring surfaces must meet the re-
quirements specified in the Table 8.
Flatness tolerance of the optical flats is equal to 0.03 m for accuracy
grades 00, 01 and 0, and is equal to 0.1 m for accuracy grades 1, 2 and 3.
Gauge blocks surface roughness parameter Rz<0.063 m is in accord-
ance with GOST 2789.
The edges of the measuring surfaces of gauge blocks should be rounded
to a radius less than 0.3 mm or have a chamfer of less than 0.3 mm.
The measuring surfaces of gauge blocks, including zone of the chamfers
transition to the measuring surface, should be free of defects that adversely
affect the use of gauge blocks.
Scratches on the measuring surfaces of gauge blocks are allowed as long
as they do not affect wringability, deviation of length from the nominal value
and deviation from flatness and parallelism.
30
Table 8
Wringability requirements
00
Without fringes and shades -
01
viewed with white light
Sliding pres-
0 sure from 29.4
to 78.5 N Sliding pressure
Without fringes. Shades in the
1, 2 and 3 form of bright spots, viewed from 29.4 to 98.1 N
with white light
Table 9
31
Carbide gauge blocks should have a coefficient of thermal expansion
and allowable elongation at a temperature range from 10 to 30 C in accord-
ance with the Tables 9 and 10. The carbide gauge blocks should be manufac-
tured as entirely solid carbide gauge block or as steel block with carbide-
tipped measuring surfaces.
Table 10
Table 11
32
Non-working surfaces of gauge blocks of nominal length over 100 mm
should have marks engraved at a distance of 0.211 l from the block sides.
To clamp gauge blocks together with the ties, according to GOST 4119,
the gauge blocks of the sets 8 and 9, as well as gauge blocks longer than
100 mm of the sets 22-24 should have two holes; wear blocks of 50 mm
nominal length and gauge blocks of 51.4 and 71.5 mm nominal length of the
sets 22-24 should have one hole.
The holes should be located at a distance of 25 mm from the measuring
surfaces, and for gauge blocks of 51.4 and 71.5 mm length at the distance
from one of the measuring surfaces.
Explanation of terms used in this section is given in the Tables 12 and
15.
Each set of gauge blocks and kits of the set should be packed in a case
with an enclosed certificate in accordance with GOST 2.601, and for the ref-
erence gauge blocks a calibration certificate according to the MI 1604 should
be enclosed as well.
The nominal length of a block should be stamped on it. For the gauge
blocks of length equal to and smaller than 5.5 mm, the nominal length mark-
ing should be shifted from the middle of the measuring surface, so that its
central zone of 9 mm long remains free of markings.
For the gauge blocks of length greater than 5.5 mm, the nominal length
marking and trademark of the manufacturer should be applied to the non-
working surface. Additional distinctive sign, in addition to the markings men-
tioned above, should be applied to the wear blocks and reference gauge
blocks. It is allowed to label gauge blocks of the 00, 01 and 0 accuracy
grades with the set number or other additional information.
Marking on the case of the gauge block set should include:
trademark of the manufacturer (on the outer surface of the cover);
serial number of the set or kit;
accuracy grade (for working gauge blocks), class (for reference
gauge blocks), the words reference gauge blocks (on the outer sur-
face of the case cover of a set or kit of reference gauge blocks);
reference to GOST 9038-90;
letter "T" (for carbide gauge blocks) on the inner surface of the case.
Each pocket should be supplied with an indication of the nominal length
of the gauge block placed in.
Gauge blocks sets and gauge block of length from 500 to 1000 mm, de-
livered individually, must be packed in cases made of materials specified in
GOST 13762.
33
Each gauge block in a set must be placed in the appropriate pocket and
shouldnt fall out when the closed case is turned upside-down.
34
Inspection and testing of gauge blocks
Verification of gauge blocks is performed in accordance with MI 2079,
MI 2186, GOST 8.367 and MI 1604.
The effect of climatic factors of environment on transportation is tested
in climatic chambers. Tests are carried out in the following conditions: at a
temperature of plus (50 3) C, at a temperature of minus (50 3) C and
relative humidity of (95 3) % at a temperature of (35 3) C. Exposure
time in the given conditions in a climate chamber is equal to 2 hours.
Upon completion of tests, all tested gauge blocks must comply with the
requirements of the standards mentioned above.
For testing effect of transport shaking a shock table, which creates shak-
ing with acceleration of 30 m/s2 and frequency of 80-120 beats per minute, is
used.
Boxes packed with gauge blocks are attached to the table and undergo a
total of 15,000 strokes. After the test, the metrological characteristics of the
gauge blocks should not exceed values, specified in GOST 9038-90.
Description of terms used in the section and gauge block sets is given in
the Tables 12, 13 and 14.
Table 12
Term Explanation
Length of a perpendicular from a given point of a measuring
surface to the opposite measuring surface.
Note. As an opposite measuring surface, in absolute inter-
Length of a gauge ferometric method of measurement of the block length, a
block (at any point) flat surface of the auxiliary plate made of the same material
and same surface finish as the gauge block, to which it is
wrung, is used.
35
Term Explanation
Property of the measuring surfaces of a gauge block that
provides a firm bond between gauge blocks or between a
Wringability of a gauge block and a flat metal or optical flat when a block is
gauge block applied or slid across a block or a plate. Wringability is
characterized by sliding pressure.
Table 13
Accuracy
Quan- Size Wear blocks
Set Block grade
tity of incre- Nominal lengths,
num- quan- Nominal Quanti-
blocks ment, mm Steel Carbide
ber tity length, ty of
in a set mm blocks blocks
mm blocks
- 1.005 1
0.01 From 1 to 1.5 51
0.1 From 1.6 to 2 5 0; 1; 2 1; 2 and
1 83 - -
0.5 0.5 1 and 3 3
From 2.5 to 10 16
10 From 20 to 100 9
- 1.005 1
0.01 From 1 to 1.1 11
1; 2 1; 2 and
2 38 0.1 From 1.2 to 2 9 - -
and 3 3
1 From 3 to 10 8
10 From 20 to 100 9
- 1.005 1
0.01 From 1 to 1.5 51
0.1 From 1.6 to 2 5 0; 1; 2 1; 2 and
3 112 - -
0.5 1 and 3 3
0.5
From 2.5 to 25 46
10 From 30 to 100 8
4 11 0.001 From 2 to 2.01 11 - - 0;1; 2 -
5 11 0.001 From 1.99 to 2 11 - - 0; 1; 2 -
36
Accuracy
Quan- Size Wear blocks
Set Block grade
tity of incre- Nominal lengths,
num- quan- Nominal Quanti-
blocks ment, mm Steel Carbide
ber tity length, ty of
in a set mm blocks blocks
mm blocks
6 11 0.001 From 1 to 1.01 11 - - 0; 1; 2 0 and 1
7 11 0.001 From 0.99 to 1 11 - - 0; 1; 2 0 and 1
25 From 125 to 200 4 0; 1
8 10 50 From 250 to 300 2 50 2 2 and
100 From 400 to 500 2 3
From 100 to 0; 1; 2
9 12 100 10 50 2 -
1000 and 3
1; 2
10 20 0.01 From 0.1 to 0.29 20 - - -
and 3
0.01 From 0.3 to 0.7 41 0; 1; 2
11 43 - - -
0.1 Over 0.8 to 0.9 2 and 3
- 1.005 1
0.01 From 0.9 to 1.5 61
12 74 0.1 From 1.6 to 2 5 1; 2; 3
- 0.5 1
0.5 From 2.5 to 5 6
- 5 1
13 11 - - 1; 2; 3 -
10 From 10 to 100 10
0.5 From 10.5 to 25 30 0; 1;
14 38 - - -
10 From 30 to 100 8 2; 3
0.001 1.005 1
0.01 From 1 to 1.1 11 1; 2
15 29
0.1 From 1.2 to 2 9 and 3
1 From 3 to 10 8
From 0.991 to 0; 1
16 19 0.001 19 - - 0 and 1
1.009 and 2
From 1.991 to 0; 1
17 19 0.001 19 - - -
2.009 and 2
1; 2 and
18 2 - - - 1 2 -
3
1; 2 and
19 2 - - - 2 2 -
3
Note: The carbide gauge blocks of sets 1, 2 and 3 with length over 5
mm may be replaced by steel gauge blocks.
37
Table 14
Accuracy grade of
a set Class of
Nominal lengths, mm
Steel Carbide a set
blocks blocks
Set 20 (23 blocks)
0.12; 0.14; 0.17; 0.2; 0.23; 0.26; 0.29; 0.34; 0.4; 0.43;
1 and 2 - 1, 2, 3, 4
0.46; 0.57; 0.7; 0.9; 1.0; 1.16; 1.3; 1.44; 1.6; 1.7; 1.9;
2; 3.5
Set 21 (20 blocks)
5.12; 10.24; 15.36; 21.5; 25; 30.12; 35.24; 40.36;
1 and 2 1 and 2 1, 2, 3, 4
46.5; 50; 55.12; 60.24; 65.36; 71.5; 75; 80.12; 85.24;
90.36; 96.5; 100
Set 22 (7 blocks)
3 3 -
21.2; 51.4; 71.5; 101.6; 126.8; 150; 175
Set 23 (13 blocks)
1.00; 1.00; 1.05; 1.10; 2.00; 2.00; 21.2; 51.4; 71.5; 2 and 3 -
101.6; 126.8; 150; 175
Set 24 (25 blocks)
1.00; 1.00; 1.04; 1.05; 1.06; 1.10; 1.11; 1.12; 1.13;
- 2 and 3 -
1.17; 1.18; 1.19; 2.00; 2.00; 21.2; 51.4; 71.5; 101.6;
126.8; 150; 175; 250; 400; 600; 1000
Set 25 (15 blocks)
0.990; 0.992; 0.994; 0.995; 0.996; 0.998; 1.000;
- - 2
1.002; 1.005; 1.010; 1.015; 1.020; 1.030; 1.040;
1.050
Set 26 (8 blocks)
0.990; 0.995; 1.000; 1.005; 1.010; 1.020; 1.030; - - 2
1.050
Set 27 (9 blocks)
- - 3
1.00; 1.02; 1.04; 1.05; 1.06; 1.08; 1.10; 1.15; 1.20
Set 28 (28 blocks)
1.00; 1.02; 1.04; 1.06; 1.08; 1.10; 1.12; 1.14; 1.16;
- - 3
1.18; 1.20; 1.24; 1.28; 1.30; 1.32; 1.36; 1.40; 1.50;
1.60; 1.70; 1.80; 1.90; 2.0; 2.2; 2.4; 2.6; 2.8; 3.0
38
Accuracy grade of
a set Class of
Nominal lengths, mm
Steel Carbide a set
blocks blocks
Set 29 (8 blocks)
0.990; 0.995; 1.000; 1.005; 1.010; 1.020; 1.030; - - 3
1.040
Set 30 (7 blocks)
- - 4
5.12; 10.24; 15.36; 19.50; 20; 21.50; 25
Set 31 (9 blocks)
- - 3
1; 1.01; 1.02; 1.03; 1.04; 1.05; 1.06; 1.08; 1.10
Set 32 (7 blocks)
- - 3
0.995; 1; 1.005; 1.010; 1.020; 1.030; 1.040
Set 33 (7 blocks)
- - 3
1; 1.06; 1.10; 1.12; 1.18; 1.20; 1.30
Set 34 (9 blocks)
1.001; 1.002; 1.003; 1.005; 1.006; 1.007; 1.008; - - 1
1.009
Set 35 (9 blocks)
- - 1
1.01; 1.02; 1.03; 1.04; 1.05; 1.06; 1.07; 1.08; 1.09
Set 36 (13 blocks)
1; 1.001; 1.002; 1.003; 1.004; 1.005; 1.006; 1.010; - - 2
1.020; 1.030; 1.040; 1.050; 1.060
Set 37 (8 blocks)
- - 1
1 2 pcs; 10 2 pcs; 50 2 pcs; 100 2 pcs
Note: The carbide gauge blocks of sets 23 and 24 with length over 5
mm may be replaced by steel gauge blocks.
39
6.4 Angle Gauge Blocks
Angle gauge blocks (GOST 2875-88) are intended for inspection of the
inner and outer angles of tools, templates, parts and verification of devices,
etc. The angle gauge blocks of five types are available: 1 and 2 with one
working angle either with a truncated top or sharp top; 3 with four working
angles; 4 regular polyhedrons; 5 with three working angles. Angle gauge
blocks of types 1, 2 and 3 are manufactured of three accuracy grades (0, 1
and 2), multi-faceted blocks of type 4 are made of four accuracy grades (00,
0, 1 and 2), angle blocks of type 5 are available of grade 1. A wide range of
nominal angles is possible by wringing angle gauge blocks together.
GOST 2875-88 applies to angle blocks accessories and angle gauge
blocks of plane angle (hereinafter the angle gauge blocks) having shape of
a right prism with a number of side faces, some of them or all of them are
measuring surfaces, pairs of which form the working angles.
Angle gauge blocks are intended to be used as:
working measures for adjusting and setting-up angle measuring in-
struments and direct measurement of angles of industrial products;
reference measures for transferring size of the unit of plane angle
from the primary standard to working angle measuring instruments.
Terms and their explanations used in GOST 2875-88, as well as descrip-
tion of angle gauge block sets are given in the Tables 15 and 16.
Table 15
Term Explanation
Right prism Prismatic block of a plane angle, the base of which is a
regular convex polygon, the nominal values of the interi-
or angles at the vertices of the polygon are equal and less
than 180, the nominal values of the lengths of its sides
are equal.
Plane of measurement The imaginary plane which is placed in the body at pos-
sibly equal distances from the base and top surfaces and
oriented so that the measuring surfaces, chosen to fix it,
40
Term Explanation
were equally inclined thereto. It is allowed to place the
plane of measurement parallel to the base surface of the
block or the block mount.
Table 16
Set
num-
ber
Incre Quan- Accu- Mass of
(quan- Block Nominal values of working an-
cre- tity of racy a set, kg,
tity of type gles
ment blocks grades less than
blocks
in the
set)
1 From 10 to 79 70
2 10' From 1510' to 1550' 5
1' From 1501' to 1509' 9
80 81 100 99
1
82 83 98 97 1, 2 15
(93)
84 85 96 95
3 - 6
86 87 94 93
88 89 92 91
90 90 90 90
41
Set
num-
ber
Incre Quan- Accu- Mass of
(quan- Block Nominal values of working an-
cre- tity of racy a set, kg,
tity of type gles
ment blocks grades less than
blocks
in the
set)
8910' - 8920' - 9050' - 9040'
8930' - 8940' - 9030' - 9020' 3
8950' - 8959' - 9010' - 9001'
10 From 30 to 70 5
1 From 10 to 20 11
2 - 45 1
2 10' From 1510' to 1550' 5 1, 2 5
(33) 1' From 1501' to 1509' 9
80 81 100 99
3 - 2
90 90 90 90
3 2 - 10, 15, 20, 30, 45, 55,60 7
1, 2 2
(8) 3 - 90 90 90 90 1
1510', 3020', 4500', 4530',
4 2 - 7
5000', 6040', 7550' 1 2
(8)
3 - 90 90 90 90 1
5 1 From 1 to 9 9
1 1 4
(24) 2' From 1' to 29' 15
an angle gauge block of type 3 angle gauge block 3-80, 81, 100,
with working angles 80-81-100-99, 992 GOST 287588.
accuracy grade 2
42
Table 17
Accuracy
Block type Drawing
grade
B
1 1; 2
5
B
M1
70
2 1; 2
M2
5
N
M2
M3 a1 B
30
a3
3 a4 M1 1; 2
a2
5
M4
M4
M3
B
4 M2 0; 1; 2
M6
20min
M1
Working angles
Blocks of the types 1, 2 and 3 should have holes for clamping them to-
gether into stacks with the holders from accessory sets.
Blocks of the type 4 must be manufactured with 6, 8, 10, 12, 18, 20, 24
and 36 measuring surfaces (side faces).
Angle gauge blocks with the number of measuring surfaces 6 8, 10 and
12 should have a central hole with a diameter d = 20H7; angle gauge blocks
with the number of measuring surfaces 18, 20, 24 and 36 should have a cen-
tral hole with a d = 32H7.
Width of the measuring surfaces (length of a polygon) must be not less
than 15 mm. The difference between the maximum and minimum width of a
measurement surface should not exceed 0.8 mm.
The distance from the measuring surface to the wall of the central hole
should be at least 15 mm.
44
Specification requirements for angle gauge blocks
Permissible deviations of gauge blocks from the nominal values, toler-
ances of perpendicularity of the measuring surfaces to the base surface of the
block or the block mount, as well as tolerances of the measuring faces flat-
ness should not exceed values given in the Table 19.
Deviations of working angles from the nominal value are determined
between the adjacent faces.
Hardness of the measuring surfaces of steel blocks must be not less than
61 HRC.
Surface roughness parameters of the gauge block surfaces are set in
technical specifications for specific types of gauge blocks.
Failure-free performance of gauge blocks of types 1, 2 and 3 shall be not
less than 220 wringings.
Mean life of the gauge blocks of types 1, 2 and 3 must be at least 2
years, gauge blocks of the type 4 no less than 10 years.
The established full service life of the gauge blocks of types 1, 2 and 3
must be at least 1 year, gauge blocks of the type 4 at least 5 years.
Failure criteria and limit state of a block are set in the technical specifi-
cations for specific types of gauge blocks.
Gauge blocks of types 1, 2 and 3, and a special ruler should be made of
steel -15 GOST 801-78 or other steel grades compliant with the basic
characteristics of the mentioned grade.
Gauge blocks of the type 4 must be made of optical grade glass-ceramic
0115M. It is allowed to use optical glass 8 or 7 GOST 3514-76 or steel
-15 GOST 801-78.
Table 19
Tolerance
Perpendicularity of the
Permissible deviations measuring surfaces
Flatness of the meas-
Block from nominal values with respect to the base
uring surfaces, m
type surface of the block or
the block mount
Accuracy grades
0 1 2 0 1 2 0 1 2
1 - 10" 30" - 60" 100" - 0.15 0.30
2 - 10" 30" - 60" 100" - 0.15 0.30
3 - 10" 30" - 60" 100" - 0.15 0.30
4 5" 8" 15" 5" 20" 30" 0.05 0.07 0.10
45
Note. Flatness requirements are not applied to the area of the measuring
surfaces adjacent to the non-measuring surfaces; the area is 3 mm wide from
the short edges and 1 mm wide from the long edges for gauge blocks of types
1, 2 and 3. Flatness tolerance for these areas for the mentioned gauge blocks
types is 0.6 m. Flatness tolerances for the edge areas of the measuring sur-
faces and their dimensions for gauge blocks of the type 4 should be set in en-
gineering documentation.
Sets of gauge blocks of types 1, 2 and 3 (see the Table 16) include a
special ruler, clamping accessories and screwdriver.
All sets (individual blocks) or a multi-faceted prism in a mount are
packed in a case or packing box. The set includes a certificate in accordance
with GOST 2.001-93 and a manual.
Gauge blocks are marked according to GOST 13762-86. Nominal val-
ues of working angles should be marked on the upper surface of each block
of type 1, 2 and 3.
The upper surface of each block of the type 1 should be labeled with
plus sign (+) and minus sign (), indicating the direction of the imaginary in-
tersection of measuring surfaces (dihedral angle vertex). The minus sign (-)
must be marked on the side of the angle vertex.
The upper surface of the blocks of the type 4 must be marked with: the
serial number according to the numbering system of the manufacturer; accu-
racy grade; order number of faces (1, 2, 3, .. n) or nominal value of the angles
in degrees (0, ..., N) from the first face in the direction opposite to the
clockwise direction.
The table on the case of the gauge blocks should include: designation
for the gauge blocks of types 1, 2, 3 or 4; the order number according to the
numbering system of the manufacturer; year of production or reference des-
ignation of the year.
For the blocks of types 1, 2 and 3 each pocket in a case should be sup-
plied with an indication of the nominal value of the gauge block placed in.
46
Acceptance and Test
47
1. The usage of a reference standard being calibrated according to the
standards. This type of verification may be conducted by any service
agency, including industrial standardization service.
2. Intercomparison of the instrument readings and readings of the ref-
erence instrument or reference device. Reference instrumentation has
higher accuracy grade and respectively quite high cost, for these rea-
sons, as a rule, verification is carried out in special organizations
centres of standardization and metrology.
3. Elemental-equivalent method is the most time-consuming type of
verification. The method consists in the fact that if the instrument
has, for example, a sensor, an amplifier, an analog-digital converter
and some other auxiliary devices, then the working performance and
measurement errors are determined for all the elements of the in-
strument, without verification of the instrument as a whole. In this
case, depending on the type of auxiliary devices, these may be tested
as the instruments that measure physical quantities different from
those for measurement of which the instrument is intended. For ex-
ample, profilograph-profilometer may consist of a diamond stylus, an
electrical measuring converter, an amplifier, an integrating block and
a high voltage direct-writing instrument or output to computer. It is
possible to verify the mechanical, electrical and electronic parts of
the instrument individually and to arrive at conclusions about work-
ing performance and accuracy grade of the instrument as a surface
layer quality measuring instrument.
In some cases, when a new type of the measuring instrument is verified,
the mentioned type of verification turns out to be more suitable and even in
some cases the only one possible. Verification of some types of measuring
instruments can be conducted without using reference instruments or stand-
ards. The measuring instrument readings may be checked by the tables of
physical constants and standard reference data. Among these constants, for
example, there are electromagnetic constant, Avogadro constant the num-
ber of particles in one mole of a substance, Newtonian gravitational constant
and so on. Readings of these measuring instruments are checked with physi-
cal constants or standard reference data.
48
6.6 Measuring Instruments and Devices
49
The measuring device is a complex including several devices and auxil-
iary components. The differences between instruments and devices are very
subtle. For example, if the temperature is measured with the help of thermo-
couple and voltmeter, one can call it either a thermoelectric device or an elec-
tric thermometer.
Another example is a universal measuring microscope (MMM) which is
used to measure geometrical parameters of parts, but essentially is a measur-
ing device with a variety of auxiliary devices and appliances.
Besides measuring devices and auxiliary devices the measuring systems
may include measures or reference sets. For example, there are sets of re-
placeable scales, interchangeable lenses with different focal distance, weight
sets, resistance multipliers and inductance boxes, normal galvanic cells, etc.
At the present time geographically spread means of measurement may
be connected by communication channels, forming a network. All in total
represent information and measurement system. Information in such a system
is provided in the most comprehensible form and can be transmitted via the
network. The measuring system allows carrying out electronic information
processing, analyzing and using it for automatic control of production pro-
cesses.
50
The scale spacing is a distance between centres of two adjacent marks
of the scale measured along the imaginary line passing through the centres of
the marks of the scale. It is clear that the bigger the scale spacing is, the high-
er the magnification is and the easier the way of comprehension of measure-
ment information by an observer is.
The measuring instrument sensitivity is a relation of the measuring in-
strument output signal variation to the caused variation of the measurand. For
example, if the measurand variation equals to 0.01 mm , when measuring a
shaft diameter with nominal dimension x=100 mm, caused travel of a pointer
of the given device over 100 mm, then it means that absolute sensitivity is
10/0.01 = 1,000, and relative sensitivity equals to 10(0.01/100) = 10,000. For
the indicating measuring instrument the absolute sensitivity is numerically
equal to the transmission ratio and with change of scale interval the instru-
ment sensitivity remains invariant. But sensitivity may differ with respect to
the section of the scale. The concept of sensitivity can be determined by
transfer function as the function of a relationship between input and output
signals of a transducer. Depending on the type of the function, the sensitivity
may be a constant quantity or a quantity dependent on this function. If a func-
tion is linear, then the scale of an instrument is linear and vice versa. The
scale linearity depends not only on the transducer characteristics but also on
the type of physical quantity unit.
Together with sensitivity there is a concept of threshold of sensitivity,
which is the minimum value of measurand variation which may be shown by
the device. The lower the threshold of sensitivity is, the greater the sensitivity
is. Furthermore it is dependable on definite conditions of observation, such as
possibility to differentiate small deviations, stability of indications, static fric-
tion magnitude and others.
Reading variation is defined as a difference in device indications ob-
tained for a point of the measurement range, when the point is slowly ap-
proached from the left and from the right. The reading variation represents
algebraic difference of the maximum and minimum values of the multiple
measurements of the same quantity in fixed conditions. Variation character-
izes instability of indications of a measuring instrument.
A calibration characteristic is a relationship between input and output
values of a measuring instrument represented by a formula, table or diagram.
In most cases instruments are calibrated in such a way that the scale interval
exceeds the maximum calibration error but this principle is not always appli-
cable. Thus, although there is a certain relation between accuracy and sensi-
tivity, we should not confuse these concepts. The device calibration charac-
teristics can be used for refinement of measurement results.
51
The important characteristic of contact measuring instruments is meas-
uring pressure, which is applied on a measurement line and creates defor-
mation at the contact of a measuring point with a part surface.
The measuring instruments can be analog and digital. In analog instru-
ments the indications are determined by the scale and are continuous function
of measurand variation. In digital devices the discrete signals of measuring
information are produced and the result is represented in a digital form.
52
7. Measurement Errors and Causes of the Errors
53
According to the sequence of errors origin there are several types of er-
rors:
instrument error is a measurement error component depending on er-
rors of the given measuring instruments. These errors are determined
by the quality of measuring instruments;
error of the method of measurement is a measurement error compo-
nent caused by imperfection of a measurement method;
calibration error is a measurement error component caused by imper-
fection of the calibration process;
reading error is a measurement error component caused by inaccurate
reading of a measuring instrument. The error is caused by visible var-
iation of the relative positions of scale marks as a result of move-
ments of the line of sight; this error is called a parallax error;
verification error is a measurement error component which is a result
of imperfection of verification of means of measurement. The errors
due to measuring pressure take place when a contact measuring in-
strument is used. In estimating of measuring pressure effect on meas-
urement error it is vital to define elastic deformation of a positioning
part of the instrument and deformation in a contact area of a measur-
ing point with a part;
influence quantity is a physical quantity that is not being measured
by a given instrument, but which influences the value of the measur-
and, for example, temperature and ambient pressure, relative humidi-
ty and other parameters different from standard values.
54
thermal deformations: deviation of air temperature from 20 C and short-term
variation of air temperature during the measurement.
Personal errors are the errors depending on an operator. Four types of
personal errors are possible:
1. reading error;
2. presence error (influence of operators thermal radiation on ambient
temperature and thus on a measuring instrument);
3. implementation error (brought in by an operator during the device
setting up);
4. professional errors (are connected with operators qualification and
his/her attitude to the procedure of measurement).
55
8. Measurement Traceability Assurance
57
8.1 Verification, Inspection and Expertise of Measuring
Instruments
59
State acceptance tests are carried out by corresponding national services
of legal metrology or special national commissions consisting of representa-
tives of institutes of metrology, organizations-developers, manufacturers and
customers. In the process of state acceptance testing of pilot samples of the
measuring instruments the service checks conformity of measuring instru-
ments with the state-of-the-art, requirements of the performance specifica-
tion, specification project and national standards.
Normalized metrological characteristics and possibility of their inspec-
tion during manufacturing, after repairing and in operation, the possibility of
verification and maintainability of the measuring instruments being tested are
also subjected to inspection. On the basis of study and analysis of the engi-
neering documentation and instruments being tested the state acceptance
commission makes recommendations on expediency (or non-expediency) of
production of the measuring instruments of the given type.
The governmental agency on standardization and metrology studies the
materials of the state testing and concludes on approval of output of a meas-
uring instrument. After that this type of a measuring instrument is registered
in the national registry of measuring instruments.
State check testing is carried out by territorial organizations of the gov-
ernmental agency on standardization and metrology.
The purpose of state check testing is verification of conformity of the
manufactured measuring instruments and measuring instruments imported
from abroad with the standard requirements and standard specifications.
Check testing of batch-produced measuring instruments is carried out in cer-
tain cases. Tests of this type are required during the manufacture of new
measuring instruments of a preproduction batch, in case there is a quality de-
terioration of the measuring instruments produced by a manufacturer.
Check testing is carried out if there are some changes in the structure or
technology of measuring instruments production, which influence standard-
ized metrological characteristics. The testing also takes place in order to con-
trol quality of the manufactured measuring instruments within the terms
which are assigned by the governmental agency.
60
9. Product Quality Control
63
10. Measurement and Inspection of the Product Parameters
The main requirement for carrying out inspection during the manufac-
turing process is to ensure accuracy. The measurement accuracy depends on a
number of factors, the main are: the maximum errors of the means of meas-
urement and inspection, metrological principles of the instruments design,
accuracy of the implemented measurement methods, influence of the external
factors.
The development and adoption of procedures of measurement and in-
spection is of great importance. The measurement procedure is a series of
methods, tools, procedures, conditions of preparation and implementation of
measurements, as well as rules for the processing of the experimental data to
perform specific measurements.
Measurements should be carried out in accordance with the appropriate-
ly certified procedures. The development of the measurement procedures
should include:
analysis of technical requirements for the accuracy of the object be-
ing measured;
identification of the required conditions of measurement;
selection of measuring instruments;
designing of the supplementary metrological equipment;
testing of the means of measurement and inspection;
planning of the processes of measurement and inspection;
development and selection of an algorithm for analysis of the results
of observation;
designing of the execution and presentation of the results of meas-
urement.
Technical documents that regulate measurement procedures are:
GOSTs and procedural guidelines on procedures of measurement.
Standards are issued in case the means of measurements are regis-
tered in National registry of measuring instruments;
industrial procedures of measurement that are used within the branch
of industry;
64
standards of enterprises on procedures of measurement that are used
in the enterprise. The procedures of measurement include: the stand-
ards of the measurement accuracy; functional features of the meas-
ured value; the need for measurement automation; the use of software
for data processing, etc.
65
10.3 Accuracy of Means of Measurement and Inspection
67
The influence of the measurement errors in acceptance inspection upon
linear dimensions can be estimated with the help of parameters m, n and c
(Fig. 2), where: m portion of the measured parts with dimensions exceeding
the limits of size, but taken among the good parts (wrongly accepted); n
portion of the parts with dimensions not exceeding limits of size, but rejected
(wrongly rejected); c the probabilistic maximum value of the wrongly ac-
cepted parts sizes overrun.
Fig. 2 shows the distribution curves of the part dimensions ( ymanuf ), and
measurement errors ( ymetr ), with the center of distribution of the measure-
ment errors coinciding with the tolerance limits.
68
The superposition of curves of ymanuf and ymetr distorts the distribution
curve y ( METR , MANUF ), as a result, the probability areas of m and n appear,
which cause the size to exceed the tolerance limit on the value of c. The
greater the ratio METR / T is, which means more accurate manufacturing pro-
cess, the smaller the number of incorrectly accepted parts compared to incor-
rectly rejected parts is, since m / n 0.1 1.1 . The maximum value of the c is
in the range (1.5-1.73) METR .
The parameters m, n, and c may be defined according to the Table 20, it
is recommended to take AMETR () =0.16 for the grades IT2-IT7;
AMETR () =0.12 for the grades IT8, IT9; AMETR () =0.1 for the grade IT10
and lower. The smaller values of m, n and c in the Table 20 correspond to the
normal distribution of measurement error, the greater values correspond to
the law of equal probability.
With the unknown law of measurement error distribution the values of
m, n and c can be defined as the average of the range values given in the Ta-
ble 20. Limit values of m, n and c/T include only the influence of the random
component of the error of measurement. Values of m, n and c are also given
in the literature as nomograms.
Table 20
AMETR () , % m, % n, % c/T
1.60 0.37...0.39 0.70...0.75 0.01
3.0 0.87...0.90 1.20...1.30 0.03
5.0 1.60...1.70 2.00...2.25 0.06
8.0 2.60...2.80 3.40...3.70 0.10
10.0 3.10...3.50 4.50...4.75 0.14
12.0 3.75...4.11 5.40...5.80 0.17
16.0 5.00...5.40 7.80...8.25 0.25
69
Example 1. Determine the accuracy of the measuring instruments
required for the procedure of acceptance of manufactured shafts with
100h6(-0.022), and determine values of the statistical parameters m, n, and c.
Acceptance limits are set matching the limits of size.
The permissible error of measurement, according to GOST 8.051-81, is
METR 6 microns for AMETR () 16% (accuracy grade IT6). According to
the Table 20 the number of defective parts being accepted is m=5.2%, the
number of incorrectly rejected parts is n=8%, and c=5.5%. The general
dispersion of the error of measurement of the accepted defective parts is in
the range from 27.5 to 5.5 microns (see Fig. 1, c), i.e. up to 5.2% of
defective parts with permissible deviations of +0.0055 mm and -0.0275 mm
can be found among the accepted ones.
71
The random errors are caused by many randomly varying factors, such
as: inaccuracies of the measuring instrument components, machining allow-
ance, mechanical properties of the material, cutting force, measuring force,
varying accuracy of installation of parts on the measuring position and other
factors, and in general, none of these factors prevails.
Manufacturing errors and measurement errors are random variables. Ex-
amples of random variables are: dimensions of parts during manufacture,
clearances in sliding joints, results of repeated measurements of the same
quantity, etc.
Random errors are difficult to eliminate, thats why they are taken into
account when assigning a tolerance for a dimensional or any other parameter.
The numeric value of a random variable being a result of a measurement
is considered as a random event. The same thing happens during product test-
ing, for example, when it is needed to establish product quality indicators.
The ratio of n events of a random value A to the N produced tests, in
which the event might occur, is called relative frequency of W(A)=n/N.
With a sufficiently large number of trials N, the ratio value for most of
the random events is found to be stable. The value of W(A) for the event A
will fluctuate around some constant number equal to one. This number, al-
ways less than one, is called the probability P(A) of the event A, i.e., P(A) is a
measure of the objective possibility of occurrence of the event A.
The probability of a certain event is equal to one, probability of an im-
possible event to zero.
The relative frequency can be taken as the approximate value of the
probability P(A) of the event A at a sufficient number of tests:
P ( A) W ( A) n / N . (1)
Relative frequency W(A) is different from the probability P(A) that it is
a random variable, which in various series of similar tests may take, depend-
ing on the random factors, different values, whereas the probability P(A) is a
constant, for a given event, number, which on average determines the relative
frequency of the event occurrence in the experiments.
With the increasing N the relative frequency approaches the probability.
The relationship between the numerical values of the random variable
and the probability of their occurrence is established by the law of probability
distribution of random variables. Probability distribution of a discrete random
variable can be represented as a table or diagram, showing how likely a ran-
dom variable x takes a particular numerical value xi.
Probability distribution of the continuous random variable, which can
take any value within a given interval, can not be represented as a table.
The distribution is represented as a differential function of distribution
or probability density function px(x). This function is the limit of the ratio of
72
the probability of the fact that the random variable x takes the value that lies
in the interval from x to x x to the value of the interval x , when x
tends to zero.
The nature of the scattering of the essentialy large set of values of a ran-
dom variable usually corresponds to a theoretical distribution law.
The scattering of the random variable values, the change of which de-
pends on a number of factors, when no one factor has predominant influence,
follows the normal distribution law (Gaussian), shown in Fig. 3.
x
3 3
a
73
( x a )2
1
2
yx e 2 , (2)
2
where a and are the parameters of the distribution; x is the argument of the
probability density function, i.e. a random variable that varies in the range
x ; e is the base of natural logarithms.
The normal distribution curve is symmetrical about the ordinate axis.
The value of a is equal to the mathematical expectation M(x) of the random
variable x, which is determined by the equations:
for discrete values
k
M ( x ) xi p ( xi ) , (3)
i 1
where xi is the possible value of a discrete random variable; p ( xi ) is the
probability of the value xi of a discrete random variable;
for continuous variables
M ( x ) xp( x)dx , (4)
where p(x) is the probability density of a continuous random variable x.
The value of M(x) represents the position of the center of variance of
random variables, the place where, for example, the sizes of the most parts of
the batch are grouped around.
In the absence of systematic errors in the results of repeated measure-
ments of the same quantity in the same conditions, the expectation can be re-
garded as the closest approximation to the true value of the measurand.
In analysis of the nature of the variance of the machined parts dimen-
sions, the expectation can be regarded as the dimension, for which the ma-
chine tool has been set up.
The magnitude of the random variable variance from the expected value
is defined by the parameter , which is called standard deviation of a random
variable and is determined by the equation:
for discrete value
k 2
( x) xi M ( x) p ( xi ) , (5)
i 1
for continuous variable
2
( x) x M ( x ) p ( x)dx . (6)
Scattering of the random variables is also characterized by variance
D ( x ) ( x ) 2 .
74
Formula (2) represents an equation of the curve for the case when the
origin is located at an arbitrary position on the x-axis. If the center of vari-
ance coincides with the origin of x-axis, the equation of the normal distribu-
tion curve will take the form:
x2
1
2
y ( x) e 2 . (7)
2
At the same time, there are other distribution laws that describe the ran-
dom variables, which have the nature of a somewhat different nature.
In this case it is necessary to mention Maxwell law, to which the essen-
tially positive quantities are subjected; such quantities are: the scattering of
eccentricity values, axial and radial run-out, concentricity deviation, imbal-
ance and other quantities that cannot be negative.
To evaluate the reliability of products Weibull law, which gives an idea
of the probability of failures, is used.
Simpson law (or the triangular distribution law) and the law of equal
probability also have become widespread.
However, for the analysis of observations the normal distribution law
Gaussian law is used.
The probability for the value to fall into a given interval can be defined
as follows. The branches of the theoretical normal distribution curve (Fig. 3)
go into infinity, asymptotically approaching the x-axis. The area enclosed by
the curve and the abscissa is equal to the probability that the random variable,
for example, error of size, belongs to range . The area under the distribu-
tion curve is equal to 1 or, what is the same, 100%, and is determined by the
integral:
x2
1
2 2 dx
e 1. (8)
2
The origin is located at the point coincident with the center of variance.
Since the integrand is even and the curve is symmetrical with respect to the
maximum ordinate, we can write:
x2
1
2 2 dx
e 0.5 . (9)
2
75
pressed in fractions of . If 0 and z are taken as limits of integration, then the
integral in equation (8) is a function of z, i.e.:
zz
1 z 2
0 (z) e dz . (10)
2 n
-3 -2 -1 0 1 2 3 x
Fig. 4 Normal distribution curve and representation of integrands
76
Therefore, with a probability close to unity, one can assert that the ran-
dom variable x will not exceed the limits of 3. Therefore, with the distribu-
tion of the random variable according to the Gaussian law, the range of dis-
persion is equal to Vlim 6 or the range 3 is considered as a sensibly
limiting range of dispersion of a random variable and is taken as the stand-
ard of accuracy tolerance. Here the probability of a random variable to ex-
ceed the limits of 3 is equal to 0.0027 or 0.27%.
In production environment, due to the limited number of measurements,
analysis involves not the mathematical expectation and variance but their ap-
proximate statistical estimates the empirical average x and the empirical
variance s2 respectively, which characterise the average result of the meas-
urements and the degree of results variance. These estimates are determined
by the equations:
x n x2 n2 ... xk nk k ni
x 1 1 xi ; (11)
n1 n2 ... nk i 1 N
k ni
s (x x)2 . (12)
i 1 N
77
The method of statistical analysis of observation results is considered on
the example of measurement of discrete sizes of the shafts with 12h10(0.07)
machined on a lathe. The size of a sample out of the statistical population
(batch size) is equal to N = 200. Measurements are carried out by instruments
like length gage or optimeter with the scale interval 0.001 mm.
Analyzing the observation results, we conclude that among these values
there are such values which are significantly different from most of the re-
sults, so we can call them gross errors. Such observations can be caused by
inspectors inattention, by extraneous parts in the sample and some other
causes that break normal conditions of experimental results generation. We
should keep in mind that these observations differ visually significantly from
the average for the given sample. In the case of gross errors, their causes
should be analyzed and eliminated.
The result that is the gross error is excluded from the population and the
remained results are processed again and new values of x and s are calculat-
ed; then the furthest analysis is carried out and, if necessary, other gross er-
rors are also excluded by means of Kolmogorov criterion, Irwins criterion or
others. In preliminary calculations the errors, i.e. deviations from x , exceed-
ing absolute value 3 are excluded.
The observation results after the preliminary analysis are arranged in or-
der of magnitude forming the variational series. We shall find maximum and
minimum values of dmax and dmin and find the range of the series.
In our example the minimum value of the observed dimension equals to
11.915 mm, the maximum value to 12.005 mm and then the range R, equal
to the difference of the found limit values, is equal to:
R=dmax dmin=12.005 11.915=0.09 mm.
Then we shall divide the variational series into k intervals. The number
of k intervals, to some extent, depends on the sample size N and can be taken
by the following recommendations: 5 k 7 with N 40 ; 7 k 9 with
40 N 100 ; 9 k 12 with 100 N 500 , moreover with the small num-
ber of intervals it is better to take k as an odd number. So we can see that the
values are considerably overlapped and selection of the interval number is
not determinant, thus the recommendations are only suggestive, not literal.
Taking k = 9, the interval value is equal to R/k= 0.09/9 = 0.01 mm and a
half interval totals to 0.5 R/k= 0.005 mm. We shall find the values of the class
marks and form interval series, for that we shall add 0.5R/k to dmin, then to
the found value we shall add 0.5 R/k again and so on, as a result we shall ob-
tain d max 0.5 R / k , i.e. 12.000 mm.
Then we shall find a number of observations falling in each interval, for
example, 20 results have fallen in the interval 11.93511.945; 12 results
78
have fallen in the interval 11.97511.985 and so on. We should keep in
mind that the values that coincide with the interval boundary are included in-
to the left interval.
The number of observations fallen in the given interval is called fre-
quency.
The order of results analysis and the example of analysis presentation is
given in the Table 21. The values x and s are determined by equations (11)
and (12):
x (11.920 2 11.930 6 ... 12.000 2) / 200 11.960 mm;
S (0.04) 2 0.01 (0.03) 2 0.03 ... (0.04) 2 0.01 0.015 mm.
Table 21
The example of measurement results analysis
from 11.915
11.920 2 0.04 0.01
to 11.925
over 11.925
11.930 6 0.03 0.03
to 11.935
over 11.935
11.940 20 0.02 0.10
to 11.945
over 11.945
11.950 48 0.01 0.24
to 11.955
over 11.955
11.960 56 0.00 0.28
to 11.965
over 11.965
11.970 34 +0.01 0.17
to 11.975
over 11.975
11.980 20 +0.02 0.10
to 11.985
over 11.985
11.990 12 +0.03 0.06
to 11.995
over 11.995
12.000 2 +0.04 0.01
to 12.005
0.10 ni
x 11.96 -- N 200 v i 0 N 1
i 0.10 i
79
ed by the histogram consisting of rectangles, which height equals to frequen-
cy and width to the range of the interval.
The dispersion is also determined by the empirical curve of distribution,
which is called distribution polygon (Fig. 5). Graphical representation of re-
sults in manual analysis is easier to perform with the help of squared paper.
X-direction means intervals of the actual dimensions of the shaft, Y-direction
is the height of rectangles equal to frequency.
Distances along X-axis and Y-axis are recommended to plot in relation
equal to 0.8 1.0. In Fig. 5 you can see polygon and histogram of distribu-
tion of shaft dimensions and location of tolerance zone that reflects require-
ments to accuracy according to the drawing; as we can see the empirical re-
sults do not meet the requirements of engineering documentation and this is
as it should be.
ni
50
Polygon
40
30
20 Histogram
10
0
-11.92 11.94 11.96 11.98 12.00 x i , mm
Empirical center of Tolerance zone
variance 11.96 midpoint 11.965
ei =-0.07 ec =-0.035 0
Tolerance zone 70 m
dmin =11.93 dmax =12.00
80
For example, noncoincidence of tolerance zone midpoint with empirical
centre of variance is equal to 0.005 mm and the range exceeds tolerance by
the value equal to 0.09 0.07 = 0.02 mm. In order to make conclusion on
batch acceptance, it is necessary to analyze the obtained results according to
the following features:
compliance of empirical distribution with the normal distribution
law;
estimation of confidence probability of empirical parameters;
manufacturing tolerancing.
The results analysis of random variable measurement becomes possible
if we know which theoretical law of random value distribution the empirical
distribution corresponds to.
On the basis of empirical curve shape and values of empirical parame-
ters, the correspondence of the curve to one of theoretical laws is suggested.
We shouldnt forget about the importance of graphical representation of
the empirical curve, which is influenced, among other things, by selection of
intervals number and ratio of values along X- and Y-axes.
Correspondence of empirical distribution to the supposed theoretical
distribution is determined on the basis of criteria 2 , for example, of the
Kolmogorov criterion, according to GOST 11.006-74.
Comparison of characteristics of empirical and theoretical distributions
is carried out in the following manner. Values of parameters of empirical and
assumed theoretical distributions are considered. The parameters x and s, de-
termined by sampled data, give only approximate response of accuracy of en-
tire population of the objects.
Mathematical expectation M(x) and standard deviation serve as a
characteristic of random variable values dispersion in entire assembly.
The difference between probabilistic characteristics M(x) and and em-
pirical values x and s lies in that the first are considered as unknown con-
stants characterizing distribution of the statistical population, and the second
are random variables, defined from the sample, and give only approximate
estimate of M(x) and .
The difference between M(x) and x and between and s reduces with
the increase of sample size and number of observations.
Analysis of the observation results of the sample allows to define the
limits, within which the values of the statistical population parameters will
lie.
81
The degree of that confidence that is so called confidence interval is se-
lected in accordance with standard specifications to the product performance
characteristics.
Limits of the confidence interval determine confidence probability,
which characterizes reliability of the results.
In case of normal distribution, such confidence interval for mathemati-
cal expectation M(x), for example, is the interval with the limits of M(x)
equal to 3 x where x is a standard deviation for distribution of values x .
Since
si
x ,
N 1
3
x si .
N 1
From the table of values 0 ( z ) we shall find that within the limits
z1 3 , there is 99.73% of all values of random variable x, expressed by z,
as 0 (3) 2 0.49865 0.9973 . Thus, with reliability 0.9973 we can predicate
that the M(x) value is within the interval x 3 x .
As x and s are random variables, the confidence intervals, as it follows
from the calculation given above, depend on a factor multiplying 3 x , which
we shall denote for general case by z.
It is evident that the reliability of that the value of M(x) will be within
limits of x z x is more than 0.9973 if z>3 and is less than 0.9973 with z<3.
It is common when reliability is equal to one of the following quantities:
0.90, 0.95, 0.99, 0.999, which is equivalent of z equal to 1.645, 1.96, 2.576,
3.291.
Lets study the example, assume that the distribution described above is
the sample with N = 200 and is normal distribution, then:
si 0.015
x 0.001 mm.
N 1 199
x z x M ( x) x z x .
82
So with reliability 0.9 or 90% we may expect:
or
11.958 M ( x ) 11.962 .
Table 22
observations
Number of
Number of
0.05 0.90 0.95 0.98 0.99 0.05 0.90 0.95 0.98 0.99
2 1.0 6.31 12.71 31.82 63.66 10 0.70 1.84 2.26 2.76 3.25
3 0.82 2.92 4.30 6.96 9.92 15 0.69 1.76 2.14 2.60 2.98
4 0.77 2.35 3.18 4.54 5.84 20 0.69 1.73 2.09 2.53 2.86
5 0.74 2.13 2.78 3.75 4.60 30 0.68 1.70 2.04 2.46 2.76
6 0.73 2.01 2.57 3.65 4.03 60 0.68 1.67 2.00 2.39 2.66
7 0.72 1.94 2.45 3.14 3.71 120 0,68 1.66 1.98 2.36 2.62
8 0.71 1.90 2.36 2.97 3.50 0,67 1.65 1.96 2.33 2.58
9 0.71 1.86 2.31 2.90 3.36
The value t depends on the sample size, i.e. on N - 1; using these table
we may find that with N = 20 and reliability 0.9 the coefficient t is equal to
1.73; with the same value N and reliability 0.95, 0.99 and 0.999 the t equals
correspondingly to 2.09, 2.86 and 3.88.
The selection of reliability is defined by the object of manufacture, for
example: for general-purpose products the reliability can be equal to 0.9; for
critical parts 0.95; for aeronautical equipment 0.99; and finally 0.999 for
83
critical equipment which malfunction can pose a hazard to human health and
life.
Thus, if the values x 11.96 and s 0.015 were obtained from the sample
of 20 pieces, but not 200 pieces (as it has been shown in the previous exam-
ple), so with reliability 0.9 the limits of confidence interval would be the fol-
lowing:
si 0.015
x 0.001 mm.
N 1 199
or
11.955 M ( x ) 11.965 .
For the reliability equal to 0.999, the confidence interval is significantly
larger:
11.96 3.88 0.001 M ( x) 11.96 3.88 0.001
or
11.948 M ( x) 11.972 .
With the sample size decreasing and the required reliability increasing,
the width of the confidence interval will increase, i.e. the limits of possible
values M(x) will expand.
Similarly to this, the confidence intervals for the value x can be found.
Open Microsoft Excel 2007 and into the Table (Fig. 6) enter data of
the example given in Section 10.5 (Table 21): average value xi of the interval
and number ni of parts in interval, having doubled the column with the val-
ues ni .
84
Fig. 6 Initial data
85
3. Then in the same panel Select data go to tab Bar/Column. In
the bar Labels on horizontal axis click on Edit and also push
the button with red arrow and select column with values xi, then
push the button with red arrow again returning to the panel of dia-
gram master. Click OK.
4. At the constructed diagram click the right mouse button on any
column of the histogram and select Format data series, go to the
tab Parameters of series and set the width of side clearance equal
to zero, press OK. So we have constructed the distribution histo-
gram for the given values (Fig. 8).
35
30
25
20
1
15
2
10
0
2,2190 2,2202 2,2214 2,2226 2,2238 2,2250
86
35
30
25
20
1
15
2
10
0
2,2190 2,2202 2,2214 2,2226 2,2238 2,2250
87
Fig. 10 Initial data
Fig. 11 2D histograms
88
With the next step it is necessary to set the number of histogram col-
umns (Categories). In our case we set 6 columns and push the button
OK. Now we can see the window of data selection for the histogram
(Fig. 12). Select a column with data and press OK again.
89
For the construction of distribution polygon it is necessary to push the
right mouse button on the constructed histogram and in the dropdown menu
select Fitting. Then it is needed to push Add new fit (Fig. 14) and select
the type Lowess (Fig. 15).
90
Fig. 16 histogram, polygon and theoretical curve of normal distribution
Thus, the package Statistica 7.0 substantially helps to simplify analysis
and processing of data and provides simple tools of diagram construction.
The outlined method allows to estimate any manufacturing process, nu-
merically assess accuracy of the process, determine values of the parameters
that exceed acceptance limits.
91
Conclusion
92
Index
T wear block, 33
Weibull law, 75
testing-calibrating measurements, 11 working measuring instruments, 22
thread pitch working standard, 23
threshold of sensitivity, 51 workshop, 63
tie, 33 wringability, 27
tolerance, 20
tolerance zone, 66
96
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