Metrology Lab 1 Fall 2023- Final
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MACH8006 - LAB 1
Name: Midhun Ayaruthodi
Date: 09/07/2023
Prerequisite: Completion of assigned readings.
Introduction:
In this lab, students will explore variation, accuracy, precision, and repeatability. The lab
includes a number of exercises, each adding more variation to the simple process of
cutting a straw, until the final exercise, which is designed to help improve accuracy and
precision, and to reduce variation as much as possible.
Items needed:
A variety of scissors and plastic straws
SAE and metric rulers of various lengths and discriminations
Name and Student Number: Aswin Anil (8913007), Midhun Ayaruthodi (8829008),
Fredinent Emerson (8895128)
Date: 09/07/2023
E
XERCISE
1 – (Week One)
Cut a plastic straw into six 25mm segments using the lined instrument provided by the
instructor. Bonus marks will be given to the group that completes this task the fastest.
Once each section is cut, line your segments up and compare the lengths of each to all the
others.
Now, answer the following questions:
1.
Was there variation in the length of each segment compared to the other? If so, how much?
Yes, there were slight variations in four of the six pieces (A, B, C, D, E, F). Upon
individual measurements, piece A measured 25 mm, B measured 24.9 mm, C measured 25.1mm, D
measured 25.1, E measured 25 mm. and F measured 24.9 mm This might be the effect of not
having a proper viewing angle when cutting the pieces, or it could be the lack of sturdiness of the
given straw
.
MACH8006 - LAB 1
Name: Midhun Ayaruthodi
Date: 09/07/2023
2.
Was each segment cut accurately?
The plastic straw was measured and divided into six equal pieces of 25 mm each. When
measuring each piece with the ruler, there were slight differences in length in four of the six cut
pieces. Upon closer inspection of these segments, it was found that the variations were caused due
to the discrepancy in the edges surface, this was due to the uneven angles on the cutting face.
Moreover, this could also be due to the straw being flexible and bending upon coming in contact
with the provided scissors, and human errors are inevitable. While the other two pieces were
similar in measure, the faulty ones varied in measurement by around 1 millimeter.
3.
Was each segment cut with the same precision?
Among the six pieces that were cut, two of them were cut precisely. However, the
other four pieces showed variations in the length when comparing them with the ones that were
found to be precise. Moreover, the dissimilarity was confirmed by measuring them with a
mechanical ruler and the difference was found out to be around 0.1 mm. This is due to human
errors or might be an instrument error (blunt cutting edge). The results can be improved by using
more care upon cutting and using more sharper cutting.
MACH8006 - LAB 1
Name:
Midhun Ayaruthodi
Date: 09/14/2023
Name and Student Number: Aswin Anil (8913007), Midhun Ayaruthodi (8829008),
Fredinent Emerson (8895128), Athul Sunil Kumar (89392260), Goutham Aykkyathil
(8930076), Harikrishnan Suresh Kumar Vasantha Kumary (8916053)
E
XERCISE
2 – (Week two)
Pair with another group and compare your straw segments to each other.
Answer the following questions:
1.
Is there any variation in the length of each of your segments compared to your partners’?
Yes, there were variations in straw length when comparing ours with that of another group.
However, the differences weren’t as profound since the six pieces our teams had cut were measured
with similar rulers. Pieces A and E were found to be near perfect, but in their case, they had just
one piece that was cut with perfection. Similarly, they, too, had deviations of ± 0.1 mm for the
other five pieces.
2.
Was each segment cut accurately?
Both of our teams followed the same procedure to measure the 25 mm sections of straw.
We both took the measurements by aligning the straw piece to a plastic ruler, upon which we
marked the 25 mm boundary with a sharp-tipped pen, which was cross-checked to verify that the
measurements were as accurate as we could bring them to be. Even after multiple checks before
cutting the 25 mm piece, those pieces were still not as accurately cut as we’d thought. Only two of
the six pieces showed the accurate size, while the other four had different dissimilarities. While
three of the four incorrect pieces were the cause of parallax error (which led to uneven cutting
edges), the other one was ever so slightly cut shorter than the rest (human error).
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MACH8006 - LAB 1
Name:
Midhun Ayaruthodi
Date: 09/14/2023
3.
Was each segment cut with the same precision?
Upon closely inspecting our six pairs of straws, the only indifference to us was that a few
of their pieces had irregularities on the cutting edge as well, which in turn led to slight deviations
in length. Also, it can be said that human error is the cause of these irregularities, as the person
cutting these straw pieces may not have had proper lighting and visibility of the line to be cut. It
can also be said that even though both our scales were similar, there could’ve been variations of
the tiniest amount, which would eventually lead both our teams to have straws of dissimilar
lengths.
MACH8006 - LAB 1
Name:
Midhun Ayaruthodi
Date: 09/14/2023
E
XERCISE
3 – (Week Three)
As a class, discuss possible methods of improving precision and accuracy and reducing
variation. Repeating this exercise achieves better results? Why or why not?
Using a regular ruler isn’t how to perform precision cuts with minimal deviation. One way
to eliminate or reduce the deviation is to use precision equipment like gauge blocks and a dial
indicator. For this to work, a gauge block of 25mm (1 inch) is taken and used to calibrate the dial
indicator. Once this process is done, it is much easier to measure the straw pieces that we cut. To
measure the 25mm pieces of straw, we keep the straw parallel to the side of the gauge block and mark
the point accurately. Once the measurement is taken, we can cut that straw into 25 mm pieces. The
main reason gauge blocks make a difference is that gauge blocks are the international standard for
measurement (like length, mass, etc.), and a ruler of mass production wouldn’t produce the same
standards. This is why a piece of 25 mm straw cut with measurements from a slip gauge is more
accurate than that of a regular ruler. Doing this experiment with the help of precision equipment has
helped in producing pieces of much more accuracy. Although using a dial gauge and slip gauges may
be a more complicated way of measurement, the accuracy and precision of these equipment stay true.
MACH8006 - LAB 1
Name:
Midhun Ayaruthodi
Date: 09/14/2023
Observations:
What did you observe in terms of accuracy and precision within your group and then again
with the entire class?
When the experiment was conducted within our group, we used a ruler to measure the
plastic straw, which was cut with scissors. Although this was the easiest and fastest method of
measuring the 25 mm, it wasn’t the most accurate. Four of the six pieces were flawed, either
caused by human error (parallax error), inaccurate measuring equipment (ruler), or a
combination of both. When this same experiment was conducted as a whole class, we used
precision equipment like slip gauges and a dial gauge. The use of proper equipment yielded
much better results; the number of accurate and nearly perfect pieces was the majority. This
made us realize that standardized precision equipment like slip gauges are much more accurate
and can be used in repeating the same task with utmost precision.
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MACH8006 - LAB 1
Name:
Midhun Ayaruthodi
Date: 09/14/2023
END-OF-CHAPTER QUESTIONS
1. Accuracy can only be checked by comparison with:
a. another technician or metrologist
b. a trade group
c. a higher standard
d. your boss
2. Measurement is most important to which one of the following applications?
a. Mass production of automotive parts
b. Mass production of aircraft parts
c. One-of-a-kind handicrafts
d. All manufacturing
e. Manufacturing of parts from prepared plans
3. Measurement involves fundamental qualities. Select three qualities from the following list.
a. Roundness
b. Mass
c. Flatness
d. Time
e. Weight
f. Modules of elasticity
g. Length
h. Width
i. Hardness
4. Which of the following best defines “dimensional metrology?”
a. The measurements required to manufacture products
b. Measurements found by the use of scales and other measuring instruments.
c. The measurement of lines, areas, volumes, and angles
d. The measurement of real things, whether they be steel, wood, plastic, or any other material
e. The measurement of lines, circles, and angles
5. Select one or more of the following that are not considered to be dimensional metrology.
a. Bolt circle spacing
b. The selection of lubricants for a given bearing allowance
c. The torque requirement for a bolted assembly
d. The tolerance required for a shaft in a bearing
e. The size limits of a mass-produced replacement part
6. The role of the inspector in industry emerged as the result of which one of the following circumstances?
a. Weapons were first mass produced.
b. Gunpowder changed the threat from weapons.
c. Foremen could not keep up with mass production rates.
d. The piece-part system was introduced.
e. Precision measurement tools such as the micrometer were introduced to industry.
7. Of the following characteristics, select the ones that affect quality control.
a. Employee morale
b. Pride of product
c. Dimensional measurements
d. Environmental conditions
e. Product specifications
MACH8006 - LAB 1
Name:
Midhun Ayaruthodi
Date: 09/14/2023
8. For every act of dimensional metrology, one or more of the following variables may apply. Identify the single most
important variable.
a. Number of decimal places
b. Metric or customary system
c. Reliability
d. Repeatability
e. Sensitivity
9. In this text, metrological methods or principles are emphasized rather than the measuring instruments themselves. There
are several reasons for this. Which of the following is the most important reason?
a. There is no complete agreement about the instruments.
b. Instrument manufacturers provide detailed information.
c. Principles are more interesting than methods of use.
d. Principles and methods are easily adaptable to all instruments.
MACH8006 - LAB 1
Name:
Midhun Ayaruthodi
Date: 09/14/2023
Discussion Question
10. Small errors can cost a company billions of dollars or have dire consequences.
Discuss the potential impact that small errors can have in the following industries: • Automotive • Aerospace •
Biotech/Medical
Errors in mass-production sectors can have major consequences for businesses. The more goods a
corporation can produce in a given amount of time, the bigger its sales and profit margins. As a result, the
tolerance for errors in such businesses is low, because time is money, and any delay in correcting mistakes
results in financial losses.
A car is created and rolled out in 45 seconds in the automobile business, such as Toyota. Any fault
on the production line halts the entire process, and the time required to identify and correct the error might
range from minutes to hours. During this troubleshooting period, the firm suffers financial losses, stressing
the need to prevent unexpected breakdowns.
Medical equipment that is defective can have disastrous effects. MRIs, for example, can save lives;
but, defects in these technologies might result in incorrect readings and, as a result, misdiagnosis. Such
mistakes can cost the industry millions of dollars, highlighting the crucial need of accuracy and
dependability.
Similarly, while not manufacturing as many products as the automobile industry, the
aviation industry suffers significant losses when flaws are uncovered. Production and shipment delays can
result in considerable financial losses for firms due to the ongoing demand for aeronautical products.
In short, Errors in mass production, as seen in the automotive, medical, and aerospace industries,
have severe financial repercussions. The need for precision is crucial, with any delay in resolving errors
translating into significant financial losses, emphasizing the importance of accuracy and reliability in these
sectors.
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