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<p>Preface xiii</p> <p>Acknowledgments xv</p> <p>About the Author xvii</p> <p><b>1 Fundamental Units and Constants in Metrology </b><b>1</b></p> <p>1.1 Introduction 1</p> <p>1.2 Current Definitions of the Main SI Units 6</p> <p>1.3 New Definition of Seven Base Units of the SI 6</p> <p>1.4 Derived International System (SI) Units 7</p> <p>1.5 SI Conversion 7</p> <p>1.6 Fundamental Constants 8</p> <p>1.7 Common Measurements 9</p> <p>1.8 Principles and Practices of Traceability 10</p> <p>1.8.1 Definition of Traceability 10</p> <p>1.8.2 Accreditation and Conformity Assessment 11</p> <p>Multiple Choice Questions of this Chapter 12</p> <p>References 12</p> <p><b>2 Scales of Metrology </b><b>13</b></p> <p>2.1 Introduction to Practical Metrology across All Scales 13</p> <p>2.2 Nanometrology 14</p> <p>2.2.1 Introduction and Need in Industry 14</p> <p>2.2.2 Definition of Nanometrology 15</p> <p>2.2.3 Importance of Nanometrology in Science and Technology 15</p> <p>2.3 Standards 18</p> <p>2.4 Micrometrology 22</p> <p>2.4.1 Introduction and Need in Industry 22</p> <p>2.4.2 Definition of Micrometrology 22</p> <p>2.4.3 Examples of Micrometrology of Microparts 22</p> <p>2.5 Macroscale Metrology 23</p> <p>2.5.1 Standards 25</p> <p>2.6 Large-Scale Metrology and Large-Volume Metrology 29</p> <p>2.6.1 Introduction and Need in Industry 29</p> <p>2.6.2 Definition 30</p> <p>2.6.3 Verification Standards 32</p> <p>2.7 Instruments Techniques 34</p> <p>2.7.1 Large Coordinate Measuring Machines 35</p> <p>2.7.2 Laser Trackers 35</p> <p>2.7.3 Theodolite 35</p> <p>Multiple Choice Questions of this Chapter 37</p> <p>References 37</p> <p><b>3 Applied Math and Statistics </b><b>39</b></p> <p>3.1 Introduction 39</p> <p>3.2 Scientific and Engineering Notation 39</p> <p>3.3 Imperial/Metric Conversions 40</p> <p>3.4 Ratio 41</p> <p>3.5 Linear Interpolation 42</p> <p>3.6 Number Bases 42</p> <p>3.7 Significant Figures, Rounding, and Truncation 43</p> <p>3.8 Geometry and Volumes 44</p> <p>3.8.1 Perimeter 44</p> <p>3.8.2 Volume and Area 44</p> <p>3.9 Angular Conversions 44</p> <p>3.10 Graphs and Plots 45</p> <p>3.11 Statistical Analysis and Common Distributions 47</p> <p>3.11.1 Definition of Measurement Data 47</p> <p>3.11.2 Statistical Measurements 47</p> <p>3.11.3 Statistical Analysis of Measurements 47</p> <p>3.11.4 Probability 48</p> <p>3.11.5 Sample and Population 49</p> <p>3.11.6 Formulation of Mean and Variance for Direct Measurements 49</p> <p>3.11.7 Mean and Variance Based on Samples 50</p> <p>3.11.8 The Standard Deviation of the Mean 51</p> <p>3.12 Formulation of the Standard Uncertainty and Average of Indirect Measurements 52</p> <p>3.12.1 How to Determine the Measured Value and Random Error? 52</p> <p>3.12.2 Repeated Measurements of One Single Quantity 52</p> <p>3.12.3 Normal Distribution 53</p> <p>3.12.4 Student’s <i>t</i>-distribution 55</p> <p>Multiple Choice Questions of this Chapter 60</p> <p><b>4 Errors and their Sources </b><b>61</b></p> <p>Introduction 61</p> <p>4.1 Definition of the Error and Their Types 61</p> <p>4.1.1 Systematic Errors 62</p> <p>4.1.2 Random Errors 63</p> <p>4.1.3 Components of Motion Error Assessment 63</p> <p>4.2 Measurement Characteristics 63</p> <p>4.2.1 Characterization of the Measurement 63</p> <p>4.2.2 Resolution, Error Uncertainty, and Repeatability 64</p> <p>4.2.3 Model of Measurement 67</p> <p>4.3 Propagation of Errors 69</p> <p>4.4 Sources of Errors 73</p> <p>4.4.1 Static Errors and Dynamic Errors 73</p> <p>4.5 Error Budget 77</p> <p>4.5.1 Components of the Error Budget 77</p> <p>4.5.2 Example of Error-Budget Table 78</p> <p>4.6 Error Elimination Techniques 79</p> <p>4.6.1 Methods 79</p> <p>4.7 Model of Errors in CNC Using HTM 81</p> <p>4.8 Case Study of Errors Budget 87</p> <p>4.8.1 Description of the Designed System 87</p> <p>4.8.2 Error Modeling and Experimental Testing 88</p> <p>4.9 Solved Problems 96</p> <p>Multiple Choice Questions of this Chapter 97</p> <p>References 97</p> <p><b>5 Measurement and Measurement Systems </b><b>99</b></p> <p>5.1 Introduction 99</p> <p>5.2 What Can Be Standard in a Measurement? 101</p> <p>5.3 Definitions of Key Measurement Components 102</p> <p>5.3.1 Measurement System 102</p> <p>5.3.2 Measurement System Analysis 103</p> <p>5.3.3 Measurement Process 103</p> <p>5.4 Physical Measurement Process (PMP) 103</p> <p>5.5 Difference between Number and an Analysis Model 104</p> <p>5.6 Measurement Methods 105</p> <p>5.6.1 Metrology and Measurement 105</p> <p>5.6.2 Metrological Characteristics of Measuring Instruments 108</p> <p>5.7 Instrumentation for Measurement 109</p> <p>5.7.1 Background 109</p> <p>5.7.2 Measurement Instrumentations 109</p> <p>5.7.3 Digital Measuring Device Fundamentals 109</p> <p>5.8 Non-Portable Dimensional Measuring Devices 110</p> <p>5.8.1 Laser Interferometry, Application to CNC Machines 110</p> <p>5.8.2 Coordinate Measuring Machine (CMM) 118</p> <p>5.9 Metrology Laboratory Test for Students 140</p> <p>Multiple Choice Questions of this Chapter 146</p> <p>References 146</p> <p><b>6 Tolerance Stack-Up Analysis </b><b>149</b></p> <p>6.1 Introduction 149</p> <p>6.1.1 Importance of Tolerance Stack-Up Analysis 149</p> <p>6.1.2 Need for Tolerance Stack-Up Analysis in Assemblies 151</p> <p>6.1.3 Manufacturing Considerations in Engineering Design 151</p> <p>6.1.4 Technical Drawing 152</p> <p>6.1.5 Definitions, Format, andWorkflow of Tolerance Stack-Up 153</p> <p>6.2 Brief Introduction to Geometric Dimensioning and Tolerancing (GD&T) 156</p> <p>6.2.1 Notation and Problem Formulation 156</p> <p>6.2.2 Dimension Types 157</p> <p>6.2.3 Coordinate Dimensioning 158</p> <p>6.2.4 Tolerance Types 160</p> <p>6.2.5 Characteristics of Features and Their Tolerances 162</p> <p>6.3 Tolerance Format and Decimal Places 164</p> <p>6.4 Converting Plus/Minus Dimensions and Tolerances into Equal-Bilaterally Toleranced Dimensions 165</p> <p>6.5 Tolerance Stack Analysis 167</p> <p>6.5.1 Worst-Case Tolerance Analysis 169</p> <p>6.5.2 Rules for Assembly Shift 169</p> <p>6.5.3 Worst-Case Tolerance Stack-Up in Symmetric Dimensional Tolerance 171</p> <p>6.5.4 Worst-Case Tolerance Stack-Up in Asymmetric Dimensional Tolerance 173</p> <p>6.6 Statistical Tolerance Analysis 173</p> <p>6.6.1 Definition of Statistical Tolerance Analysis 173</p> <p>6.6.2 Worst-Case Analysis vs RSS (Root-Sum Squared) Statistical Analysis 175</p> <p>6.6.3 Second-Order Tolerance Analysis 176</p> <p>6.6.4 Cases Discussions 176</p> <p>6.6.5 Understanding Material Condition Modifiers 178</p> <p>Appendix A from ISO and ASME Y14 Symbols 188</p> <p>Multiple Choice Questions of this Chapter 189</p> <p>References 189</p> <p><b>7 Instrument Calibration Methods </b><b>191</b></p> <p>7.1 Introduction 191</p> <p>7.2 Definition of Calibration 191</p> <p>7.3 Need for Calibration 192</p> <p>7.4 Characteristics of Calibration 193</p> <p>7.5 Calibration Overall Requirements and Procedures 195</p> <p>7.5.1 Calibration Methods/Procedures 195</p> <p>7.6 Calibration Laboratory Requirements 197</p> <p>7.7 Industry Practices and Regulations 198</p> <p>7.8 Calibration and Limitations of a Digital System 199</p> <p>7.9 Verification and Calibration of CNC Machine Tool 201</p> <p>7.10 Inspection of the Positioning Accuracy of CNC Machine Tools 202</p> <p>7.11 CNC Machine Error Assessment and Calibration 207</p> <p>7.12 Assessment of the Contouring in the CNC Machine Using a Kinematic Ballbar System 219</p> <p>7.13 Calibration of 3-axis CNC Machine Tool 221</p> <p>7.14 Calibration of a Coordinate Measuring Machine (CMM) 225</p> <p>7.14.1 CMM Performance Verification 225</p> <p>7.14.2 Accreditation of Calibration Laboratories 226</p> <p>Section 1: Scope and Description 231</p> <p>Section 2: Calibration Requirements 232</p> <p>Section 3: Preliminary Operations 232</p> <p>Section 4: Calibration Process 233</p> <p>Section 5: Data Analysis 234</p> <p>Section 6: Calibration Report 234</p> <p>Multiple Choice Questions of this Chapter 235</p> <p>References 235</p> <p><b>8 Uncertainty in Measurements </b><b>237</b></p> <p>8.1 Introduction and Background 237</p> <p>8.2 Uncertainty of Measurement 238</p> <p>8.3 Measurement Error 238</p> <p>8.4 Why Is Uncertainty of Measurement Important? 239</p> <p>8.5 Components and Sources of Uncertainty 239</p> <p>8.5.1 What Causes Uncertainty? 239</p> <p>8.5.2 Uncertainty Budget Components 240</p> <p>8.5.3 The Errors Affecting Accuracy 240</p> <p>8.6 Static Errors and Dynamic Errors 241</p> <p>8.7 Types of Uncertainty 241</p> <p>8.8 Uncertainty Evaluations and Analysis 242</p> <p>8.9 Uncertainty Reporting 243</p> <p>8.10 How to Report Uncertainty 245</p> <p>8.11 Fractional Uncertainty Revisited 247</p> <p>8.12 Propagation of Uncertainty 247</p> <p>Multiple Choice Questions of this Chapter 252</p> <p>References 252</p> <p><b>9 Dimensional Measurements and Calibration </b><b>255</b></p> <p>9.1 Length Measurement 255</p> <p>9.2 Displacement Measurement 255</p> <p>9.3 Manual Instruments 260</p> <p>9.3.1 Caliper 260</p> <p>9.3.2 Vernier Caliper 261</p> <p>9.3.3 Micrometer 262</p> <p>9.3.4 Feeler Gauge 262</p> <p>9.3.5 Liner Measurement Tool 263</p> <p>9.3.6 American Wire Gauge 263</p> <p>9.3.7 Bore Gauge 263</p> <p>9.3.8 Telescopic Feeler Gauge 264</p> <p>9.3.9 Depth Gauge 265</p> <p>9.3.10 Angle Plate or Tool 265</p> <p>9.3.11 Flat Plate 266</p> <p>9.3.12 Dial Gauge 266</p> <p>9.3.13 Oil Gauging Tapes 267</p> <p>9.3.14 Thread Measurement 267</p> <p>9.3.15 Planimeter 267</p> <p>9.4 Diameter and Roundness 269</p> <p>9.4.1 How to Measure a Diameter? 269</p> <p>9.4.2 Roundness 270</p> <p>9.5 Angular Measurements 276</p> <p>9.5.1 Line Standard Angular Measuring Devices 277</p> <p>9.5.2 Face Standard Angular Measuring Devices 277</p> <p>9.5.3 Measurement of Inclines 279</p> <p>9.5.4 Optical Instruments for Angular Measurement 280</p> <p>9.6 Metrology for Complex Geometric Features 282</p> <p>9.6.1 Edge Detection Techniques Using a CCD Camera 282</p> <p>9.6.2 Full Laser Scanning for Reverse Engineering 283</p> <p>9.7 Measurement Surface Texture 285</p> <p>9.7.1 Geometry of Surface 285</p> <p>9.7.2 Surface Integrity 286</p> <p>9.7.3 Specification of Surfaces 286</p> <p>9.7.4 Sampling Length 287</p> <p>9.7.5 Instruments and Measurement of Roughness 290</p> <p>Multiple Choice Questions of this Chapter 291</p> <p>References 291</p> <p><b>10 Mechanical Measurements and Calibration </b><b>293</b></p> <p>10.1 Importance of Mechanical Measurements 293</p> <p>10.2 Mechanical Measurements and Calibration 293</p> <p>10.3 Description of Mechanical Instruments 294</p> <p>10.3.1 Mass Measurements 294</p> <p>10.3.2 Force Measurements 295</p> <p>10.3.3 Vibration Measurements 295</p> <p>10.3.4 Volume and Density 296</p> <p>10.3.5 Hydrometers 298</p> <p>10.3.6 Acoustic Measurements 298</p> <p>10.4 Calibration of Mechanical Instruments 300</p> <p>10.4.1 When Is Equipment Calibration Needed? 300</p> <p>10.4.2 When Is There No Need for Calibration? 301</p> <p>10.4.3 Process of Equipment Calibration 301</p> <p>10.5 Equipment Validation for Measurement 301</p> <p>10.5.1 Is There a Need of Equipment Validation? 302</p> <p>10.5.2 Features and Benefits of Validation 302</p> <p>10.5.3 Process of Validation of Equipment 302</p> <p>10.6 Difference between Calibration and Validation of Equipment 303</p> <p>10.7 Difference between Calibration and Verification 303</p> <p>10.8 Calibration of Each Instrument 304</p> <p>10.8.1 Mass Calibration 304</p> <p>10.8.2 Force Calibration 304</p> <p>10.8.3 Pressure Calibration 304</p> <p>10.8.4 Vibration Measurements 306</p> <p>10.8.5 Volume and Density 307</p> <p>10.8.6 Hydrometers 308</p> <p>10.8.7 Acoustic Measurements 308</p> <p>Multiple Choice Questions of this Chapter 308</p> <p>References 308</p> <p><b>11 Thermodynamic Measurements </b><b>309</b></p> <p>11.1 Background 309</p> <p>11.2 Scale of Temperature 309</p> <p>11.2.1 Ideal Gas Law 310</p> <p>11.2.2 Vacuum 310</p> <p>11.2.3 Gas Constants 310</p> <p>11.3 Power 312</p> <p>11.4 Enthalpy 312</p> <p>11.5 Humidity Measurements 312</p> <p>11.6 Methods of Measuring Temperature 313</p> <p>11.7 Temperature Measured through Thermal Expansion Materials 314</p> <p>11.7.1 Liquid-in-Glass Thermometer 314</p> <p>11.7.2 Bimetallic Thermometer 314</p> <p>11.7.3 Electrical Resistance Thermometry 315</p> <p>11.7.4 Resistance Temperature Detectors 316</p> <p>11.7.5 Examples for Discussion 318</p> <p>11.7.6 Thermistors 320</p> <p>11.8 Thermoelectric Temperature Measurement or Thermocouples 321</p> <p>11.8.1 Basic Thermocouples 321</p> <p>11.8.2 Fundamental Thermocouple Laws 322</p> <p>11.9 Thermocouple Materials 323</p> <p>11.9.1 Advantages and Disadvantages of Thermocouple Materials 324</p> <p>11.9.2 Thermocouple Voltage Measurement 325</p> <p>11.10 Multi-Junction Thermocouple Circuits 326</p> <p>11.11 Thermopiles 327</p> <p>11.12 Radiative Temperature Measurement 327</p> <p>Multiple Choice Questions of this Chapter 329</p> <p>References 329</p> <p><b>12 Quality Systems and Standards </b><b>331</b></p> <p>12.1 Introduction to Quality Management 331</p> <p>12.2 Quality Management 332</p> <p>12.2.1 Total Quality Management (TQM) 332</p> <p>12.2.2 Quality Management System (QMS) 333</p> <p>12.2.3 TQM Is Essential to Complete TQS 333</p> <p>12.2.4 ISO-Based QMS Certification 333</p> <p>12.3 Components of Quality Management 334</p> <p>12.3.1 Quality System (QS) 334</p> <p>12.3.2 Quality Assurance (QA) 335</p> <p>12.3.3 Quality Control (QC) 335</p> <p>12.3.4 Quality Assessment 335</p> <p>12.4 System Components 336</p> <p>12.4.1 Quality Audits 336</p> <p>12.4.2 Preventive and Corrective Action 336</p> <p>12.4.3 Occupational Safety Requirements 337</p> <p>12.4.4 Housekeeping Practices 338</p> <p>12.5 Quality Standards and Guides 338</p> <p>Multiple Choice Questions of this Chapter 339</p> <p>References 340</p> <p><b>13 Digital Metrology Setups and Industry Revolution I4.0 </b><b>341</b></p> <p>13.1 Introduction 341</p> <p>13.1.1 What Is a Digital Measurement? 341</p> <p>13.1.2 Metrology and Digitalization 341</p> <p>13.1.3 Implementation Strategy 343</p> <p>13.2 Data Acquisition 343</p> <p>13.3 Setup Fundamentals for Measurement and Data Acquisition 344</p> <p>13.3.1 Length Measurement in Open Loop 344</p> <p>13.3.2 Thermal Measurement and Data-Acquisition Considerations 345</p> <p>13.3.3 Data Transfer to Cloud 349</p> <p>13.3.4 Internet of Things (IoT) Metrology 349</p> <p>13.3.5 Closed-Loop Data Analysis- (In-Process Inspection) 350</p> <p>13.4 Digital Twin Metrology Inspection 352</p> <p>Multiple Choice Questions of this Chapter 354</p> <p>References 354</p> <p>Index 357</p>

<p><b>Samir Mekid, PhD,</b> is Professor of Mechanical Engineering and Founding Director of the Interdisciplinary Research Center for Intelligent Manufacturing and Robotics at King Fahd University of Petroleum and Minerals in Saudi Arabia. He has worked as a design engineer with Caterpillar and is a Chartered Engineer registered with IMechE.</p>

<p><b>Metrology and Instrumentation</b></p> <p><b>A comprehensive introduction and exploration of fundamental concepts in metrology and their industrial and manufacturing applications</b> <p>In <i>Metrology and Instrumentation: Practical Applications for Engineering and Manufacturing,</i> distinguished engineer Dr. Samir Mekid delivers an accessible foundation in the metrology techniques, instruments, and governing standards used in mechanical engineering and manufacturing. The book offers readers an overview of metrology units and scale before moving on to explain topics like the sources of error, calibration systems, uncertainty, and dimensional, mechanical, and thermodynamic measurement systems. <p>A comprehensive chapter on tolerance stack-ups covers GD&T, ASME Y14.5-2018, and the ISO standard for general tolerances and a chapter on digital measurements demonstrates the connection between metrology and cutting-edge Industry 4.0 applications. <p>The book offers hundreds of multiple-choice questions and open-ended problems designed to help students and readers retain the information contained within, while instructors can access a corresponding online solutions manual. <p><i>Metrology and Instrumentation</i> also includes: <ul><li>A thorough introduction to the fundamental units and constants in metrology, including base and derived SI units, SI conversions, fundamental constants, and common measurements</li> <li>Comprehensive explorations of the scales of metrology, including nano-metrology, micro-metrology, standard size metrology, and large-scale metrology, as well as applied math and statistics in metrology</li> <li>Practical discussions of errors and their sources, including the definition and types of errors and error measurement, the propagation of errors, and the classification of errors</li> <li>Includes an additional appendix on mobile phone apps related to Metrology (38 apps) to be used by students for easy access</li> <li>In-depth examinations of measurement systems, including measurement data and statistical analysis, measurement characteristics, CNC machine and CMM calibration, and the principles and practices of traceability</li></ul> <p>Perfect for professional mechanical, industrial, and manufacturing engineers, <i>Metrology and Instrumentation: Practical Applications for Engineering and Manufacturing</i> is also a must-read reference for technicians in similar fields, as well as students and professors in metrology courses.

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