LAB MANUAL

Metrology Measurement & control

Estd. 2004

Prepared by
(Department of Mechanical Engineering)

LAKSHMI NARAiN COLLEGE OF TECHNOLOGY

Bhawrasala, Sanwer Road, Rewati Range, 453 331 Indore

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY,

INDORE

DEPARTMENT OF MECHANICAL ENGINEERING

LIST OF EXPERIMENTS
Name of the Lab: Metrology Measurement & control (Au-503)
S.NO.

DESCRIPTION

Study and use of Verniers, micrometer and dial gauge

To study limit gauges

To study slip gauges and sine bar

To study Tool Makes Microscope

Measurement of straightness , flatness and squareness

Measurement of surface finish

Measurement of screw threads by two wire and three wire

Measurement of parameters of gear teeth

To study use of profile projector

10

study use of comparators

11

study use of Coordinate measurement machine

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY, INDORE

DEPARTMENT OF MECHANICAL ENGINEERING
SUBJECT: Metrology Measurement & control (AU-503)
________________________________________________________________________

Experiment No.: 1
Date of Conduction:
Date of submission:
Aim: Study and use of Verniers, micrometer and dial gauge

Requirements: Verniers, Micrometer and Dial gauge

Theory:
Verniers caliper: Vernier caliper consist of two scales, one is fixed and other is movable.
The fixed scale called main scale is calibrated on L shaped frame and carried a fixed
jaw. The movable scale called vernier scale slides over the main scale and carries a
movable jaw. Both the scales have two measuring tips. When two measuring tip
surfaces are with each other, scale show reading. An adjustment screw is provided for
finer adjustment of movable jaw. Also an arrangement is provided to lock the sliding
scale on the main scale.

Micrometer:

Micrometer uses the principle of screw and nut. When a screw is turned through nut
through one revolution, it advances through one pitch distance. One rotation of screw
thread corresponds to pitch length. If the circumference of screw is divided into
number of n equal parts its rotation through one division (circumference) will cause to
advance (Pitch/n) length

Dial gauge : Dial gauges are used for checking flatness of surfaces & parallelism of bars &
rods. It has two pointer arms which actuated by rack and pinion arrangement which acts as
mechanical amplifier. The rack is cut in the spindle.The spindle is made to come in contact with
the work piece

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY, INDORE

DEPARTMENT OF MECHANICAL ENGINEERING
SUBJECT: Metrology Measurement & control (AU-503)

Experiment No.:3
Date of Conduction:
Date of submission:
Aim: Study and use of

Slip gauges and Sine bar

Requirements: Slip gauges and Sine bar

Theory:

Slip gauges: Slip gauges are used as standards of measurement in practically every precision
engineering works. These are invented by C.E Johansen of Sweden .Slip gauges are rectangular
blocks made of high grade steel to exceptionally close tolerances. Sectional dimension of the are
9mm X 30mm for sizes upto 10mm.
Slip gauges are available in following five grades of accuracy;Grade II: used in workshop for setting up machine tools.
GradeI ; Used for more precise work such as setting up sine bar checking gap gauges etc
Grade0; It is inspection grade and is used for tool room or machine shop inspection
Grade00; Used for highest precision work such as measuring Grade I and grade II

Fig : SLIP GUAGE BLOCK DAIGRAM

Sine bar: Sin bar is precision instrument used along with slip gauges for
accurate angle measurements or angle setting. It consists of steel bar and
two rollers. The rollers are of accurate and equal diameters. They are
attached to the bar at the end. When rollers are brought in contact with a
flat surface, the top of the bar is parallel to the surface. The use of sine bar
is based on laws of geometry & trigonometry.

Fig: SINE BAR DAIGRAM

Sine bars or sine plates usually have a length of 5 inches or 10 inches.
These standard lengths are commonly used by the tool maker or inspector.
The sine bar or sine plate is used for accurately setting up work for
machining or for inspection. Gage blocks are usually used for establishing
the height.

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY, INDORE

DEPARTMENT OF MECHANICAL ENGINEERING
SUBJECT: Metrology Measurement & control (AU-503)

Experiment No.:4
Date of Conduction:
Date of submission:
Aim: Study of Tool Makers Microscope

Requirements: Tool Makers Microscope

Theory: Tool Makers Microscope; This is versatile instrument based on optical
means. It consist of a heavy hollow base accomadating the illuminating unit underneath.
Work table is mounted on the base of the instrument on cross slides and is equipped
with accurate micrometer screw to move it in two mutually perpendicular direction in
the horizontal plane i.e. longitudinal and lateral directions
Optical head is mounted on a vertical column and can be moved up and down and
focused over the work. To clamp the optical head at any desired postion a clamping
screw is provided.
Use: The following application of tool makers microscope;
i.
Measurement of length in rectangular polar co -ordinate
ii.
Measuring tool angles , milling cutter angles, thread angle etc
iii.
Comparing thread form with standard profiles
iv.
Cheaking countours
v.
Determining the relative postion of various point on work

TOOL MAKERS MICROSCOPE

The large Tool Makers Microscope (TMM) essentially consists of the cast base, the
main lighting unit, the upright with carrying arm and the sighting microscope. The rigid
cast base is resting on three foots screws by means of which the equipment can be
leveled with reference to the build-in box level. The base carries the co-ordinate
measuring table, consists of two measuring slides; one each for directions X and Y and a
rotary circular table provided with the glass plate (Fig.1). The slides are running on
precision balls in hardened guide ways warranting reliable travel. Two micrometer
screws each of them measuring range of 0 to 25 mm permit the measuring table to be
displaced in the directions X and Y. The range of movements of the carriage can be
widened up to 150 mm in the X direction and up to 50mm in the Y direction with the
use of gage blocks.

The work piece to be checked is arranged in the path of the rays of the
lighting equipment. It produces a shadow image, which is viewed with the
microscope eyepiece having either a suitable mark for aiming at the next
points of the objects or in case of often occurring profiles. e.g. Threads or
rounding standard line pattern for comparison with the shadow image of
the text object is projected to a ground glass screen. The text object is
shifted or turned on the measuring in addition to the comparison of shapes.
The addition to this method (shadow image method), measuring operations
are also possible by use of the axial reaction method, which can be
recommended especially for thread measuring. This involves approached
measuring knife edges and measurement in axial section of thread
according to definition. This method permits higher precision than shadow
image method for special measuring operations.

Applications
The large tool makers microscope is suitable for the following fields of
applications;
Length measurement in cartesian and polar co-ordinates.
Angle measurements of tools; threading tools punches and gauges,
templates etc.
Thread measurements i.e., profile major and minor diameters, height of
lead, thread angle, profile position with respect to the thread axis and the
shape of thread. (rounding, flattering, straightness of flanks)
Comparison between centres and drawn patterns and drawing of projected
profiles.

SUBJECT: Metrology Measurement & control (AU-503)

________________________________________________________________________

Experiment No.:4
Date of Conduction:
Date of submission:
Aim: Measurement of straightness , flatness and squareness
Requirements: Auto-collimator,surface of which straightness is to be
checked
Measurement of straightness:
A straight line is drawn on the surface whose straightness is to be
cheaked.Block fitted with two feet at convenient distance apart and
carrying a plane refector is moved along the surface in step equal to the
pitch of the feet .Angular variation are measured by Auto-collimator.
Auto-collimator may be used on surface in any plane.
Testsforstraightnesscanbecarriedoutbyusingspiritlevelorauto
collimator.Thestraightnessofanysurfacecouldbedeterminedbyeitherof
theseinstrumentsbymeasuringtherelativeangularpositionsofnumberof
adjacentsectionsofthesurfacetobetested.Sofirstastraightlineisdrawn
onthesurfacewhosestraightnessistobetested.Thenitis
dividedintoanumberofsections,thelengthofeachsectionbeingequalto
thelengthofspiritlevel base or the plane reflectors base in case of auto
collimator.Generallythebasesofthe
spiritlevelblockorreflectorarefittedwithtwofeetsothatonlyfeethave
linecontactwiththesurfaceandwholeofthesurfaceofbasedoesnot
touchthesurfacetobetested.Thisensuresthatangulardeviationobtained
isbetweenthespecifiedtwopoints.Inthiscaselengthofeachsectionmust
beequaltodistancebetweenthecentrelinesoftwofeet.Thespiritlevel
canbeusedonlyforthemeasurementofstraightnessofhorizontalsurfaces
whileautocollimatormethodcanbeusedonsurfacesinanyplane.Incase
ofspiritlevel,theblockismovedalongthelineonthesurfacetobetested
instepsequaltothepitchdistancebetweenthecentrelinesofthefeetand
the angular variations of the direction of block are measured by the
sensitivelevelonit.Angularvariationcanbecorrelatedintermsofthe

differenceofheightbetweentwopointsbyknowingtheleastcountoflevel
andlengthofthebase.
Incaseofmeasurementbyautocollimator,theinstrumentisplaced
atadistanceof0.5to0.75metrefromthesurfacetobetestedonanyrigid
supportwhichisindependentofthesurfacetobetested.Theparallelbeam
fromtheinstrumentisprojectedalongthelengthofthesurfacetobetested.
Ablockfixedontwofeetandfittedwithaplaneverticalreflectorisplaced
onthesurfaceandthereflectorfaceisfacingtheinstrument.Thereflector
andtheinstrumentaresetsuchthattheimageofthecrosswiresofthe
collimator appears nearer the centre of the field and for the complete
movementofreflectoralongthesurfacestraightline,theimageofcross
wireswillappearinthefieldofeyepiece.Thereflectoristhenmovedtothe
otherendofthesurfaceinstepsequaltothecentredistancebetweenthe
feetandthetiltofthereflectorisnoteddowninsecondsfromtheeyepiece.
1sec.ofarc=0.000006mm/mm
Therefore,1sec.ofarcwillcorrespondtoariseorfallof0.000006*
lmm,whereIisthedistancebetweencentresoffeetinmm.Thecondition
forinitialandsubsequentreadingsisshowninFig.7.2inwhichtherise
andfallofthesurfaceisshowntoomuchexaggerated.

Withthereflectorsetatab(1streading),themicrometerreadingis
notedandthislineistreatedasdatumline.Successivereadingsatbc,c
d,deetc.aretakentillthelengthofthesurfacetobetestedhasbeen
steppedalong.Inothertoeliminateanyerrorinprevioussetofreadings,
thesecondsetofreadingscouldbetakenbysteppingthereflectorinthe
reversedirectionandmeanoftwotaken.Thismeanreadingrepresentsthe
angularpositionofthereflectorinsecondsrelativetotheopticalaxisor
autocollimator.
Column1givesthepositionofplanereflectoratvariousplacesat
intervalsofle.g.ab,bc,cdetc.,column2givesthemeanreading
ofautocollimatororspiritlevelinseconds.Incolumn3,differenceofeach
readingfromthefirstisgiveninordertotreatfirstreadingasdatum.These
differencesarethenconvertedintothecorrespondinglinearriseorfallin
column4bymultiplyingcolumn3byl.Column5givesthecumulative
riseorfall,i.e.,theheightsofthesupportfeetofthereflectorabovethe

datumlinedrawnthroughtheirfirstposition.Itshouldbenotedthatthe
valuesincolumn4indicatetheinclinationsonlyandarenoterrorsfromthe
truedatum.Forthisthevaluesareaddedcumulativelywithdueregardfor
sign.ThusitleavesafinaldisplacementequaltoLattheendoftherun
whichofcoursedoesnotrepresentthemagnitudeoferrorofthesurface,
butismerelythedeviationfromastraightlineproducedfromtheplaneof
thefirstreading.Incolumn5eachfigurerepresentsapoint,therefore,an
additionalzeroisputatthetoprepresentingtheheightofpointa.
Theerrors of any surfaced maybe required relativeto anymean
plane.Ifitbeassumedthatmeanplaneisonejoiningtheendpointsthen
wholeofgraphmustbeswungrounduntiltheendpointisontheaxis(Fig.
7.3).ThisisachievedbysubtractingthelengthL
proportionatelyfromthereadingsincolumn5.Thusifnreadingsbetaken,
thencolumn6givestheadjustments L/n, 2L/n etc.,tobringboth
endstozero.Column7givesthe
differenceofcolumns5and6andrepresentserrorsinthesurfacefroma
straightlinejoiningtheendpoints.Thisisasifastraightedgewerelaid
alongthesurfaceprofiletobetestedandtouchingtheendpointsofthe
surfacewhentheyareinahorizontalplaneandthevariousreadingsin
column7indicatetheriseandfallrelativetothisstraightedge.

Measurement of flatness:
Requirements;OpticalFlat:

1. Opticalflatareflatlenses,madefromquartz,havingaveryaccuratesurfaceto

transmitlight.
2. Theyareusedininterferometers,fortestingplanesurfaces.
3. Thediameterofanopticalflatvariesfrom50to250mmandthicknessvariesfrom
12to25mm.
4. Opticalflatsaremadeinarangeofsizesandshapes.
5. Theflatsareavailablewithacoatedsurface.
6. Thecoatingisathinfilm,usuallytitaniumoxide,appliedonthesurfacetoreduce
thelightlostbyreflection.
7. Thecoatingissothinthatitdoesnotaffectthepositionofthefringebands,buta
coatedflat
Thesupportingsurfaceonwhichtheopticalflatmeasurementsaremademustprovidea
clean,rigidplatform.Opticalflatsarecylindricalinform,withtheworkingsurfaceand
areoftwotypesarei)typeA,ii)typeB.
i. TypeA:Ithasonlyonesurfaceflatandisusedfortestingflatnessofprecision
measuringsurfacesofflats,slipgaugesandmeasuringtables.
Fortheseopticalflats.theirdiameterandgradeareimportant.Thedimensionsof
anopticalflatofgradesIandIIcanbe25x10,30x10,50x15,75x20,100x
25,125x30,160x35(diameterthicknessinmm).Thetoleranceonflatshould
be0.05mfortypeA.
TypeB:Ithasbothsurfacesflatandparalleltoeachother.Theyareusedfortesting
measuringsurfacesofmicrometers.measuringanvilsandsimilarlengthofmeasuring
devicesfortestingflatnessandparallelism.Fortheseinstruments,theirthicknessand
gradesareimportant.Thetolerancesonflatness,parallelismandthicknessshouldbe
0.05m
Tochecktheflatnessofslipgaugesurfaceusingopticalflat:
The apparatus required is a monochromatic light source and optical flat. If
opticalflatis placed on slip gauge, it will not form an intimate contact, but will be at
some angle ''
makinganinclinedplane.Iftheopticalflatisilluminatedbymonochromaticlightand
eyeifplacedinproperpositionwillobservenumberofbands.Theyareproducedby
interferenceoflightraysreflectedfromlowerplaneofopticalflatandtopsurfaceof
slipgauge

Theyareproducedbyinterferenceoflightraysreflectedfromlowerplaneof

opticalflatandtopsurfaceofslipgauge.AsshowninFigure,if'S'ismonochromatic
lightsource.At'C'rayisreflectedindirectionCDE.Thetworeflectedcomponentsare
combinedbyeye,havingtraveledpathwhosewavelengthsdifferbyanamountACD.If
pathlengthsdifferbyoddnumberof/2theninterferenceissaidtohaveoccurred.If
surfaceisperfectlyflatthen
thesurfacewillbecrossedbythepatternofalternatelightanddarkbandswhichwillbe
straightanddarklineisseenpassingatC.Thenextlineoccurs at 3 / 2 (i.e. FHI =3 / 2
)
alternatedarkandbrightfringesareseenandvariationfromthestraightnessofthe
bandsmeasuretheerrorintheflatnessofslipgauge

Thepitchofthebandsdependsontheangleofthewedgeanditcanbeeasilyseenthat
increaseinthisanglereducesthepitch.

The orientation of the bands depends on the orientation of the wedge. The
sphericalsurfacecanbeconcaveorconvexandalittlepressureontheopticalflatatthe
centrewillspreadthebandsoutwardsinaconvexway.Figureshowsinterferenceband
patternsonvarioussurfaces.Thisfactcanbeusedfordrawingvariousconclusions
aboutthenatureofthesurfacebyapplyingpressureontheopticalflatatvariouspoints
andobservingthechangeinthepatternofbands.
SQURENESS TEST:

Indicator method :
The indicator method is particularly suitable for checking the squareness
of the block whose opposite faces are supposed to be parallel. It is
assumed that the squareness of the block has already been assumed to a

reasonable accuracy by the use of squares etc. as otherwise the full

sensitivity of the method cant be obtained.
The instrument for the purpose is designed by N.P.L. and is very suitable
for checking squareness while manufacturing a square block.
The instruments consists of a parallel strip (framework) and flat base. A
knife edge and some form of indicator is mounted on the framework as
shown in fig.4.250.
In the indicator method, means are also available to produce and measure parallel
surfaces by some form of Indicator and a comparator respectively. The height of
the indicator is adjusted such that it makes contacts near the top of the side of the
square block is then place against the knife edge as shown in fig..4.250 (a) and a
reading is noted on the indicator. The block is then turned so that now the
opposite side is facing the knife edge [fig. 4.250(b] and again a reading is noted
on the indicator. If two sides AD and BC are truly parallel. Then the two reading
will be same for true right angle. In case the face are not exactly at right angle,
the two reading will be equally above and bellow the reading for a true right
angle. Thus the differences of two reading is double the error in squareness of the
work over the length L between the contact points.

SUBJECT: Metrology Measurement & control (AU-503)

________________________________________________________________________

Experiment No.:6
Date of Conduction:
Date of submission:
Aim: Measurement of surface finish
Requirements; A Instrument designed by Dr. Tomlinson
Measurement of surface finish; Comparatively cheap and reliable
instrument using cum optical magnification design by Dr. Tomlinson.
The instrument consist of diamond probe( stylus) held by spring
pressure against the suface of lapped cylinder by leaf spring.For
measuring surface finish the body of instrument is moved across the
surface by screw and motor arrangement. The vertical movement of the
probe caused by surface irregularties makes the horizontal lapped
cylinder to roll. This causes the movement of the arm attached to
lapped cylinder.A magnified vertical movement of diamond scriber on
smoked glass is obtained by movement of arm. This vertical movement
of scriber together with horizontal movement produces trace on the
smoked glass plate.This trace is futher magnified at X50 or X100 by
optical projector.

Direct Instrument Measurements:

Direct Instrument Measurements:

These methods enable to determine a numerical value

of the surface finish of any surface. Nearly all
instruments used are stylus probe type o finstriments.
These operate on electrical principles. Further, threes
electrical instruments can be of two kinds. In first type
they operats on the carrier modulating principle. The
movements of the stylus expiring the surface are caused
to modulate a high frequency carrier current. The carrier
modulated frequency type of instruments have the
advantage that the signal fed to the recorder depends
only upon the position of the stylus. While in the voltage
generating type, when the oscillatory movement of the
stylus stops, the output falls to zero no matter where the
stylus may be.

Some pneumatic instruments are also used for

measuring surface finish.
. Stylus Probe Instruments:
This type of instrument generally consists of the
following units:

(i) A skid or shoe which is draw slowly over the

surface either by hand or by motor drive. This skid
when moved over the surface, follows its general
contours and provides a datum fro the
measurements. In case a skid is not used and only a
probe is used then probe will trace the actual
profile, but upward and downward movement of
probe will be dependent upon the setting of the
work under probe. But since the roughness of the
surface does not depend the position of the work, it
will be necessary to choose a datum from which the
measurement is to be taken. A line touching the
crest of the profile, that is the envelope line which
defines the macro-geometrical form is generally
cheosen as datum line and this is obtained by using
a skid of such a size which can span a large number
of surface undulations. A lot of work has been done
on shape of skid, and different types of skids are
available for different purposes by which the true
macro-geometrical form may be obtained.
(ii) A stylus or probe which moves over the surface
with the skid. The stylus for Ra measurement on
new instrument can have a radius of 10 microns +
30 %. When in use, tip radius is allowed to vary
20%. The stylus should be cone shaped with a
spherical tip. This recoreds the micro-geometrical
form surface. Generally it is desired that if the dkid
is moving up then the stylus must also be moving
up.
But when the pitch between the skid and sty plus is
comparable to that of half the wavelength of surface
, then record will not be desirable one, e.g. in the
dkid and stylus position shown in Fig. 11.7 skid is
moving up , while stylus is giving downward
indication.
(iii) An amplifying device for magnifying the stylus
movement and an indicator.

(iv) A recording device to produce a trace or record of

the surface profile. Usually the vertical movement is
magnified more in comparison to horizontal
movement, thus the record will not give the actual
picture of surface roughness but a distorted trace
obtained.
(v) A means for analyzing the trace is
obtained. The analysis can be
done separately or some
automatic device may be
incorporated in the instrument for
analysis.
Fig. 11.7
.: Fig. Tomlinson Surface Meter.
This instrument is most commonly used in U.S.A for
direct. This is a dynamic instrument similar in principle
to a gramophone pick-up, A finely pointed stylus
mounted in the pick-up unit is traversed across the
surface either by hand or by motor drive. The instrument
records the rectified output from the pick-up which is
amplified further and operates an indicating device. Thus
this records the average height of the surface roughness.
In this instrument, roughness together with waviness and
flaws comprises the irregularities found on the surface.
An indication is obtained only when the pick-up is
moving. This instrument is best suited for measuring
surface
linish of
deep
bores.

The
Tomlinson Surface Meter:

This instrument was designed by Dr. Tomlinson. This

instrument uses mechanical-cum-optical means for
magnification (Fig\ 11.8).
The diamond stylus on the surface finish recorder is
held by spring pressure against the surface of a lapped
steel cylinder. The stylus is also attached to the body of
the instrument by a leaf spring and its height is
adjustable to enable the diamond to be positioned
conveniently. The lapped cylinder is supported on one
side by the stylus and on the other side by two fixed
rollers as shown in Fig. 11.8. The stylus is restrained
from all motion except the vertical one by the tensions in
coil and leaf spring. The tensile forces in these two
springs also keep the lapped steel cylinder in position
between the stylus and it carries at its tip a diamond
scriber which bears against a smoked glass.
When measuring surface finish, body is traversed
across the surface by a screw rotated by a synchronous
motor. Any vertical movement of the stylus caused by
the surface irregularities, causes the magnified
movement on a smoked glass plate. This vertical
movement coupled with the horizontal in horizontal
direction. The smoked glass trace is then, further
projected at 50 or 100 magnification for
examination. This instrument is comparatively cheap one
and gives reliable results.
Taylor-Hobson Talysyrf:

The Talysuf
is an electronic
instrument
working on
carrier
modulating
principle. This
instrument also
gives the same
information as
the previous
instrument, but
much more
rapidly and
accurately.
This
instrument as
also the
previous one
records the
static displacement of the stylus and is dynamic
instrument like profilometer.
The measuring head of this instrument consists of a
diamond stylus of about 0.002 mm tip radius an skid or
shoe which is drawn across the surface by means of a
motorized driving unit (gearbox), which provides three
motorized speeds giving respectively 20 and 100
horizontal magnification and a speed suitable fro average
reading. A neutral position in which the pick-up can be
traversed manually is also provided. In this case the arm
carrying the stylus forms an armature which povots
about the centre piece of E-shaped stamping as shown in
Fig. 11.9. On two legs of (outer pole pieces) the Eshaped stamping there are coils carrying an a.c. current.
These two coils with other two resistances form an
oscillator. As the armature is pivoted about the central
leg, any movement of the stylus causes
Fig. 11.9.
Schematic Layout of Talysurf.

the air gap to vary and thus the amplitude of the original
a.c.
current flowing in the coils is modulated. The output of
the bridge thus consists of modulation only as shown in
Fig.. This is further demodulated so that the current now
is directly proportional to the vertical displacement of
the stylus only.

The demodulated output is casued to operator a pen

recorder to produce a permanent record and a mere to
give a numerical assessment directly. In recorder of this
instrument the marking medium is electric discharge
through a specially treated paper which blackens at the
point of the stylus, so this has no distortion due to drag
and the record is strictly rectilinear one.
Now-a-days microprocessors have made available
complete statistical multi- trace systems measuring
several places over a given area and can provide
standard deviations and average over area-type readings
and define complete surface characterization. These
systems lend themselves to research applications where
specialized programming can achieve auto-correlation,
power spectrum analysis and peak curvature.

SUBJECT: Metrology Measurement & control (AU-503)

________________________________________________________________________

Experiment No.:7
Date of Conduction:

Date of submission:
Aim: Measurement of screw thread by one wire and two wire
Measurement of screw thread
(i)MeasurementofMajorDiameter.
Forthemeasurementofmajor diameterofexternalthreads, agoodquality
handmicrometerisquitesuitable.Intakingreadings,alightpressuremustbeusedas
theanvilsmakecontactwiththegaugeatpointsonlyandotherwisetheerrorsdueto
compressioncanbeintroduced.Itis,however,alsodesirabletocheckthemicrometer
readingonacylindricalstandardofapproximatelythesamesize,sothatthezeroerror
etc.,mightnotcomeintopicture.
For greater accuracy and convenience, the major diameter is measured by
bench micrometer. This instrument was designed by N.P.L. to estimate some
deficiencies inherent in the normal hand micrometer. It uses constant measuring
pressureandwiththismachinetheerrorduetopitcherrorinthemicrometerthreadis
avoided. In order that all measurements be made at the same pressure, a fiducial
indicatorisusedinplaceofthefixedanvil.Inthismachinethereisnoprovisionfor
mountingtheworkpiecebetweenthecentresanditistobeheldinhand.Thisisso,
because,generallythecentresoftheworkpiecearenottruewithitsdiameter.This
machineisusedasacomparatorinordertoavoidanypitcherrorsofmicrometers,
zeroerrorsettingetc.Acalibratedsettingcylinderisusedasthesettingstandard.
Theadvantageofusingcylinderassettingstandardandnotslipgaugesetc.,is
thatitgivesgreatersimilarityofcontactattheanvils.Thediameterofthesetting
cylindermustbenearlysameasthemajordiameter.Thecylinderisheldandthe
readingofthemicrometerisnoteddown.Thisisthenreplacedbythreadedworkpiece
andagainmicrometerreadingisnotedforthesamereadingoffiducialindicator.Thus,
ifthesizeofcylinderisapproaching,thatofmajordiameter,thenforagivenreading
themicrometerthreadisusedoverashortlengthoftravelandanypitcherrorsit
containsarevirtuallyeliminated.

Thenmajordiameter=D1+(R2R1).
Inorder to determine the amount of taper, the readings should be taken at
variouspositionsalongthethreadandtodetecttheovality,twoorthreereadingsmust
betakenatoneplaneinangularpositions.

(ii) MeasurementofMinorDiameter
ThisisalsomeasuredbyacomparativeprocessusingsmallVeepieceswhich
make
contactwitharootofthethread.TheVeepiecesareavailableinseveralsizeshaving
suitableradiiattheedges.TheincludedangleofVeepiecesislessthantheangleof
the thread to bechecked sothatit can easily probeto the root of the thread. To
measuretheminordiameterbyVeepiecesissuitableforonlyWhitworthandB.A.
threadswhichhaveadefiniteradiusattherootofthethread.Forotherthreads,the
minordiameterismeasuredbytheprojectorormicroscope.

The measurement is carried out on a floating carriage diameter measuring

machineinwhichthethreadedworkpieceismountedbetweencentresandabench
micrometerisconstrainedtomoveatrightanglestotheaxisofthecentrebyaVee
ball slide. The method of the application of Veepieces in the machine is shown
diagrammaticallyinFig..ThedimensionsofVeepiecesplaynoimportantfunctionas
theyareinterposedbetweenthemicrometerfacesandthecylindricalstandardwhen
standardreadingistaken.
Itisimportantwhiletakingreadings,toensurethatthemicrometerbelocated
atrightanglestotheaxisofthescrewbeingmeasured.TheselectedVeesareplaced
on each side of the screw with their bases against the micrometer faces. The
micrometerheadisthenadvanceduntilthepointeroftheindicatorisoppositethezero
mark,andnotebeingmadeofthereading.Thescrewisthenreplacedbystandard
referencediscoraplaincylindricalstandardpluggaugeofapproximatelythecore
diameterofthescrewtobemeasuredandsecondreadingofthemicrometeristaken.
IfreadingonsettingcylinderwithVeepiecesinposition=R 1andreadingonthread
=R2
anddiameterofsetting
cylinder=D1Thenminor
diameter=D1+(R2R1)
Readingsmaybetakenatvariouspositionsinordertodeterminethetaperandovality.
(iii) EffectiveDiameterMeasurements.
Theeffectivediameterorthepitchdiametercanbemeasuredby.anyoneof
thefollowingmethods:
(i) Themicrometermethod
(ii) Theonewire,twowire,orthreewireorrodmethod.
TwoWireMethod.
Theeffectivediameterofascrewthreadmaybeascertainedbyplacingtwo
wiresorrodsofidenticaldiameterbetweentheflanksofthethread,asshowninFig.
13.15, and measuring the distance over the outside of these wires. The effective
diameterEIsthencalculatedas

E=T+P
WhereT=Dimensionunderthewires
=M2d
M=dimensionoverthewires,d=diameterofeachwire

Fig(a)

Fig(b)

Thewiresusedaremadeofhardenedsteeltosustainthewearandtearinuse.
Theseare givenahighdegree ofaccuracyandfinishby lappingtosuitdifferent
pitches.
DimensionTcanalsobedeterminedbyplacingwiresoverastandardcylinderof
diametergreaterthanthediameterunderthewiresandnotingthereadingR 1andthen
takingreadingwithoverthegauge,sayR 2.ThenT=S(R1R2).
P=Itisavaluewhichdependsuponthediaofwireandpitchofthethread.
If
P=pitchofthethread,then
P=0.9605p1.1657d (for Whitworth thread).
P=0.866pd(formetricthread).
ActuallyPisaconstantValuewhichhastobeaddedtothediameterunderthe
wirestogivetheeffectivediameter.TheexpressionforthevalueofPintermsofp
(pitch),d(diameterofwire)andx(threadangle)canbederivedasfollows:
InFig.13.15(b),

sinceBCliesontheeffectivediameterline

BC=pitch=p
OP=dcosecx/22
PA=d(cosecx21)2
PQ=QCcotx2=p4 cot x2
AQ=PQAP=p cot x24 d(cosecx2 1)2
AQishalfthevalueofP
..

Pvalue=2AQ
=p2 cot x2 d (cosecx21)

Twowiremethodcanbecarriedoutonlyonthediametermeasuringmachine
describedformeasuringtheminordiameter,becausealignmentisnotpossibleby2
wiresandcanbeprovidedonlybythefloatingcarriagemachine.Inthecaseofthree
wiremethod,2wire,ononesidehelpinaligningthemicrometersquaretothethread
whilethethirdplacedontheothersidepermitstakingofreadings.

ThreeWireMethod.
Thismethodofmeasuringtheeffectivediameterisanaccuratemethod.Inthis
threewiresorrodsofknowndiameterareused;oneononesideandtwoontheother
side{Fig.13.17(a)and(&)].Thismethodensuresthealignmentofmicrometeranvil
facesparalleltothethreadaxis.Thewiresmaybeeitherheldinhandorhungfroma
standsoastoensurefreedomtothewirestoadjustthemselvesundermicrometer
pressure.

M=distanceoverwires
E=effectivediameter
r=radiusofthewires
d=diameterofwires
h=heightofthecentreorthewireorrodfromthe
effectivex=angleofthread.

Fig(a)
Fromfig.(b),
AD=ABcosecx2=rcosecx2
H=DEcotx2=p2 cot x2
CD=H=p4 cot x2
H=ADCD
r=cosecx2 p4cotx2
Distanceoverwires=M=E+2h+2r
=

E+2(rcosecx2 p4cotx2)+2r

E+2r(l+cosecx2 ) p2 cot x2
or M=E+d(1+cosecx2) p2 cot x2
(since2r=0)
(i)IncaseofWhitworththread:
X=55,depthofthread=0.64p,sothat
E=D0.64pandcosecx2 =2.1657
Cotx2=1.921
M=E+d(1l+cosecx2) p2 cotx2

D0.64p+d(1+2.1657)p2(1.921)

Fig(b)

D+3.1657d1.6005p
M=D+3.1657d1.6p
whereD=outsidedia.

(ii)Incaseofmetricthreads:
Depthofthread=0.6495p
so,

E=D0.6495p.

x=60,cosecx2=2;cotx2 = 1.732
M=D0.6495 p+d(l+2)p2 (1.732)
=

D+3d(0.6495+0.866)p

D+3d1.5155p.
We can measure the value of M practically and then compare with the
theoreticalvalueswiththehelpofformulaederivedabove.Afterfindingthecorrect
valueofMandknowingd,Ecanbefoundout.
IfthetheoreticalandpracticalvaluesofM(i.e.measuredoverwires)differ,
thenthiserrorisduetooneormoreofthequantitiesappearingintheformula.

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY, INDORE

DEPARTMENT OF MECHANICAL ENGINEERING
SUBJECT: Metrology Measurement & control (AU-503)
_________________________________________________

Experiment No.: 8
Date of Conduction:
Date of submission:
Aim: Measurement of parameters of gear teeth
Requirements:
Theory:
GearMeasurement
Themostcommonlyusedformsofgearteethare
1. Involute
2. Cycloidal
Theinvolutegearsalsocalledasstraighttoothorspurgears.
Thecycloidalgearsareusedinheavyandimpactloads.
Theinvoluterackhasstraightteeth.
Theinvolutepressureangleiseither20or14.5
GearToothCaliper
Ingeartoothverniermethodthethicknessismeasuredatthepitchline.Geartooth
thicknessvariesfromthetipofthebasecircleofthetooth,andtheinstrumentiscapableof
measuringthethicknessataspecifiedpositiononthetooth.Thetoothverniercaliperconsistsof
vernierscaleandtwoperpendiculararms.Inthetwoperpendiculararmsonearmisusedto
measurethethicknessandotherarmisusedtomeasurethedepth.Horizontalvernierscale
readinggiveschordalthickness(W)andverticalvernierscalegivesthechordaladdendum.
Finallythetwovaluesecompared.The theoretical values of W and d can be found out by
consideringonetoothinthegearanditcanbeverified.

InfignotethatwisachordADBandtooththicknessisspecifiedbyAEB.The
distancedisnotedandadjustedoninstrumentanditisslightlygreaterthanaddendumCE
Therefore, W is chordal thickness andd is named as chordal addendum.

So,W=AB=2AD
And angle, AOD = =
Where,

n=numberofteeth
W = 2AD = 2 x AO sin
=2Rsin360/4n

Where,

R=Pitchcircleradius

Module,m=

Pitch circle Diameter

2R

Therefore,R=
And OD = R Cos = nm/2 Cos(90/n)
D=nm/2Cos(90/n)/
Alsofromthefigure,
d=OCOD

Addendumistheradialdistancefromthepitchcircletothetipofthetooth.Its
valueisequaltoonemodule
But OC=OE+Addendum=R+m
=
And

OD = R cos
=

Therefore,

d=

d=

Verniermethodlikethechordalthicknessandchordaladdendumaredependsupon
thenumberofteeth.Duetothisformeasuringlargenumberofgearsdifferentcalculationsare
tobemadeforeachgear.Sothesedifficultiesareavoidedbythisconstantchordmethod.

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY,

INDORE
DEPARTMENT OF MECHANICAL ENGINEERING
SUBJECT: Metrology Measurement & control (AU-503)
________________________________________________________________________

Experiment No.: 10
Date of Conduction:
Date of submission:
Aim: To study use of comparators
Theory:
MechanicalComparator:
Itisselfcontrolledandnopoweroranyotherformofenergyisrequired.Itemploys
mechanical means for magnifying the small movement of the measuring stylus. The
movementisduetothedifferencebetweenthestandardandtheactualdimensionbeing
checked

The method for magnifying the small stylus movement in all the mechanical
comparatorsisbymeansoflevers,geartrainsorcombinationofthese.Theyareavailable
ofdifferentmakeandeachhasit'sowncharacteristic.Thevarioustypesofmechanical
comparatorsaredialindicator,rackandpinion,sigmacomparator,Johanssonmikrokator.
a.DialIndicator:
Itoperatesontheprinciple,thataveryslightupwardpressureonthespindleatthe
contactpointismultipliedthroughasystemofgearsandlevers.Itisindicatedontheface
of the dial by a dial finger. Dial indicators basically consists of a body with a round
graduateddialandacontactpointconnectedwithaspiralorgeartrainsothathandonthe

dialfaceindicatestheamountofmovementofthecontactpoint.Theyaredesignedforuse
onawiderangeofstandardmeasuringdevicessuchasdialboxgauges,portaldial,hand
gauges,dialdepthgauges,diametergaugesanddialindicatorsnapgauge.

Correspondstoaspindlemovementof1mm.Themovementmechanismofthe
instrumentishousedinametalcaseforit'sprotection.Thelargedialscaleisgraduatedinto
100divisions.Theindicatorissettozerobytheuseofslipgaugesrepresentingthebasic
sizeofpart.
Applications:
1. Comparingtwoheightsordistancesbetweennarrowlimits.
2. Todeterminetheerrorsingeometricalformsuchasovality,roundnessandtaper.
3. Fortakingaccuratemeasurementofdeformationsuchasintensionandcompression.
4. Todeterminepositionalerrorsofsurfacessuchasparallelism,squarenessandalignment.
5. Tocheckthealignmentoflathecentersbyusingsuitableaccuratebarbetweenthe
centers.
6. Tochecktruenessofmillingmachinearboursandtochecktheparallelismofshaper
armwithtablesurfaceorvice.
b)JohanssonMikrokator:
ThiscomparatorwasdevelopedbyC.F.Johansson.
Principle:
ItworksontheprincipleofaButtonspring,spinningonaloopofstringlikeinthecaseof
Childrens toys.
Construction:
ThemethodofmechanicalmagnificationisshowninFigure.Itemploysatwisted
metalstrip.Anypullonthestripcausesthecentreofthestriptorotate.Averylightpointer
made of glass tube is attached to the centre of the twisted metal strip. The measuring
plungerisontheslitwasherandtransmitsitsmotionthroughthebellcranklevertothe
twistedmetalstrip.Theotherendofthetwistedmetalstripisfastenedtothecantilever
strip. The overhanging length of the cantilever strip can be varied to adjust the
magnificationoftheinstrument.Thelongerthelengthofthecantilever,themoreitwill
deflectunderthepullofthetwistedmetalstripandlessrotationofthepointerisobtained.

Whentheplungermovesbyasmalldistanceinupwarddirectionthebellcranklever
turnstotherighthandside.Thisexertsaforceonthetwistedstripanditcausesachangein
itslengthbymakingitfurthertwistoruntwist.Hencethepointeratthecentrerotatesby
someamount.Magnificationupto5000Xcanbeobtainedbythiscomparator
AdvantagesofMechanicalComparator:
1. Theydonotrequireanyexternalsourceofenergy.
2. Thesearecheaperandportable.
3. Theseareofrobustconstructionandcompactdesign.
4. Thesimplelinearscalesareeasytoread.
5. Theseareunaffectedbyvariationsduetoexternalsourceofenergysuchair,electricity
etc.
Disadvantages:
1. Rangeislimitedasthepointermovesoverafixedscale.
2. Pointerscalesystemusedcancauseparallaxerror.
3. Therearenumberofmovingpartswhichcreateproblemsduetofriction,andultimately
theaccuracyisless.
4. Theinstrumentmaybecomesensitivetovibrationduetohighinertia.
c)MechanicalOpticalComparator:
Principle:
Inmechanicalopticalcomparator,smallvariationintheplungermovementis
magnified:firstbymechanicalsystemandthenbyopticalsystem.
Construction:
Themovementoftheplungerismagnifiedbythemechanicalsystemusingapivoted
lever.FromtheFigurethemechanicalmagnification=x2/x1.Highopticalmagnificationis

possiblewithasmallmovementofthemirror.Theimportantfactoristhatthemirrorused
isoffrontreflectiontypeonly.

ThebackreflectiontypemirrorwillgivetworeflectedimagesasshowninFigure,
hencetheexactreflectedimagecannotbeidentified.
Advantages:
1. TheseComparatorsarealmostweightlessandhavelessnumberofmovingparts,dueto
thisthereislesswearandhencelessfriction.70
2. Higherrangeevenathighmagnificationispossibleasthescalemovespasttheindex.
3. Thescalecanbemadetomovepastadatumlineandwithouthavinganyparallaxerrors.
4. Theyareusedtomagnifypartsofverysmallsizeandofcomplexconfigurationsuchas
intricategrooves,radiiorsteps.
Disadvantages:
1. Theaccuracyofmeasurementislimitedto0.001mm
2. Theyhavetheirownbuiltinilluminatingdevicewhichtendstoheattheinstrument.
3. Electricalsupplyisrequired.
4. Eyepiecetypeinstrumentmaycausestrainontheoperator.
5. Projectiontypeinstrumentsoccupylargespaceandtheyareexpensive.
6. Whenthescaleisprojectedonascreen,thenitisessentialtotaketheinstrumenttoa
darkroominordertotakethereadingseasily.
d)SigmaComparator:
Theplungerisattachedtoabarwhichissupportedbetweenthebendingplatesatthe
topandbottomportionasshowninFigure(a)

Thebarisrestrictedtomoveintheverticaldirection.Aknifeedgeisfixedtothe
bar.Theknifeedgeisattachedtothesapphireplatewhichisattachedtothemovingblock.
Theknifeedgeextortsaforceonthemovingblockthroughsapphireplate.Movingblockis
attachedtothefixedblockwiththehelpofcrossedstripsasshowninFigure(b).Whenthe
forceisappliedonthemovingblock,itwillgiveanangulardeflection.AYarmwhichis
attachedtothemovingblocktransmitstherotarymotiontothedrivingdrumofradiusr.
Thisdeflectsthepointerandthenthereadingisnoted.
Ifl=Distancefromhingepivottotheknifeedge
L=Lengthofyarm
R=Drivingdrumradius
DLengthofthepointer
Thenthetotalmagnification=(L/l)*(D/R)
PneumaticComparators(SolexGauge):
Principle:
Itworksontheprincipleofpressuredifferencegeneratedbytheairflow.Airis
suppliedatconstantpressurethroughtheorificeandtheairescapesintheformofjets
througharestrictedspacewhichexertsabackpressure.Thevariationinthebackpressure
isthenusedtofindthedimensionsofacomponent.
Working:
AsshowninFigure(a)theairiscompressedinthecompressorathighpressure
whichisequaltoWaterheadH.Theexcessairescapesintheformofbubbles.Thenthe
metricamountofairispassedthroughtheorificeattheconstantpressure.Duetorestricted
area,atA1position,thebackpressureisgeneratedbytheheadofwaterdisplacedinthe
manometertube.Todeterminetheroundnessofthejob,thejobisrotatedalongthejetaxis,
ifnovariationinthepressurereadingisobtainedthenwecansaythatthejobisperfectly
circularatpositionA1.
ThenthesameprocedureisrepeatedatvariouspositionsA2,A3,A4,positionand
variationinthepressurereadingisfoundout.AlsothediameterismeasuredatpositionA1

corresponding tothe portion againsttwo jetsand diameter is also measured atvarious

positionalongthelengthofthebore

Figure (b)

Anyvariationinthedimensionchangesthevalueofh,e.g.Changeindimensionof
0.002mmchangesthevalueofhfrom3to20mm.Moderateandconstantsupplypressure
isrequiredtohavethehighsensitivityoftheinstrument
.Advantages:
1. Itischeaper,simpletooperateandthecostislow.
2. Itisfreefrommechanicalhysteresisandwear.
3. Themagnificationcanbeobtainedashighas10,000X.
4. Thegaugingmemberisnotindirectcontactwiththework.
5. Indicatingandmeasuringisdoneattwodifferentplaces.
6. Tapersandovalitycanbeeasilydetected.
7. Themethodisselfcleaningduetocontinuousflowofairthroughthejetsandthis
makesthemethodidealtobeusedonshopfloorforonlinecontrols.
Disadvantages:
1. Theyareverysensitivetotemperatureandhumiditychanges.
2. Theaccuracymaybeinfluencedbythesurfaceroughnessofthecomponentbeing
checked.
3. Differentgaugingheadsareneededfordifferentjobs.
4. Auxiliaryequipmentssuchasairfilters,pressuregaugesandregulatorsareneeded.
5. Nonuniformityofscaleisapeculiaraspectofairgaugingasthevariationofback
pressureislinear,overonlyasmallrangeoftheorificesizevariation.

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY,

INDORE
DEPARTMENT OF MECHANICAL ENGINEERING
SUBJECT: Metrology Measurement & control (AU-503)

Experiment No.: 9
Date of Conduction:
Date of submission:
Aim: To study use of profile projector
Profile projector :
Profile projector is an optical device which is used to check profile of components
having special format surfaces as gears, screws and those objects having regular or
irregular profile.
It is highly sophisticated and is versatile optical instrument which is designed as
per international standard.
It is ideal for rapid inspection of linear and angular measurements of small to
medium size components as gears, tools, rubber components, electronic
assemblies etc.
Its best quality, high resolution optics provide accurate, bright, clear and sharp
images.

Construction and working :

Construction:
It consists of halogen of high intensity 24V and 150W. The light source is placed
at the principal focus of the collimating lens.
The projection lens is a combination of lenses and forms a real image of the
objects placed between it and collimating lens.
The work stage is mounted on ball bearing and is rotatable from 0-360 degree
The two micrometer are attached to provide motion in X and Y axes directions.
The range of magnification varies from 10X to 20X.
The screen is of 100mm deameter and rotatable from 0 to 360 degree

Working :
The jobs is placed on the work table. Its profile is viewed on the screen and is
measured with the help of micrometer attached by shifting the image on the screen.

PROFILE PROJECTOR

PROFILE PROJECTOR O