Novel Techniques To Measure Angle Errors In Angular Artifacts Based On Minimum Zone Plane

Measurement is one of the prime stages in any manufacturing process.Machined parts are sent to assembly line based upon measurement protocol.Measurement ensures that manufactured product will perform its intendedfunction by ensuring that components are manufactured according to designrequirements. In addition to other physical parameters, geometrical tolerancesalso play a prime role in assembly fitting and performing its intended function.Measurement error is the deviation of the measured parameters from thetrue value, true value of the measured parameters cannot be determined perfectly;however, measurement error analysis is an effective tool to get control over themeasurement error. Measurement uncertainties embark upon the problem whichresults due to measurement errors and characterize measurement result. Newgeneration geometrical product specification (GPS) is a chain of geometricalspecification that connect the entire course of geometrical product includingresearch, development, design, production, inspection/verification to its delivery,exploitation and maintenance. This dissertation proposed a new method of angle measurement for angularartifacts like prisms, polygons, gauge blocks and also similar mechanicalcomponents. New method is based upon the minimum zone plane and circleclosure technique. Minimum zone planes has been developed according to ISO12781-1standard by optimization technique exploiting minimum zone method.This new method can measure angular parameters like angle error betweenangular artifact faces, pitch angle and cumulative pitch angles etc. The methodhas advantages of simplicity and fewer sources of errors over other measurementmethods e.g.by using autocollimator and interferometer.Like other kinds of form errors, flatness error is one of the importantcharacteristics which affect the functionality of component. Therefore the anglemeasurement should take account of the flatness of the faces. This dissertationdefined angle between two planes based on minimum zone planes. The minimumzone plane is determined by means of evaluation method of flatness.Mathematical models are developed for flatness, minimum zone plane anddetermination of various angular parameters. The thesis also proposed an efficientgenetic algorithm for measurement of flatness error and determination ofminimum zone plane using minimum zone method. An angle measurementexperimental setup is developed for angle measurement. The experimental setupis equally applicable for flatness error measurement.Method of uncertainty error evaluation has been developed for flatness andangular error. Flatness error and angle error verification has been performedusing new generation geometrical product specification standard. Mathematicaltechniques are developed for determination of propagation coefficients.