Fundamentals Of Dimensional Metrology, 6th Edition Solution Manual

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Fundamentals Of Dimensional Metrology, 6th Edition Solution Manual helps you prepare for exams with a complete textbook overview.

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Lab Manual
Steve Hastings
Fundamentals of Dimensional Metrology
Sixth Edition
Connie L. Dotson

iii
Table of Contents
Preface ......................................................................................................... iv
Lab 1 - Chapter 1: Measurement and Metrology ........................................ 1
Lab 2 - Chapter 2: Language and Systems of Measurement ....................... 6
Lab 3 - Chapter 5: Measurement with Graduated Scales
and Scaled Instruments ....................................................................... 12
Lab 4 - Chapter 6: Vernier Instruments ..................................................... 16
Lab 5 - Chapter 7: Micrometer Instruments .............................................. 20
Lab 6 - Chapter 8: Development and Use of Gage Blocks ....................... 24
Lab 7 - Chapter 9: Calibration ................................................................... 27
Lab 8 - Chapter 10: Measurement by Comparison .................................... 30
Lab 9 - Chapter 11: Reference Planes ....................................................... 33
Lab 10 - Chapter 12: Angle Measurement ................................................ 37
Lab 11 - Chapter 13: Surface Measurement .............................................. 41
Lab 12 - Chapter 14: High-Amplification Comparators ........................... 44
Lab 13 - Chapter 15: Pneumatic Measurement ......................................... 47
Lab 14 - Chapter 16: Optical Flats and Optical Alignment ....................... 50
Lab 15 - Chapter 17: Optical Metrology ................................................... 53
Lab 16 - Chapter 18: Coordinate Measuring Machines ............................ 57
Appendix ..................................................................................................... 60

iv
PREFACE
This is the first edition of the lab manual that is being introduced in association with the
release of the 6th edition of Fundamentals of Dimensional Metrology by Connie L.
Dotson. This lab manual may be used as a guide or as a complete workbook to provide a
hands-on lab experience with select chapters of the book. In addition to the experience of
using various metrological instruments, technical writing is a critical feature of this lab
manual. The goal is to help students develop their writing abilities as they become skilled
in using metrological instruments and are more able to accurately and succinctly
document their data findings.
Introduction
Of the many challenges associated with teaching metrology, students’ ability to gain
hands-on experience with various measurement instruments and systems is important. To
this end, the following recommendations are made:
Consider dividing the class of students into teams comprised of just of two
members. Each team will then be able to have one student conduct a measurement while
the other student records the data. It has been my experience that this mutual support
works very well with larger class sizes. However, this approach does not negate the
student’s responsibility to individually complete their own work and lab reports.
The chapters are divided into two sections. The first part of each chapter describes the
content, learning objectives, and required classroom material or tools for you as the instructor.
The second part contains student exercises, which may be printed as handouts.
Provide as many variations of measurement instruments and equipment as possible
to provide as broad an exposure as possible, reduce the delay of team use, and increase
throughput. Certainly, having more than one of the more technically advanced systems
such as the optical comparator, or the coordinate measuring or vision system may present
their own unique challenges.

v P REFACE
The labs in this manual generate data, so students should bring their own writing
utensils and paper to record their data. An emerging trend is the use of personal electronic
devices such as phones with cameras and electronic tablets to take pictures of lab setups
and parts, as well as to record data directly to a spreadsheet format for the lab report.
Geometric and dimensional tolerancing, as well as statistical analysis, are key
ingredients to successful measurements and process control. Statistical calculations have
been incorporated into the lab process to allow insight into the usefulness of the generated
data. It is recommended that GD&T be incorporated into the CMM demonstration.
Lab Safety
A safe learning environment is required for any lab to be successful. Standard safety
operating procedures and the use of personal protection items should be reviewed at the
beginning of each new term. The following suggestions are the minimum
recommendations that should be considered for any metrology lab.
• Provide a map showing the location of emergency exits and that describes exit
procedures and review it often.
• ANSI Z87.1 certified safety glasses. Preferably non-tinted. Students already
wearing glasses should verify the impact resistance of their glasses and
incorporate the use of appropriate side shields.
• Closed-toe shoes.
About the Author
Steve gained over 37 years of experience working in the automotive industry in a number
of capacities and functions. His experiences included engineering labs, original equipment
sales, marketing and aftermarket sales, and service distribution networks. During the latter
part of his career, he returned to his passion of engineering and gained varied experiences
in product engineering, systems engineering, and engineering management. His global
experiences gave him valuable insight into the integration of science, technology,
engineering, and manufacturing. He is currently working at a major state university as a
senior lab coordinator and has taught a metrology class for a number of years.

1
L AB 1
Prerequisite: Chapter 1, Measurement and Metrology
Introduction:
This lab has three exercises designed to provide insight into the sources from which
various lab standards can be traced the art of observation and the ability to accurately
record an observation. Finally, the lab will help your students gain insight and practice
technical and descriptive writing.
Items needed:
• For Exercise 2, choose objects for students to prepare a written description. Objects
may include various size gage blocks, steel rules, sine plates, angle blocks, feeler
guages, or other classroom objects. The purpose of Exercise 2 is, not it to provide
practical technical writing practice.

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2 LAB 1
Name: Date:
EXERCISE 1
Use the Internet to visit the National Institute of Standards and Technology (NIST.gov).
Answer the following questions:
1. What is the purpose of NIST?
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2. Who can use NIST resources?
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LAB 1 3
3. In what areas of expertise does NIST offer support?
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4. Where are NIST’s primary locations?
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4 LAB 1
5. Why does the United States need NIST?
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6. List three organizations similar to NIST that reside in other countries.
a. _________________________________________________________________
b. _________________________________________________________________
c. _________________________________________________________________

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LAB 1 5
EXERCISE 2
Select an item provided by your instructor and give enough written detail for others to be
able to identify the item you are describing. All reports from this exercise must be
detailed enough that if the report was handed to someone else, and the experiment or
measurement repeated, the results would be the same or nearly the same.
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EXERCISE 3
Technical writing is crucial to successful engineering communication. The metrological
document must provide complete, concise, accurate information and data to allow the
reader to reconstruct the activity over the course of time. Discuss the differences that may
exist between descriptive writing and technical writing.
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6
L AB 2
Prerequisite: Chapter 2, Language and Systems of Measurement
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
• The more variants of each tool, the better

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LAB 2 7
Name: Date:
EXERCISE 1
Cut a plastic straw into six one-inch increments using the lined instrument provided by
the instructor. 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?
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2. Was each segment cut accurately?
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3. Was each segment cut with the same precision?
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8 LAB 2
EXERCISE 2
Pair with another student 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’?
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2. Was each segment cut accurately?
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3. Was each segment cut with the same precision?
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LAB 2 9
EXERCISE 3
Line up your straw segments with the segments from the rest of the class. Compare the
lengths of all straw segments and answer the following questions.
1. Is there any variation in the lengths of the entire class’s segments?
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2. If so, why?
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EXERCISE 4
As a class, discuss possible methods of improving precision and accuracy and reducing
variation. Repeating this exercise achieve better results? Why or why not?
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10 LAB 2
REPORT
Write a report summarizing Exercises 1, 2, and 3. Use the following sections to organize
your report.
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Objective: ______________________________________________________________
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Outcome(s): _____________________________________________________________
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Data: ___________________________________________________________________
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LAB 2 11
Observations: ____________________________________________________________
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Conclusion: _____________________________________________________________
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