Kongu Engineering College: Metrology and Measurement Laboratory

Instrumentation and Metrology laboratory 1
KONGU ENGINEERING COLLEGE

PERUNDURAI, ERODE - 638 052
(Autonomous)

SCHOOL OF BUILDING AND MECHANICAL SCIENCES

LABORATORY MANUAL
METROLOGY AND MEASUREMENT LABORATORY

NAME:____________________________________
ROLL NO:__________________________________

DEPARTMENT OF MECHANICAL ENGINEERING


EXPERIMENT INDEX
S.NO NAME OF EXPERIMENT
PAGE
NO.
MARKS
AWARDED
DATE
INCHARGE
SIGN
1.
CALIBRATION OF DIAL GAUGE AND MEASUREMENT
OF COMPONENT
3
2.
CALIBRATION OF BORE GAUGE, INSIDE
MICROMETER AND MEASUREMENT OF THE
COMPONENT

6

3.
CALIBRATION OF DEPTH GAUGE, VERNIER HEIGHT
GAUGE AND MEASUREMENT OF THE COMPONENT
10
4.
CALIBRATION OF LVDT AND COMPARE AND CHECK
THE DIMENSIONAL TOLERANCE USING LVDT OR
ELECTRICAL COMPARATOR
14
5.
CALIBRATION OF VERNIER CALIPER AND
MICROMETER AND MEASUREMENT OF THE GIVEN
COMPONENT
18
6.
MEASUREMENT OF TAPER ANGLE BY USING SINE
BAR
23
7.
CALIBRATION OF GEAR TOOTH VERNIER AND
MEASUREMENT OF GEAR TOOTH THICKNESS BY
GEAR TOOTH VERNIER CALIPER
25
8. FLATNESS AND STRAIGHTNESS CHECKING USING
AUTOCOLLIMATOR
28
9.
ELECTRONIC COMPARATOR
30
10. CHARACTERISTICS OF FIRST ORDER INSTRUMENT
THERMOMETER
33
11.
MEASUREMENT OF FORCE USING A PROVING RING
38
12.
POWER MEASUREMENT USING ROPE BRAKE
DYNAMOMETER
40
13.
PROFILE PROJECTOR
42
14.
ANGLE MEASUREMENT USING BEVEL PROTRACTOR
45
15.
HYSTERISIS CURVE OF A CANTILEVER BEAM
49
16.
MEASURING CYLINDER AND CONE DIMENSIONS
COORDINATE MEASURING MACHINE
51


CALIBRATION OF DIAL GAUGE AND MEASUREMENT OF COMPONENT
AIM:
To calibrate the dial gauge using slip gauge and to measure the given components using dial
gauge.
APPARATUS REQUIRED:
V - Block, Dial gauge with stand, Work piece, Slip gauges.
PROCEDURE:
Calibration:
1. The dial gauge is fitted to the stand to match the range of calibration of the dial gauge.
2. Adjust the dial gauge reading to zero with respect to reference plane.
3. Insert the selected length standard (slip gauge) between the reference surface and the dial gauge
plunger .
4. Repeat step 3 for the incremental increaser standard input.
5. Note down output values for the each of standard inputs.
6. Calculate error in Dial Gauge.
7. Plot a graph of (i). Standard input vs Output and (ii). Standard input vs Error
8. Calculate sensitivity of the instrument.
Measurement:
1. Without disturbing the calibration setup insert the work piece to be measured between the
reference surface and the Dial Gauge plunger.
2. Set a datum point or line.
3. Observe the Dial Gauge reading by moving the work piece to the edges for measurement.
4. Note down the reading of all the measurement.
5. Calculate compensating factor based on the error in the instrument.
6. Give a report of the work piece.


CALIBRATION OF DIAL GAUGE:
S.No STD Dimension
in
mm
Reading From Dial Gauge Average
Error in
mm

R
1
in mm R
2
in mm R
3
in mm mm deg
1
2
3
4
5
6
7
8
9
10

CHARACTERISTICS OF DIAL GAUGE:
Range : mm
Span : mm
Least Count : mm
Linearity : Output / Input =
% Linearity : %
Error/Bias : mm
Compensation Factor : mm
Sensitivity


MEASUREMENT OF SPECIMEN:
S.No
Parameter
measured
Observed Readings in mm

Compensating
factor in mm
Actual Readings in
mm

1
2
3
4
5
6
7
8
9
10

MODEL GRAPH:

Output Error

Standard Input Standard Input
RESULT:
Error of the instrument :
Sensitivity :
Lest count :


CALIBRATION OF BORE GAUGE, INSIDE MICROMETER AND MEASUREMENT OF
THE COMPONENT
AIM:
To calibrate the Bore Gauge and Inside Micrometer and also to measure the given component.
APPARATUS REQUIRED:
Vernier Calliper, Inside Micrometer, Bore gauge, Slip gauges, Component.
PROCEDURE:
Calibration:
1. Note down the range of instrument and the plunger displacement of the Bore Gauge.
2. Use a standard venier calliper as standard length and calibrate the gauges.
3. Note down the readings and plot the calibration graph.
4. Find the Least count, Error, Sensitivity of the instrument etc.,
Measurement:
1. Insert the gauge into the given cylindrical work piece and carry out measurement at different
plane and at different position.
2. Draw a circularity graph and give a report of the circularity and taper of work pieces.
3. Give a report of the measurement.


CALIBRATION OF THE BORE GAUGE & INSIDE MICROMETER:
S.
No
Name of the
instrument
Standard Input
values
in mm
Output values in mm
Error in
mm
I. II. III.
Average
values
1
B
O
R
E

G
A
U
G
E

2

3

4

6

7

8

9

10

11
I
N
S
I
D
E

M
I
C
R
O
M
E
T
E
R

12

13

14

15

16

17

18

19

20


CHARACTERISTICS OF BORE GAUGE:
Range:
Span:
Error: % Error
Compensation factor:
Least count=

CHARACTERISTICS OF INSIDE MICROMETER:
Range:
Span:
Error of the instrument
Compensation factor:
Least count:
Sensitivity:
MEASUREMENT OF THE COMPONENT:
S.no
Instrument
used
Plane Position
Observed
Reading in mm
Compensation
Factor
Actual Reading
in mm
1
2
3
4
5
6
7
8
9
10


MODEL CALCULATION FOR BORE GAUGE:
Measured value = MSR + (VSC*LC)

Correct value = measured value + zero correction

MODEL CALCULATION FOR INSIDE MICROMETER:
Measure value = MSR + (PSR*LC)

Correct value = measured value + zero correction
BORE GAUGE SENSITIVITY ANALYSIS:
RESULT:
Least count of the Instrument:
Error :
Sensitivity :
Attach the analysis report :

S.no

Input
value
In mm
Output value
Average value

Error in
mm
I II
Div Rad Div Rad Div Rad
1
2
3
4
5
6
7
8
9
10


CALIBRATION OF DEPTH GAUGE, VERNIER HEIGHT GAUGE AND MEASUREMENT
OF THE COMPONENT
AIM:
To calibrate the venire height gauge and depth gauge and to measure the given component.
APPARATUS REQUIRED:
Venire Height Gauge, Depth Gauge, Slip Gauge.
Calibration:
1. With the help of slip gauges as standard, calibrate the gauges .
2. Plot a graph of (i) Standard Input vs Output and
(ii) Standard Input vs Error
3. Observe the characteristics like error, least count, sensitivity, etc.,
Measurement:
1. Place the work piece and the gauge appropriately and carry out the measurement of the job.
2. Prepare a report of the measurement and indicate the characteristics of the work pieces.
CALIBRATION OF DEPTH GAUGE:
S.
No
Name of
instrument
Input value
in mm
Output value in mm Error in
mm
I II III
Average
value
1
D
E
P
T
H

G
A
U
G
E

2
3
4
5
6
7
8
9
10


S.
No
Input value
in mm
Output value in mm Error in
mm I II III Average value
11
V
E
R
N
I
E
R

H
E
I
G
H
T

G
A
U
G
E

12
13
14
15
16
17
18
19
20
CHARACTERISTICS OF DEPTH GAUGE:
Range :
Span :
Least count:
Sensitivity :
Error :

CHARACTERISTICS OF VERNIER HEIGHT GAUGE:
Range :
Span :
Least count:
Sensitivity :
Error :


Position MSR in mm PSR in Div OR=MSR+(PSR*LC) in mm CR=OR+ZC in mm

Parameter
measured
MSR
in mm
VSR
in DIV
OR=MSR+(PSR*LC)
in mm
CR=OR+ZC
in mm


RESULT:
Depth gauge :
Error :
Sensitivity :
Vernier Height gauge:
Error :
Sensitivity :


CALIBRATION OF LVDT AND COMPARE AND CHECK THE DIMENSIONAL
TOLERANCE USING LVDT OR ELECTRICAL COMPARATOR
AIM:
To calibrate the LVDT and to measure the incremental input.
APPARATUS REQUIRED:
LVDT, Micrometer, Slip gauge.
PROCEDURE:
Calibration:
1. Note down the range and span of LVDT .
2. Chose suitable slip gauges to make enough number of readings for calibration.
3. Set the LVDT such that when the plunger is at the middle, indicating zero output.
4. Calibrate the LVDT on both side of plunger movement from its mean position.
5. Plot a graph of (i) Standard Input vs Output and
(ii) Standard Input vs Error
6. Calculate the error, least count, sensitivity, etc.,

Measurement:
1. Insert the work piece to be measured, between the reference plane and LVDT plunger with out
disturbing the calibration setup.
2. Note down the indicated readings or the difference between the standard value and the
indicated reading if used as a comparator.
3. Make enough number of readings if used as a comparator and classify the items indicated as
accepted or rejected and produced a statistical report.
4. If its a measurement of a job, then produce a report of measurement.


CALIBRATION OF LVDT
Basic size: Increment/Decrement =

S.NO STD Input Output
micron
Output
value in mm
Error
(m) mm m
1
2
3
4
5
6
7
8
9
10

Average error = m
Compensation factor = m

CHARATERISTICS OF ELECTRICAL COMPARATOR:
Range:
L.C :
Compensation factor =
Sensitivity = Change in output signal
Change in input signal

Accuracy = output-input
Input


CHECKING OF COMPONENT: Compensation factor = m

Piece
Readings Displayed/ Attribute outcome
in micron
Compensation
Factor

Actual Value
in micron

MODEL CALCULATION:
Error =
Compensation factor =
L.C =
Sensitivity = Change in output signal
Change in input signal

Accuracy = output-input
Input
Error =

MODEL GRAPH:

Output Error

Standard Input Standard Input


RESULT:
Error of the instrument:
Least count :
Sensitivity :
Accuracy :


CALIBRATION OF VERNIER CALIPER AND MICROMETER AND MEASUREMENT OF
THE GIVEN COMPONENT
AIM:
To calibrate and measure the given component by using vernier calliper and micrometre.
APPARATUS REQUIRED:
Slip gauges, Micrometer and Vernier Calliper.
PROCEDURE:
Calibration:
1. With the help of slip gauges as standard, calibrate the gauges.
2. Plot a graph of (i) STD Input vs Output and
(ii) Standard Input vs Error .
3. Observe the characteristics like error, least count, sensitivity etc.,
Measurement:
1. Place the work piece and the gauge appropriately and carry out the measurement of the job.
2. Prepare a report of the measurement and indicate the characteristics of the work pieces.


CALIBRATION OF VERNIER CALLIPER:
CHARACTERISTICS OF VERNIER CALLIPER:
Parameter Formula used Result
Range -

Span -
Error
-

Compensation factor
-

Least count

value of 1MSD
no of VSD

Sensitivity
change in O/P
change in I/P

S.N
O
Slip gauge in
mm
MSD VSD Output value
in mm
Actual value in
mm
Error in
mm
1
2
3
4
5
6
7
8
9
10



CALIBRATION OF MICROMETER:
S.No Slip Gauge MSD in mm PSD in mm Out put value in mm Error in mm
1
2
3
4
5
6
7
8
9
10

S.no Position of
component
MSR in mm VSD in
DIV
VSR in
mm
Output
value in
mm
Actual
vlaue in
mm
1
2
3
4
5
6
7
8
9
10


CHARACTERISTICS OF MICROMETER:
Parameter Formula used Result
Range

-

Span

-

Error

-

Compensation factor
-

Least count
Value of 1 PSR
Number of PSD

Sensitivity

Change in O/P
Change in I/P

MEASUREMENTS OF COMPONENT:
Position of
component
HSD in mm PSD in mm PSD*LC
Out put
value
Actual value
mm


RESULT:
Venier calliper :
Least count :
Sensitivity :
Accuracy :
Micrometer
Least count :
Sensitivity :
Accuracy :


MEASUREMENT OF TAPER ANGLE BY USING SINE BAR
AIM :
To measure taper angle of given work piece by sine bar.
To set the given sine bar to the given angle.
APPARATUS REQUIRED:
1. Sine Bar 2.Slip gauge 3.Workpiece
PROCEDURE:
Measurements of Taper Angle:
1. Set the work piece to measure the taper angle using sine bar and dial gauge.
2. Transverse the dial gauge plunger over the ramp of work piece.
3. Note down the initial reading, final reading and the length of the traverse.
4. Alternately, try to king the inclined surface of the work piece ,whose taper angle is to be
measure ,to the horizontal plane by placing suitable combination of slip gauge under the lower
end of the work piece.
5. Note down the length of the slip gauge.
6. Calculate the taper angle through the formula given.

Setting the given sine bar to the given angle:

1. Take note of the given angle for which the top surface of the sine bar is to be set.
2. Theoretically calculate the height of the slip gauge required to lift one end of sine bar
Such that top surface of the sine bar make the required slope.
3. Insert the selected combination of slip gauge under one end of the sine bar.
4. Use dial gauge with stand and traverse the plunger of the dial gauge over a know length and check
the slope of the sine bar.
SINE BAR DIGRAM


MEASUREMENT OF GIVEN TAPER ANGLE USING SINE BAR:

MODEL CALCULATION:
=

USING DIAL GAUGE:
S.NO Length of bar
(mm)
Height obtained (mm)
(mm)

Angle in deg

RESULT:

The angle measurement is.........
Also sensitivity of sine bar .............................degree have been carried out
S.No Length of sine bar
(mm)
Height of Slip Gauge
(mm)
Difference in
Height

(mm)
Angle


CALIBRATION OF GEAR TOOTH VERNIER AND MEASUREMENT OF GEAR TOOTH
THICKNESS BY GEAR TOOTH VERNIER CALIPER
AIM:
To calibrate the gear tooth vernier and to measure the thickness of gear tooth.
APPRATUS REQUIRED:
Gear tooth vernier and slip gauge.
PROCEDURE:
Calibration:
1. Note down the range of the vernier scale in X and Y axis.
2. Select suitable slip gauges and calibrate X and Y axis independently.
3. Produce a calibration report and draw necessary graph.
4. Note down the error in the instrument if any.
Measurement:
1. Calibrate the instrument using slip gauge.
2. Find outside diameter of given gear using vernier calliper and count number of tooth in gear.
3. Calculate pitch scale circle diameter of given gear using formula
Pitch diameter=N*OD/ (N+2) mm
Where,
OD=outer diameter of gear.
N=number of teeth
Module m=D/N mm
Addendum= (Nm/2) [1+ (2/N)-cos (90/N)]
4. Find out tooth thickness in mm
Tooth thickness=N*m *sin (90/N)mm
5. Set variable side of calculated addendum of job place side on top gear tooth to be
measured.
6. Repeat it for variable tooth and find average tooth thickness of given gear.
7. Thickness of the tooth=2.70mm


CALIBRATION OF THE GEAR TOOTH VERNIER :
Sno
Axis
STD Input
in mm
Output value in mm Average
output in
mm
Error in
mm
I II II
1
X

2
3
4
5
Y

6
7
8

CHARATERISCTICS OF GEAR TOOTH VERNIER:
Parameter Formula Result
Range -
Span -
Least count Distance moved
(no. of PSD)

Sensitivity Change in output
Change in input

E
R
R
O
R
INPUT
O
U
P
U
T
INPUT


Tooth No MSR in mm VSR in mm OR in mm CR in mm

OBSERVATION:
Number of teeth on gear=
Outer diameter=

CALCULATION:

RESULT:
Thus the thickness of tooth was found out and compared with practical value.


FLATNESS AND STRAIGHTNESS CHECKING USING AUTOCOLLIMATOR

AIM:
To check the flatness and straightness of the given component using autocollimator.
APPARATUS REQUIRED:
1) Auto collimator
2) Work piece /object to be tested
DESCRIPTION:
An optical system of an auto collimator consists of a light source, condensers, semi-reflectors,
target wire, collimating lens and reflector apart from microscope eyepiece. A target wire takes place of
the light source into the focal plane of the collimator lenses. Both the target wire and the reflected
image are seen through a microscope eyepiece.
The eyepiece incorporates a scale graduated in 0.05mm interval and a pair of parallel setting
wires which can be adjusted. Movements of wires are effected through a micrometer, one rotation of
the drum equals to one scale division movement of the wires.
The instrument is designed to be rotated through 90 degrees about its longitudinal axis so that
the angles in both horizontal & vertical planes are measured.


PROCEDURE:
1) Keep the auto collimator on the reference surface.
2) Place the reflector on the surface to be tested, such that the reflected beam of light goes back to
the collimating lens.
3) The position of auto collimator is adjusted until the two target wires set in focal plane of
instrument are each covered.
4) Any horizontal tilt in the surface under test leads to vertical target wire to move to the right.
5) The angular tilt 20 of the reflector is obtained by taking into account the distance (d) between
wires.

d=2Fd

Where, F=Focal length of collimating lens.


TABULATION:
Mirror distance
(mm)
Micrometer reading(mm)
Average(mm)
Angle
Tan=y/x
A B C

RESULT:

The values are analyzed and necessary modification of the surface may be recommended based on the
accuracy required on flatness. If the values observed from the micrometer are varying linearly then
straightness/flatness can be judged.


ELECTRONIC COMPARATOR
AIM:
To compare the dimensions of given work pieces with length standards using an Electronic
comparator.
APPARATUS REQUIRED:
Electronic comparator, slip gauge set and work pieces
DESCRIPTION:
The Electronic comparator consists of LVDT (Linear Variable Differential Transformer) as
transducer fitted on a stand. The position of the LVDT can be changed. The LVDT provides an a.c.
voltage output proportional to relative displacement of transformer core to the windings. The LVDT
has three coils; the center or primary coil(P1) is energized from the external a.c. source. The two
secondary identical coils(S1,S2) which are connected together in phase opposite as shown in fig.

The output amplitude and phase depends on the relative coupling between the two pick up coils
and power coils. There should be a core position for which the voltage induced in each pickup coil will
be of same magnitude, and the resulting output will be zero. The linear range of LVDT is primarily
dependent on the length of the secondary coils.


PROCEDURE:
1. First the system is switched on and the slip gauge (size equal to the design dimension of the
parameter being checked) is placed between the worktable and the sensor of LVDT. The
table height is adjusted so that the display unit shows zero.
2. Then the slip gauge is removed and the work-pieces manufactured for the set design
dimensions are inserted between the table and the sensor of LVDT one by one.
3. The display unit displays the deviation(microns) of the work piece dimension from the
standard value.
4. The jobs whose deviations are within the specification limits (customer specified) are
accepted and the rest are rejected (scrap or rework).
TABULATION
Setting.n
o
Slip gauge
size(mm)
Indicated diff in microns Remarks

lot 1

a)
b)
c)
d)

lot 2 a)
b)
c)
d)

Result:
The scrap and reworks are identified and separated. Only the work-pieces confirming to the
specifications are accepted. This type of separating defectives has found acceptability in mass
production of components


CHARACTERISTICS OF FIRST ORDER INSTRUMENT THERMOMETER
AIM:
To find the following using thermometers
1) Range of thermometer.
2) The steady state response time.
3) Time constant of the instrument and to draw the time Vs response curves.
APPARATUS REQUIRED:
1) Alcohol filled thermometer
2) Mercury filled thermometer
3) Stop watch
DESCRIPTION:
Glass thermometer is one of the common type of temperature measuring device .The envelope
comprises of thick walled glass capillary tube ,a spherical wall bulb filled with the liquid at the bottom
and a small bulb at its top end act as safety reservoir. A change in temperature will cause the liquid to
expand or contract in the stem. The raise and fall of liquid in the capillary against the calibrated scale
indicates the temperature of the source.
PROCEDURE:
1) The thermometer bulb is dipped in the water at high temperature (temperature source).
2) Thermometer readings are noted for every equal interval of time until we get steady state reading.
3) Then the above procedure is repeated with ice water as the temperature source and thermometer
readings are noted.
4) Graphs are plotted between time and response.
5) Time to get 63.3% response is found out.
6) The horizontal line in the plot indicates the steady state condition.


VERIFICATION OF THE THEORETICAL RESPONSE WITH THE EXPERIMENTAL VALUES:

HOT WATER SOURCE:

O
=
i

(-t/)

Theoretical Response after 10 sec =
Experimental value after 10 sec =

COLD WATER SOURCE:

O
=
i

(-t/)

Theoretical Response after 10 sec =
Experimental value after 10 sec =


TABULATION:
ALCOHOL THERMOMETER
(A) COLD WATER
S.NO TEMPERATURE(C) TIME
(SEC)

(B) HOT WATER
(SEC)


1) MERCURY THERMOMETER

(A) COLD WATER
(SEC)

(B) HOT WATER
(SEC)


Model Graph

RESULT:
Thus the experiment is conducted in liquid thermometer, the variation of time with temperature
is noted and graph is plotted and time constant was found.


MEASUREMENT OF FORCE USING A PROVING RING
AIM:
To understand the elastic transducers and measure the force applied on a proven ring.
APPARATUS REQUIRED:
1) Proving ring
2) Displacement measuring and indicating device-dial gauge
3)
DESCRIPTION:
A proving ring is a ring of known physical dimensions and mechanical properties. When an
external compressive or tensile load is applied to lugs or external bosses, the ring change its diameter,
the change being proportional to the applied force. The amount of ring deflection is measured by
means of a highly sensitive displacement measuring device. A dial gauge/electrical strain gauge
system may be used as a secondary transducer.
PROCEDURE:
1) Clamp the proving ring rigidly.
2) Ensure the secondary displacement transducer is properly aligned.
3) The axis of the dial gauge plunger and the line of forces should coincide.
4) Apply a known force at the top most point of the proving ring.
5) Increase the input force in steps and note down the corresponding reading in the dial gauge.


TABULATION
Load in
Kg
Load in g(Defelction in div) Unload in g(Defelction in div) Deflection
for
Loading
in mm
Deflection
for
unloading
in mm
I II III I II III

MODEL GRAPH:
Range:
Least Count:
Sensitivty : Change in O/P/ Change in I/P
Proving ring sensitvity :
Dial Gauge sensitvity:
Overal Sensityvity :

RESULT:
Thus the instrument behaves linearly and the linearity range depends upon the material property of the
proving ring.


POWER MEASUREMENT USING ROPE BRAKE DYNAMOMETER
AIM:
To measure the power and torque by conducting a load test on engine and to draw the
characteristic curves
a) Torque vs. load
b) Power vs. load
APPARATUS REQUIRED:
1) Tachometer
2) Measuring tape
3) Spring balance
DESCRIPTION:
A rope brake dynamometer consists of one or more rope wrapped around the flywheel of
engine and brake drum whose power is to be measured. The ropes are placed evenly across the width
of the drum. The upward rings of ropes are connected to the spring balance on each side. The rotation
of flywheel produces frictional force and ropes are tightened and consecutively a force is exerted on
the drum. Due to this enormous amount of heat is produced. The heat is removed using water as
coolant.
PROCEDURE:
1) Check the fuel supply to engine, lubrication oil level in the oil pump, water circulation in the
cooling system, etc.
2) Start the engine and ensure no load condition on the brake drum.
3) Allow the engine to stabilize before loading.
4) Now the load is applied gradually on the rope brake dynamometer.
5) For every increase in load, the speed is measured using tachometer.
6) Repeat the procedure for various load and power is measured.
7) Calculate the torque and power using the given formulae.
SAMPLE DATA:
1) Speed, N = 1500 rpm
2) Radius of the brake drum, R = 0.2 m
3) Theoretical power applied = 1.5 kW
4) Theoretical torque = P*60/(2*pi*N) N-m
5) Actual Torque= W * 9.81 * R N-m


RESULT:

Thus the torque and power measurement is done using rope brake dynamometer.


PROFILE PROJECTOR
AIM:
1) To calibrate profile projector.
2) To check the dimensions of small size components using a profile projector.
3) To draw the profile of the given job.

APPARATUS REQUIRED:
1) Profile Projector
2) Small Screws/Small Gears

DESCRIPTION:
The profile projector is basically an optical instrument/comparator which makes use of the
enlarged image principle. The purpose of optical projector is to compare the shape or profile of a
relatively small engineering component with an accurate standard or drawing. It throws an enlarged
image of the component onto a screen. The magnification of the system will be equal to the size of the
object image in screen divided by size of the component. The available magnified are 10x, 20x & 50x.

CALIBRATION PROCEDURE:
1) The least count of the micrometer in the profile projector is noted down.
2) A standard input (slip gauge) is projected onto the screen and the screen reading is noted.
3) The error is calculated from the standard input & the output readings are calculated.
4) Then while taking the reading of job, the error is suitably compensated.


CALIBRATION:
S.NO.
Std
Input
(mm)
Micrometer Readings Template Reading
Remarks
Initial
(mm)
Final
(mm)
Net
(mm)
Screen
Reading
Actual
reading(S.R/
M.F)

CALIBRATION REPORT OF PROFILE PROJECTOR:

Characteristics Quality
Sensitivity
Least count at template
Error
Magnification factor


MEASUREMENT PROCEDURE:
1) Initially clean the work piece and the table.
2) The fan is switched on and the episcope is turned on.
3) The height of the table is adjustable, so that the clear image of the work piece is seen on the
screen.
4) Then using the micrometer provided for X-direction & other one for Y-direction, image of the
object could be positioned & matched with a template location on the screen. The worktable is
moved with a template location on the screen. The worktable is moved with the help of
micrometer. The readings of the micrometer & that of the screen are noted.
5) Then by imposing a graph sheet on the screen the profile is plotted for further reference.

TABULATION:
S.NO.
Parameter
under Test

Micrometer
Readings(mm)
Template Reading(mm)
Remarks
Initial

Final

Net

Screen
Reading
M.F
Actual
reading(S.R/
M.F)

RESULT:

Thus, the profile projector is calibrated & the various parameters of a given watch stud are
measured.


ANGLE MEASUREMENT USING BEVEL PROTRACTOR

AIM:
To measure the angle of the given work-piece using Bevel protractor.
.

APPARATUS REQUIRED:
Bevel protractor
work-piece.
Rollers and pins
shafts

DESCRIPTION:
The equipment consists of a vernier protractor with a movable measuring blade and a reference blade.
The blades are adjustable for both angle and length and are readily applied to a variety of measuring
applications.
The main scale is graduated in degrees of arc. The vernier scale has 12 divisions each side
of the centre zero. These are marked 0-60 minutes of arc, so that each division equals 1/12 of 60,that is
5 minutes of arc. These 12 divisions occupy the same space as 23 degrees on the main scale. Therefore
each division of the vernier is equal to 1/12 of 23 or 1 11/12. Since 2 divisions on the main scale
equals 2 degrees of arc, the difference between 2 divisions on the main scale and one division on the
vernier scale is 2- 1 11/12 = 1/12= 5 minutes of arc. The accuracy of measurement will largely
depend upon the skill of the user.
PROCEDURE:
ANGLE MEASUREMENT USING BEVEL PROTRACTOR:
1. The given work piece is cleaned before taking measurement.
2. The fixed blade of the bevel protractor is made to coincide with the reference surface of
work piece.
3. Move the movable blade of protractor to coincide with outer surface.
4. The angle between the blade is taken from protractor main scale and vernier scale reading.
Checking of angle between centre lines of holes:


1. A pin, which must be of good fit, is inserted in each hole (for which the angular
spacing is to checked) and rollers are placed in positions as shown.
2. The dimension M over the rollers is measured and from this, together with the
diameters of the pins ,rollers and shaft,the angle can be measured.
Referring to fig.
M d
Sin = ---------------
D + d

P + d
Sin = ---------------
D+ d

= 2(-)
Where,
M- Distance between the outer edges of the Rollers
P- Diameter of the Pins
d- Diameter of the Rollers
D- Diameter of the Shaft


TABULATION:
ANGLE MEASUREMENT USING BEVEL PROTRACTOR:
WORKPIE
CE
NAME
OF
ANGLE
DESIGN
VALUE IN
DEGREES
OBTAINED
VALUE IN
DEGREES
DIFFERENCE
IN DEGREES
I a)
b)
c)
d)

II a)
b)
c)
d)

III a)
b)
c)
d)


CHECKING OF ANGLE BETWEEN CENTRE LINES OF HOLES:
S.NO Diameter of
the Pins (P)
Diameter of
the
Rollers(d)
Diameter of
the Shaft(D)
Distance between the outer
edges of the Rollers(M)

RESULT:
Thus using the bevel protractor, all the angles of the given-machined plate are found out and
compared with design values and errors are noted.
And the angle between the centre lines of holes is measured.


HYSTERISIS CURVE OF A CANTILEVER BEAM
AIM:
To draw the hysteresis curve of a wooden cantilever beam using a dial gauge setup.
APPARATUS REQUIRED:
1. wooden cantilever beam
2. dial gauge
3. weights
DESCRIPTION:
The arrangement consists of a wooden beam of length 1metres with a loading arrangement at
its free end. The cantilever beam setup is kept on a reference surface. A dial gauge with stands is used
to measure the deflection of the beam.
PROCEDURE:
1. A wooden cantilever beam is loaded at its free end and a dial gauge which is also kept on a
reference surface measure the deflection of length of beam
2. The indicated readings of the dial gauge are noted down
3. After noting down the deflection for the applied load the load is increased in steps of 50 grams.
4. The Load is decereased in step of 50gms and the reading are noted down
5. The above procedure is repeated by keeping the dial gauge at different sections of the beam
6. From the readings, a graph between load and deflection is ploted.
Least count = 1/100 = 0.01mm
Cantilever sensitivity :
Dial gauge sensitivity:
Overall sensitivity :


Load in
gms
Deflection for loading in mm Deflection for unloading in mm
Section-I Section-II Section-I Section-II
1 2 1 2 1 2 1 2

Model Graph

Result :
From the graph the hysteresis of the give wooden cantilever beam


MEASURING CYLINDER AND CONE DIMENSIONS COORDINATE MEASURING MACHINE

AIM:

To study the functions of different parts of CMM.
To study the conventions used for Machine Coordinate System and Work piece Coordinate System.
To calibrate the probe tip at three different angles.
To check different dimensional attributes like circularity, cylindricity, flatness, run out, etc and the
corresponding tolerance values

APPARATUS REQUIRED:
1.CMM unit
2.Job

DESCRIPTION & PRINCIPLE OF MEASUREMENT:

Co-ordinate Measuring Machine with its parts

It is used for geometrical feature measurement. The typical "bridge" CMM is composed of three axes,
X, Y and Z. These axes are orthogonal to each other in a typical three dimensional coordinate system.
Each axis has a scale system or encoder that indicates the translation of the axes. The machine will
read the input points from the touch probe by touching the required location, as directed by the
operator or programmer. The machine then uses the X,Y,Z coordinates of each of these points to
determine size and position of the job. Then the measurands (e.g. length, diameter, angle, flatness,
straightness etc.) can be determined by those points. A coordinate measuring machine (CMM) is also a
device used in manufacturing and assembly processes to test a part or assembly against the design
intent. By precisely recording the X, Y, and Z coordinates of the target, points are generated which can
then be analyzed via regression algorithms for the construction of features. These points are collected
by using a probe that is positioned manually by an operator CMMs can be programmed to repeatedly
measure identical parts; thus a CMM is a specialized form of industrial robot. In CMM there are


mainly two major parts. There are structural system and probing system. Machine structure, bridge,
bearings for moving the bridge, granit table to support the work piece, vibration isolation system and
are included in the structural systems. Air bearings are the chosen method for ensuring friction free
travel. Compressed air is forced through a series of very small holes in a flat bearing surface to provide
a smooth but controlled air cushion on which the CMM can move in a frictionless manner. In probing
system one touch trigger probe is attached to the Z-axis quill of the bridge. When probe is rotated about
X-axis it is then called as angle A, and when the probe is rotated about Z-axis, then it is called as angle B.

PROCEDURE:

Job : Artefact supplied by TESA
1. Define plane, line and origin in manual mode.
2. Measure:
a. Hole diameter, circularity of the Hole and Height,
b. Cone angle and Diameter of the Cone
c. Round slot
d. Measurement of all the holes in polar array in manual mode
e. Probe calibration is important while creating a new Part Program

FEATURE DIMENSION 1 2 3
AVG VALUE
mm
Cylinder
Diameter
Circularity
Cone
Height
Diameter
Cone angle
Sphere Diameter


REPORT SHOULD CONTAIN:

a. A neat sketch of CMM with proper mentioning of the machine and probe axes.
b. Calibration procedure of probe tip at angles: A__B__, A__B__ and A__B__ and show results.
c. Comment on variation of the standard deviation errors (if any) in previous results.
d. Check dimensional attributes and tolerances for the job provided.
e. Comment on why a sphere has been chosen for the tip.
f. What is the material for probe tip and why is it chosen?
g. Why is it better to use a bigger diameter tip for measurement?
h. What is the principle of slide-guide mechanism for all the three machine axes?

PRECAUTIONS:
! Never touch the granite base on the machine for accuracy issues.
! Do not touch the Axis slides, probe head/tip, and the guides.

Kongu Engineering College: Metrology and Measurement Laboratory

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Instrumentation and Metrology laboratory 1

KONGU ENGINEERING COLLEGE

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