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T 4
360
Where m module and d= mT
Page | 21
d = OCOD
OC =OE + addendalum = R + m =
2
mT
+ m
OD=OA cos
d = m
|
\
|
\
|
+
T
R
T
4
360
cos 1
2
Chord addendum =
(
\
|
+
T T
mT
4
360
cos
2
1
2
Procedure :
1. First we calculate the chordal thickness and chordal addendum theoretically by given
in a mathematical relation.
2. By fixing chordal addendum on the vertical scale of the gear tooth vernier caliper.
3. Then calculate the thickness the tooth by horizontal scale of gear tooth vernier caliper.
4. The experimental value and theoretical value is compared. If any error is observed it is
noted.
5. The above procedure is repeated for different teeth.
Observations:
Error is vertical scale of gear tooth vernier calipers = -------------------- (1)
Module of gear wheel, m _____________________________
No. of teeth on gear wheel = T= ______________________
Theoretical chordal addendum =
(
\
|
+
T T
mT
4
360
cos
2
1
2
= ----------------------------- (2)
The vertical scale is set at [(1) + (2)] = _____________________ Q (1) = error correction
Q (2) addendum height
Theoretical chordal thickness = m T sin
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\
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T 4
360
Page | 22
S.No.
Theoretical
Tooth thickness (mm)
Actual tooth thickness
Error
M.SR
(mm)
V.S.R
Total Reading
[M.S.R+(V.S.R L.C)]
1
2
3
4
5
Precautions:
1. Accuracy in measurement is limited by the coast count the instrument.
2. Need different settings for variation in number of fore given pitch.
3 . As the user, during use is concentrated on both the jaws, the calipers has to be calibrated at
regular intervals.
Result : Actual chordal tooth thickness by using Gear
Page | 23
Stylus-type profilometer, Talysurf
Page | 24
SURFACE ROUGHNESS MEASUREMENT BY TALY SURF
AIM: To measure the surface roughness using taly surf instrument.
APPARATUS:- Taly surf, work piece, surface plate.
Theory:
Tally surf is an electronic instrument working on carrier modulating principle. This
instrument gives the information rapidly and accurately. This instrument is also as the previous
one record the static displacement of the system and is dynamic instrument like profilometer.
The measuring head of this instrument consists of a diamond stylus of about 0.002 mm
tip radius and skid as shoe which is drawn across the surface by means of motorized driving unit,
which provides three speeds giving 20 x 20 horizontal magnifications and a speed suitable for
average reading. A neutral portion in which pivots about E shaped stamping. There are 2
resistances from an oscillator. As the armature is pivoted about central leg. Any movement of the
original AC current flowing the coils is modulated. The output of the bridge thus consists of
modulation . This is further demodulated so that the current flow is directly proportional to the
vertical displacement of the stylus only.
The demodulated output is caused to operate a pen recorder to produce a permanent
record and the meter to give a numerical assessment directly. In recorder of this instrument the
making medium is a electrical discharge, there is a specially treated paper which blanks at the
point of the stylus. So this has no distortion due to drag and stylus. So this has the records strictly
rectilinear one.
Procedure:-
1. The power supply to the tally surf measuring instrument is given and it is checked
with the reference sample for current roughness
2. The instrument is bound on the specimen properly and then the measurement is stored
by pressing start/stop button. Note down Ra & R
z
values using parameter button.
3. Repeat the experiment on specimen by changing the distribution.
4. Repeat the above process for the remaining specimen and tabulate the readings.
Page | 25
Observations:
S.No Measurement roughness value m
Sample, direction R
a
R
z
Average
R
a
Average
R
z
Grade
1
2
3
4
5
Result:
Page | 26
FLATNESS OF SURFACE PLATE BY USING SPIRIT LEVEL
AIM: To determine the flatness of surface plate by using spirit level.
Apparatus Required: surface plate, spirit level
Theory:
The spirit of level consists of a sealed glass tube mounted on a base. The inside surface of
the tube is ground to a convex barrel shape having large radius. The precision of the level
depends on the accuracy of this radius of the tube. A scale is engraved on the top of the glass
tube. The tube is nearly filled with either ether or alcohol, except a small air or vapor in the form
of a bubble.
The bubble always tries to remain at the highest point of the tube. If the base of the spirit
level is horizontal, the centre point is the highest point of the tube. So, that when the level is
placed on a horizontal surface, the bubble rests at the centre of the scale. If the base of the level
is fitted through a small angle, the bubble will more relative to the tube a distance along its
radius corresponding to the angle.
Surface Plate spirit level
The figure shows two positions of the base of the level(OA
1
and OA
2
) and corresponding
positions of the bubble (Bl,B2). When the base OA
1
is horizontal, the bubble occupies position
B
1
. Let be the small angle through which the base is fitted. The bubble now occupies the
position B2.Let L be the distance travelled by bubble along the tube and h the difference in
heights between the ends of the base. Then L= R and h =. L
Therefore =
L
h
R
l
=
L
R
h l =
Page | 27
Where R = radius of curvature of the tube
L = length of base
Finally h =
R
L
Procedure:
1 Place the spirit level on the surface plate for which we have to find out the flatness
2 Find the base length of the spirit level
3 Note the radius of curvature of the spirit level tube
4 Find the tilt in the bubble
5 Finally find out the difference in heights between the ends of the base.
Observations:
S.NO. Distance traveled by the bubble Difference in height between
ends
Angle
1
2
3
4
5
Precautions:
1 .Clean the surface plate and ensure there is no dust particles
2. Take the bubble reading without any parallax error.
Result:
Flatness of the surface plate can be found by using spirit level.
Page | 28
ALIGNMENT TESTS FOR LATHE
1. Test for level of installation.
(a) In a longitudinal b) In transverse direction
Measuring instruments. Spirit level, gauge block to suit the guide ways of the lathe bed.
Procedure: - The gauge block with the spirit level is placed on the bed ways on the front
position, back position and in the cross wise direction. The position of the bubble in the
spirit level is checked and the readings are taken.
Permissible error : Front guide ways. 0.02 mm/meter convex only. Rear guide ways, 0.01 to
0.02 convexity. Bed level in cross-wise direction 0.02/meters. Straightness of slide ways
(for machines more than 3 mm turning length only, measurement taken by measuring tight
wire and microscope or long straight edge). Tailstock guide ways parallel with movement of
carriage 0.02 mm/m. No twist is permitted.
The error in level may be corrected by setting wedges at suitable points under the support feel or
pads of the machine.
2. Straightness of saddle in horizontal plane:-
Measuring instruments: Cylindrical test mandrel (600mm long), dial indicator.
Procedure: - The mandrel is held between centres. The dial indicator is mounted on the saddle.
The spindle of the dial indicator is allowed to touch the mandrel. The saddle is then moved
longitudinally along the length of the mandrel. Readings are taken at different places.
Permissible error 0.02 mm over length of mandrel.
3.Alignment of both the centres in the vertical plane:
Measuring instruments: Cylindrical mandrel 600 mm long, dial gauge.
Procedure: The test mandrel is held between centres. The dial indicator is mounted on the
saddle in vertical plane as shown in figure. Then the saddle along with the dial gauge is traveled
longitudinally along the bed ways, over the entire length of the mandrel and the readings are
taken at different places.
Page | 29
Permissible error: 0.02 mm over 600 mm length of mandrel (Tail stock centre is to lie higher
only).
4. True running of taper socket in main spindle
Instruments required: Test mandrel with taper shank and 300 mm long
cylindrical measuring part, dial gauge.
Procedure: The test mandrel is held with its taper shank in a head stock spindle socket. The dial
gauge is mounted on the saddle. The dial gauge spindle is made to touch with the mandrel. The
saddle is then traveled longitudinally along the bed ways and readings are taken at the points A
and B as shown in figure.
Permissible error: Position A 0.01 mm, position B 0.02 mm.
5. Parallelism of main spindle to movement:
(a) In a vertical plane (b) In a horizontal plane
Measuring instruments: Test mandrel with taper shank and 300 mm long cylindrical measuring
part, dial gauge.
Procedure: The dial gauge is mounted on the saddle. The dial gauge spindle is made to touch the
mandrel and the saddle is moved to and fro. It is checked in vertical as well as in horizontal
plane.
Permissible error: (a) 0.02/300 mm mandrel rising towards free end only.
(b) 0.02/300 mm mandrel inclined at free end towards tool pressure only.
Page | 30
6. Movement of upper slide parallel with main spindle in vertical plane:
Measuring instruments: Test mandrel with taper shank and 300 mm long cylindrical measuring
part, dial gauge.
Procedure: The test mandrel is fitted into the spindle and a dial gauge clamped to the upper
slide. The slide is transversed along with the dial gauge plunger on the top of the stationary
mandrel.
Permissible error: 0.02 mm over the total movement of the slide.
7. True running of locating cylinder of main spindle:
Measuring instrument: Dial gauge.
Procedure: The dial gauge is mounted on the bed, touching at a point on main spindle. The main
spindle is rotated by hand and readings of dial gauge are taken.
Permissible error: 0.01 mm.
Page | 31
8. True running of head stock centre:
Measuring instruments: Dial gauge.
Procedure: The live centre is held in the tail stock spindle and it is rotated. Its trueness is
checked by means of a dial gauge.
Permissible error: 0.01 mm.
9. Parallelism of tailstock sleeve to saddle movement:
Measuring instruments: Dial indicator
Procedure: Tailstock sleeve is fed towards. The dial gauge is mounted on the saddle. Its spindle
is touched to the sleeve at one end and the saddle is moved to and fro, it is checked in H.P. and
V.P. also.
Permissible error: (a) 0.0 1/100 mm (Tailstock sleeve inclined towards
tool pressure only). (b) 0.0 1/100 mm (Tailstock sleeve rising towards free end only).
10.Paralle1ism of tail stock sleeve taper socket to saddle movement
(a) in V.P.
(b) in H.P.
Measuring instruments: - The mandrel with taper shank and a cylindrical measuring part of 300
mm length, dial gauge.
Procedure: - Test mandrel is held with its taper shank in tail-stock sleeve taper socket. The dial
gauge is mounted on spindle. The dial gauge spindle is made to touch with the mandrel. The
saddle is then transverse longitudinally along the bed way and readings are taken.
Permissible error:-
(a) 0.03/300 mm (mandrel rising towards free end only)
(b) 0.03/300 mm (Mandrel inclined towards tool pressure only).
Page | 32
ALIGNMENT TESTS ON MILLING MACHINE KNEE TYPE
HORIZONTAL AND VERTICAL
(1) Flatness of work table
(a) In longitudinal direction.
(b) In transverse direction.
Measuring instruments: - Spirit level.
Procedure: - A spirit level is placed directly on the table at points about 25 to 30 cm apart, at A,
B, C for longitudinal tests and D, E and F for the transverse test. The readings are noted.
Permissible error:
Direction A-B-C, 0.04 mm
Direction D-E-F, 0.04 mm
(2) Parallelism of the work table surface to the main spindle
Measuring instruments: Dial indicator, test mandrel 300 mm long, spirit level.
Procedure: The table is adjusted in the horizontal plane by spirit level and is then set in its
mean position longitudinally. The mandrel is fixed in the spindle taper. The dial gauge is set on
the machine table, and the feeder adjusted to touch the lower surface of the mandrel. The dial
gauge readings at (A) and (B) are observed, the stand of the dial gauge being moved while the
machine table remains stationary.
Permissible error: 0.02/3 00 mm.
Page | 33
.
(3) Parallelism of the clamping surface of the work table in its longitudinal motion:
Instruments: Dial gauge, straight edge.
Procedure: A dial gauge is fixed to the spindle. The dial gauge spindle is adjusted to touch the
table surface. The table is then moved in longitudinal direction and readings are noted. If the
table surface is uneven it is necessary to place a straight edge on its surface and the dial gauge
feeder is made to rest on the top surface of the straight edge.
Permissible error: 0.02 up to 500 mm length of transverse, 0.03 up to 1000 mm and 0.04 above
1000 mm length of transverse.
(4) Parallelism of the cross (transverse) movement of the worktable to the main spindle:
(a) In vertical plane
(b) In horizontal plane
Instruments: Dial gauge, test mandrel with taper shank.
Procedure: The work table is set in its mean position. The mandrel is held in the spindle. A dial
gauge fixed to the table is adjusted so that its spindle touches the surface of the mandrel.
The table is moved cross-wise and the error is measured in the vertical plane and also in the
horizontal plane.
Permissible error: 0.02 for the overall transverse movement of the work table.
Page | 34
(5) True running of internal taper of the spindle:
Instruments: 300 mm long test mandrel, dial gauge.
Procedure: The test mandrel with its taper shank is held in the main spindle. Dial gauge is kept
scanning the periphery of the mandrel. Spindle is rotated and dial gauge readings are noted at
different points say A and B as shown.
Permissible error: Position A: 0.01 mm, Position B: 0.02 mm.
(6) Square nests of the centre T-slot of worktable with main spindle
Instruments: Dial gauge, special bracket.
Procedure: To check the perpendicularity of the locating slot and the axis of the main spindle.
The table should be arranged in the middle position of its longitudinal movement, and a bracket
with a tenon at least 150 mm long inserted in the locating slot as shown in figure. A dial gauge
should be fixed in the taper, the feeder being adjusted to touch the vertical face of the bracket.
Observe the reading on the dial gauge when the bracket is near one end of the table, the swing
over the dial gauge and move the bracket so that the corresponding readings can be taken near
the other end of the table.
Permissible error: 0.025 mm in 300 mm.
Page | 35
(7) Parallelism of the T-slot with the longitudinal movement of the table:
Instruments: Dial gauge, special bracket.
Procedure: The general parallelism of the T-slot with the longitudinal movement of the table is
checked by using 150 mm long braked having a tenon which enters the slot, The dial gauge is
fixed to the spindle taper and adjusted so that its feeder touches the upper surface of the bracket.
The table is then moved longitudinally while the bracket is held stationary by the hand of the
operator and dial gauge deviations from parallelism are note down.
Permissible error: 0.0 125 mm in 300 mm.
(8) Parallelism between the main spindle and guiding surface of the overhanging arm
Instruments: Dial gauge, mandrel.
Procedure: The overhanging arm is clamped in its extreme extended position. The dial gauge is
fixed to the arbor support. The feeder of the dial gauge is adjusted to touch the top or ride of the
test mandrel. The arbor can then be moved along the overhanging arm and the deviations from
parallelism observed on the dial gauge.
Page | 36
4 Diagrams