Dimensional and surface metrology

Training workshop on

DIMENSIONAL AND SURFACE METROLOGY FUNDAMENTALS

11, 12 & 13 August 2026 (Mines Beach Resort, Kuala Lumpur)

What does this training cover?

Metrology plays an important role in the product quality control and assurance in the increasingly competitive manufacturing industry to meet the demand of today’s quality conscious customers. Knowledge of dimensional and surface roughness measurement are essential to ensure and maintain product quality, as well as provide solutions to challenging measurement tasks in the industrial environment.

This three-day intensive training workshop is designed to complement the participant’s practical knowledge in using metrology tools in the industry with the underlying principles of precision dimensional and surface roughness measurement. Basics concepts covered in this training include terminologies in metrology such as precision, resolution, uncertainty, accuracy etc., types and sources of measurement errors, methods of reducing errors during measurement, working principles of precision measuring instruments, basics of flatness measurement using an optical flat, and essentials of surface roughness and roundness measurement. Participants will be guided into grasping the fundamental concepts through interactive sessions with plenty of worked examples and activities. The self-assessment at the end of each topic will allow participants to gauge the depth of their knowledge on the related topic.

How will I benefit?

At the end of the three-day training workshop, the participant should be able to:

Compare the various terminologies in metrology, e.g. resolution vs. sensitivity, error vs. uncertainty etc.
Distinguish between systematic and random errors in measurement
Identify the various sources of errors in measurement and methods of reducing them
Determine errors due to ambient temperature, misalignment between part and instrument, parallax etc.
Understand the design and working principles of precision linear measuring instruments
Learn how to measure angle on a tapered part
Determine flatness of a polished surface using an optical flat
Differentiate between roughness, waviness and form
Define the commonly used spatial, amplitude and hybrid roughness parameters
Understand the influence of cut-off value on the measured roughness
Explain the four common methods of roundness measurement
Determine roundness error from a given trace using the LSC, MIC and MCC methods
Determine eccentricity and concentricity from roundness test data

What are the detailed topics covered?

Day 1

Part 1: Basic Concepts in Metrology (9.00 am - 10.45 am)

Definition of metrology

The need for measurement and inspection

Job of a metrologist

Basic terminologies in metrology: precision, accuracy, error, resolution, sensitivity, range, span, repeatability, reproducibility, uncertainty, and tolerance

Quiz 1: What can you tell about the dial indicator shown?

Activity 1: What is the difference between the dial indicators shown?

Activity 2: From a given set of digital calipers, determine which has: (i) the highest accuracy, (ii) the lowest accuracy, (iii) the highest precision, (iv) the lowest precision

Part 1 Self-assessment

Part 2: Measurement Errors, Traceability & Calibration (11.00 am - 1.00 pm)

Types of measurement errors

Causes of measurement errors

Difference between systematic and random errors

Method of detecting systematic error in an instrument

Method of detecting random errors

Causes of systematic and random errors

Types of controllable errors: Catastrophic error, cosine error, calibration error, error due to ambient conditions, error due to elastic deformation, and parallax error

Analysis of random errors

Relationship between standard deviation of measurement process and manufacturing process

Measurement standards, calibration and traceability

Hierarchy of measurement standards

Activity 1: Calculate the misalignment error in dial gauge reading

Activity 2: Determine measurement error due to temperature deviation from calibration temperature

Part 2 Self-assessment

Part 3a: Linear Measurement (2.00 pm - 3.45 pm)

Meaning of linear measurement

Characteristics of linear measuring instruments

Abbe’s rule

Amplification mechanisms in precision instruments

Principle of vernier instruments

Principle of micrometer instruments

Principles of comparators: mechanical, electrical, pneumatic, optical

Precision measurement using dial comparators and gauge blocks

Length standards: Slip and block gauges according to BS4311:1968, rules for gauge block care

Activity 1a: What is the resolution of the vernier caliper shown?

Activity 1b: Design a caliper having a resolution of 0.01 mm

Activity 2: Calculate the resolution of the micrometer

Activity 3: Arrange the instruments in order of increasing resolutions

Activity 4: Determine the dimensions of the specimen block measured using a dial comparator

Activity 5: Select gauge/slip blocks to construct a given length

Part 3b: Angular Measurement (4.00 pm - 5.00 pm)

Angular measurement: Measuring angles using Sine bar, measurement method, combination angle gauges

Activity 6: Determine angle on a tapered block nearest to arc seconds

Activity 7: Determine the combination of angle gauges to construct given angles.

Part 3 self-assessment

Day 2

Part 4a: Straightness Measurement (9.00 am - 10.45 am)

Straightness measurement using autocollimator

Basic principle of autocollimator

Application of autocollimator for straightness measurement

Activity 1: Determine straightness error of guide way on a lathe machine.

Part 4a: Flatness Measurement (11.00 am - 1.00 pm)

Flatness measurement using optical flats: Basics of fringe formation, interference of light waves, measurement of flatness and parallelism of block gauges

Activity 2: Estimate flatness error on a polished surface from fringe pattern

Part 2 self-assessment

Part 5a: Roughness Measurement (2.00 pm - 5.00 pm)

Importance of roughness

Why measure roughness?

Factors affecting surface texture

Separating roughness from waviness

Methods of measuring surface roughness

Skidded and skidless roughness testers

Activity 1: Estimate the roughness parameters Ra, Rq and Rz for a given trace

Day 3

Part 5a: Roundness Measurement (9.00 pm - 1.00 pm)

Roughness parameters: Maximum peak-to-valley roughness (Rmax or Rt), ten-point average roughness (Rz) (ISO 4287-1 (1984)), maximum height of roughness (Rz) (ISO 4287:1997), average roughness (Ra), root-mean-square roughness (Rq), maximum height of peaks (Rp) (ISO4287-1997), maximum depth of valley (Rv) (ISO1997), skewness (Rsk ), kurtosis (Rku )

Roundness measurement

Methods of expressing roundness error: LSC, MCC, MIC, MZC

Concentricity, eccentricity, and cylindricity

Activity 2: Estimate roundness error for a trace shown using LSC, MCC and MIC methods.

Topic 5 self-assessment

Who should attend: This training will benefit technicians, junior engineers and others regularly involved in dimensional measurement and quality assurance, but need to brush up their basic knowledge of metrology. Potential participants are encouraged to take this simple quiz to find out whether they need to attend this workshop.

Course duration: Two days (12 hours)

Course fee: RM1,900.00 (inclusive of training materials, lunch and tea breaks)

Maximum number of participants: 20