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MECHANICAL MEASUREMENT AND METROLOGY

SAFFRONY INSTITUTE OF TECHNOLOGY


S.P.B.PATEL ENGINEERING COLLEGE
(Approved by AICTE and Affiliated to Gujarat University & Gujarat Technological University)

DEPARTMENT OF MECHANICAL ENGINEERING

Laboratory Manual
MECHANICAL MEASUREMENT AND METROLOGY
(2141901)

Student Name ._______________________


Enrollment No._______________________
Year ._______________________________

PREPARED BY:
Prof. KIRAN PATEL
Prof . N.K.PRAJAPATI
Prof . FALGUN PATEL
S.P.B.PATEL ENGINEERING COLLEGE

MECHANICAL MEASUREMENT AND METROLOGY

CERTIFICATE

This is to certify that Mr./Ms. ____________________


Enroll.no._____________Of

B.E 4thSEM MECHANICAL

ENGINEERING in the Year ___________Has satisfactorily


completed theTerm Work in Subject Of MECHANICAL
MEASUREMENT & METROLOGY.

Date of submission:-

/ / 2016

Incharge Faculty

S.P.B.PATEL ENGINEERING COLLEGE

Head of Department

MECHANICAL MEASUREMENT AND METROLOGY

S.P.B.PATEL ENGINEERING COLLEGE MEHSANA


MECHANICAL MEASUREMENT AND METROLOGY
LABORATORY PRACTICAL INDEX
Sr
No.
1

3
4
5

7
8
9

10

11

12

Name of Experiment
Study the static characteristics of
a given measuring instrument.
Measurement
of
various
elements by vernier calipers, Dial
vernier, Digital vernier,Height
gauge.
Measurements using
outside
micrometers
and
inside
micrometers.
Study and use of slip gauges.
Angular measurement by bevel
protector,combination
set,sinebar and angle dekkor.
Study and measurement of
roundness,straigtness
and
flatness.
To study about GO and NO-GO
type Plug, Snap and Ring gauges.
To study about profile projecotor
& Tool makers Microscope.
To study about surface roughness
measurement.
To
study
about
pressure
measurements and Calibration of
pressure gauge with dead weight
pressure gauge.
To study about temperature
measurement
using
thermocouple and other devices.
To
study
about
R.P.M
measurement using Opto-coupler
pick up and Tachometer.

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Page
no.

Dateof
Start

Dateof
Comp.

Comp.
Sign

Marks

MECHANICAL MEASUREMENT AND METROLOGY

PRACTICAL NO:-01
TITLE: - Study about static characteristics of measuring instruments.
AIM: - To gain knowledge of terminology related with Metrology.
What is Metrology?
Metrology is the scientific study of measurements. Measurements come in all
forms. Gemstones can be measured for hardness or carat size. Pieces of wood can
be measured for length. Electricity can be measured in amps, volts, and watts.
Mechanical
metrology
concentrates
on
standardizing
acoustics,
force/pressure, vibration, volume, density, and dimensions. As Asian companies
begin sweeping the country in terms of inexpensive manufacturing, other companies
are relying on mechanical metrology to help them compete. With a set of standards
in place, customers can buy products from any country and know they will be getting
parts with universal measurements. This helps keep repair costs competitive.
As early as the 1950s, businesses worldwide determined that there was a
need to bring unity to measurement in the manufacturing process. As a result, the
International Organization of Legal Metrology was created in 1955. Today, dozens of
countries are members of the organization and share a common goal, to unify
manufacturing and business throughout the world.
With so many countries competing for the market share of manufacturing
business, metrology is essential to keep the market competitive. Having unified
measurements can help with repair costs in the future and ensure that products can
be used worldwide without difficulty. Many organizations hold international
conventions where metrology members can share ideas and concerns, and compare
notes. These metrology conventions are becoming a popular means for unifying the
wide array of measurements used throughout the world.
Over the past decade, there has been an increased need for metrology in
chemistry labs. Metrology of chemistry makes it possible to create strong processes
for quality control of many goods manufactured worldwide. As pollution controls
increase, there is an intense need to regulate worldwide emission controls.
Metrology of chemistry helps ensure that different countries utilize chemicals in a
manner that protects the environment. Chemistry metrology helps define standards
to be used in gas/air mixtures, gas analyzers, inorganic materials, spectrometry, and
microanalysis.
Accuracy: -It is the nearness of the indicated value to the true value of the
quantity being measured.
Precision: - It defines the degree of refinement with which a measured value is
stated.

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Threshold: -The smallest measurable input while the resolution defines the smallest
measurable input change.
Resolution:- When the input is slowly increased from arbitrary
(Non-zero) input value, it is observed that the output does not change at all until a
certain increment is exceeded; this increment is called resolution or discrimination
of the output.
Sensitivity: -It is the ratio of the change in output signal to a change in input
quantity.
Linearity: - It is the proportionality between input quantity and output signal.
Drift: -It is a slow variation in output signal of a measuring system which is not due
to any change in input quantity.
Dead zone: - Dead zone is caused by backlash and hysteresis in the instrument.
Range: - The difference between the largest and the smallest reading of the
instrument is called the range of an instrument. The Range is expressed by stating
the lower and upper values.
Span: - Span represents the algebraic difference between the upper and lower
range values of the instrument.
Quiz:
Difference between Accuracy and Precision.
A 0-50V voltmeter has accuracy 2% of f.s.d. what reading will it indicate when
input voltage is 30V.
Now 2 % accuracy of f.s.d. means 1 V; therefore the voltmeter will indicate either
29V or 31V.. Ans.
The sensitivity of a thermo-couple is 0.03 mill volt per C. for a temperature
difference of 10 C. What will be the difference in its voltage?
A voltmeter has 100 equal divisions, full scale reading 200V. it is possible to
detect 1/10 of a division easily. Find resolution.
Now 1 scale division = 200/100=2V. Resolution = 1/10*2=0.2VAns.
The car speedometer does not indicate any reading below 20 km/hr. The
maximum reading indicate by it is 160 km/hr, find out the range and dead zone of
the meter.
A transducer measures a range of 0-200n force with a resolution of 0.15 percent
full scale. What is the smallest change which can be measured this transducer?.
Determine the resolution of a moving coil voltmeter having a uniform scale with
50 divisions; the full scale reading is 50V and 1/10 of a scale division can be
estimated with a fair degree of certainty.

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Determine the resolution of a digital voltmeter which has read-out range 0 to


9999 counts and its full scale reading is 9.999V.
The calibration range of a certain pyrometer is 300C to 800C. If the dead zone in
it is 0.11 percent of span, determine the temperature which might occur before it
is detected.
OBSERVATION TABLE:
Static Characteristics
SR. NO.

NAME OF INSTRUMENT

Vernier calipers

Vernier Height gauge

Vernier depth gauge

Out side micrometer

Inside micrometer

Micrometer depth gauge

CONCLUSION :

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Range

Span

L.C

Zero
error

0-200

200

0.02

0.00

MECHANICAL MEASUREMENT AND METROLOGY

PRACTICAL NO: - 02
AIM:-Measurement of diameters, length and height of various machines parts using
(i) Vernier calipers (ii) Dial vernier (iii) Digital vernier calipers (iv) Height gauge
APPARATUS:- Vernier calipers, Dial vernier, Digital vernier, Vernier height gauge,
Rectangular MS block, connecting rod, gear etc.
VERNIER CALIPERS:
TERM
Caliper
Instrument
least count

Main Scale

Vernier
scale

BRIEF DEFINITION
A tool that can be used to measure outside dimensions, inside
dimensions, or depths of holes.
The size of the smallest division on a scale. For the main scale on
the common vernier caliper this is probably 0.1 cm. With the vernier
scale the least count might be 0.002 cm.
The scale on the larger, fixed portion of the caliper. It gives the
most significant digits in the reading. Make the reading to the nearest
least count of the main scale opposite the zero of the vernier.
The scale on the smaller sliding portion of the caliper. It gives the
least significant digits in the reading, and sub-divides a mark on the
main scale into 10, 20, or 50 subdivisions. Read the vernier scale at
the point where a vernier line and a main scale line best line up.
Combine the main scale reading with the vernier scale reading to get
a final reading.

CONSTRUCTION:
The vernier caliper consists of two scales:
One is fixed while other is movable. The fixed scale called main scale is calibrated
on L-shaped frame and carries a fixed jaw. The movable scale called vernier scale
slides over the main scale and carries a movable jaw. In addition, an arrangement is
provided to lock the sliding scale on the fixed main scale. For the precise setting of
movable jaw, an adjustment screw is provided.
PROCEDURE:
Before using the instrument, it should be checked for zero error. The zero line on
vernier scale should coincide with zero on the main scale. Then take the reading in
mm on main scale to the left of zero on the main scale.
Now count the number of division on the vernier scale from zero to a line, which
exactly coincides, with any line on main scale. From the figure, we can observe that
the 41st division exactly coincides the main scale.
The total reading is now = Main scale reading +

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No. of division that coincides the main scale *


L. C. of Vernier Caliper.
The total reading in mm = 13 + 41 * 0.02
= 13.82 mm.

DIAL VERNIER:

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CONSTRUCTION:
The Dial vernier itself suggests that dial is provided for measurement. Its
construction is same as the vernier calipers. One fixed scale on which movable scale
is provided. According to the movement of vernier scale the dial, indicate the
reading.
DIGITAL VERNIER:
The Vernier Caliper is a precision instrument that can be used to measure internal
and external distances extremely accurately. The example shown below is a digital
vernier caliper as the distances are read from a LCD display.
The most important parts have been labeled. Earlier versions of this type of
measuring instrument had to be read by looking carefully at the imperial or metric
scale and there was a need for very good eyesight in order to read the small sliding
scale. Manually operated vernier calipers can still be bought and remain popular
because they are much cheaper than the digital version. Also, the digital version
requires a small battery whereas the manual version does not need any power
source.
Digital vernier calipers are easier to use as the measurement is clearly displayed and
by pressing the inch/mm button, the distance can be read as metric or imperial.

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PROCEDURE OF MEASUREMENT:
The display is turned on with the on/off button. The external jaws should then be
brought together until they touch and the zero buttons should be pressed. The
vernier caliper can then be used to measure distances. Always go through this
procedure when turning on the display for the first time.
Measuring External Distances:
The material to be measured is placed between the external jaws and they are
carefully brought together. The locking screw is tightened so that the jaws do not
move apart. The digital display can then be read. The distance can be read by in
metric and imperial by pressing the inch/mm button.

Measuring internal distance:

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The example below shows a vernier calipers being used to measure the internal
diameter of a piece of copper tube. The internal jaws are adjusted carefully until they
touch the internal sides. The locking screw is tightened so that an accurate
measurement can be made even if the jaws are knocked against the sides as the
jaws are removed from the hole. The measurement is shown on the LCD display.

Measuring Depth:
Measuring the depth of a hole can be very difficult. However, using a vernier caliper
makes this task easy. The base of the vernier caliper rests on the top of the hole and
the depth-measuring blade is adjusted until it touches the bottom of the hole. The
locking screw is tightened and the measurement can be read on the LCD display.

VERNIER HEIGHT GAUGE:


CONSTRUCTION:
A finely ground and lapped base, the base is massive and robust in construction to
ensure rigidity and stability. A vertically graduated beam or column supported on a
massive base. Attached beam is a sliding vernier and head the vernier scale and a

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FIG:-VERNIER HEIGHT GAUGE

clamping screw. The auxiliary head, which is also calculated to the beam above
sliding vernier head. A measuring jaw or scriber attached to the front of sliding
vernier. Procedure for vernier height gauge: It is same as vernier caliper but the
vernier height gauge is measured height from the reference.

PRECAUTIONS:

First clean vernier caliper by wiping of oil, dust, grit etc.


Clean the two jaws with clean piece of papers.
Set the zero reading of the instrument to be the measure between two jaws.
While measuring dimensions of vernier caliper, it must move carefully.
Hold the past whose dimension is to measure between two jaws.

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OBSERVATION TABLE:
Sr.
No

Measured
Part name

Instrument

Dimension

Actual Measurement

Avg.

Main
scale

X mm

Varnier
scale

L.C

QUIZ:1. Give a list of possible errors in vernier instruments?


2. Define least count of vernier instruments? How is it determined? Explain
3. Explain the construction and use of the following:
Vernier height gauge
Vernier depth gauge
CONCLUSION:-

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PRACTICAL NO: - 03
AIM: - Measurement of diameters and length of various machine parts using outside
micrometers and inside micrometer.
APPARATUS:

Outside micrometer [0-25mm]


Outside micrometer [25-50mm]
Inside micrometer [0-25mm]
Inside micrometer [25-50mm]
Screw thread micrometer
Various machined parts.

THEORY: INTRODUCTION: It is one of the most common & most popular forms of measuring instrument for
precise measurement with 0.01 mm accuracy. In addition, micrometer screw gauges
are available with 0.001 mm accuracy.
It classify as: Outside micrometer
Inside micrometer
Screw thread micrometer
Depth gauge micrometer.
PRINCIPLE OF MICROMETER: The micrometer works on the principle of screw & nut. We know that when screw
is turned through one revolution it advances by one pitch distance i.e. one
revolution of screw corresponds to a linear movement of a distance equal to pitch of
the thread.
COMPONENTS AND THEIR FUNCTIONS: U-SHAPED STEEL FRAME: -The outside micrometer has U shaped & C

shaped frame. It holds all the micrometer parts together. It is made of


steel C.I.
ANVIL AND SPINDLE: - The micrometer has fixed anvil protruding 3mm

from the left hand side of frame. Its diameter is same as spindle.

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LOCK NUT: -The Lock provides on the micrometer spindle to lock. When

micrometer is at correct, the Lock nut provides the tight holding of job as
well as reading.

SLEEVE AND BASSEL: -The sleeve divided accurately and marked

correctly in 0.5mm division along the length, which serves as a main


scale.

THIMBLE: -Thethimblecan move over the parallel. It has 50 equal divisions


around its circumference each division has a value of 0.01mm.
RATCHET: -It provides on the end of the thimble. It used to assure accurate
measurement & to prevent too much pressure applied to microscope.

THE OUTSIDE MICROMETER


The micrometer is a precision measuring instrument, used by engineers. Each
revolution of the rachet moves the spindle face 0.5mm towards the anvil face. The
object to be measured is placed between the anvil face and the spindle face. The
rachet is turned clockwise until the object is trapped between these two surfaces
and the rachet makes a clicking noise. This means that the rachet can not be
tightened any more and the measurement can be read.

Fig. Outside Micrometer


EXAMPLE MEASURE READINGS
Using the first example seen below:
1. Read the scale on the sleeve. The example clearly shows 12 mm divisions.
2. Still reading the scale on the sleeve, a further mm (0.5) measurement can be
seen on the bottom half of the scale. The measurement now reads 12.5mm.

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3. Finally, the thimble scale shows 16 full divisions (these are hundredths of a
mm).The final measurement is 12.5mm + 0.16mm = 12.66

INSIDE MICROMETER
The inside micrometer, as the name implies, isused for measuring inside
dimensions, such as pumpcasing wearing rings, cylinders, bearings, and bushings.
Inside micrometers usually come in a set thatincludes a micrometer head, various
length spindles(or extension rods) that are interchangeable, and aspacing collar that
is 0.500 inch in length. The spindles (or extension rods) usually graduate in 1inchincrements of range; for example, 1 to 2 inch, 2 to 3inch (fig.).
The 0.500 spacing piece is used between the spindle and the micrometer head so
the range of the micrometer can be extended. A knurled extension handleis usually
furnished for obtaining measurements inhard-to-reach locations.

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To read the inside micrometer, read the micrometer head exactly as you would an
outside micrometer,then add the micrometer reading to the rod length(including
spacing collar, when installed) to obtainthe total measurement.
When the 1- to 2-inch spindle is used, and thesleeve and thimble scales are
set to 0.00 inch, thedistance between the face of the anvil and the face ofthe
spindle is exactly 1.00 inch.
SCREW THREAD MICROMETER
Screw thread micrometers measure the pitch of the thread directly. The screw thread
micrometer has a 60-degree pointed spindle and a double V-shaped swiveling anvil
(Figure).

Fig.3.4. Screw Thread Micrometer

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The screw thread micrometer reading indicates the pitch diameter of the thread.
When the micrometer is set at zero, the pitch line of the spindle and anvil coincide
(Figure). When the micrometer is measuring the thread it is measuring along the
pitch diameter of the thread (Figure).

Fig. The pitch line indicates the imaginary thread profile engagement.
Fixed anvil screw thread micrometers are those types of screw thread micrometers
that can only measure thread pitches within a limited range. It is important to make
sure that the screw thread micrometer that you will be using falls within the screw
pitch range of a particular thread. With fixed anvil screw thread micrometers, seven
micrometers will be needed to cover threads from 3 to 64 threads per inch.

Fig. Set of interchangeable


anvils for an interchangeable
anvil screw thread micrometer

Fig. The pitch diameter of the thread


is the most important dimension
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The type of screw thread micrometer shown in Figure has interchangeable anvils to
cover a wide range of thread pitches. Whenever you change the anvils on the thread
pitch micrometer, check the micrometer for accuracy.

Fig. 12 inch screw thread micrometer with interchangeable anvils


THE DEPTH GAUGE MICROMETER
The depth gauge micrometer is a precision measuring instrument, used by engineers
to measure depths. Each revolution of the rachet moves the spindle face 0.5mm
towards the bottom of the blind hole. The diagram below shows how the depth
gauge is used. The ratchet is turned clockwise until the spindle face touches the

Fig. Depth gauge Micrometer


Bottom of the blind hole. The scales are read in exactly the same way as the scales
of a normal micrometer (see previous information sheets).

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PROCEDURE OF MEASUREMENT WITH MICROMETER:

Before a micrometer used to measure the dimension of a component, it is


necessary to set zero.
After setting the zero, again open the touched anvils and put the job between the
anvils & take reading.
First, of all take the main scale reading & then take Vernier scale reading. Now
add the reading of Vernier scale multiplying with the least count value to main
value. This is the accurate & final reading.

PRECAUTION IN USING THE MICROMETER:

First, clean the micrometer by wiping of oil, dirt, dust etc.


Clean measuring face of anvil & spindle with clean piece of paper.
Set the zero reading of instrument.
While measuring dimensions of circular parts the micrometer must moved
carefully over representative area to note maximum dimension only.

OBSERVATION TABLE: Sr.


No

Measured
Part name

Instrument

Characteristic
Dimension

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Actual
Measurement
X1
X2
X3
mm
mm
mm

Avg.
X
mm

MECHANICAL MEASUREMENT AND METROLOGY

QUIZ:1. State the principle of a micrometer.Sketch a outside micrometer and Name its
various parts.
2. State the precautions to be taken while using a micrometer?
3. Describe the procedure for checking
Zero error
Flatness
Parallelism of a micrometer
4. State the possible sources of error in micrometers.
5. Name any four types of outside micrometers and state their specific uses.
CONCLUSION:-

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PRACTICAL NO: - 04
AIM:- Study and use of slip gauge.
OBJECTIVES:After completing this experiment, the student should be able to know
various uses of slip gauges acquire skill in wringing of gauge blocks
and know the procedure of selection of slip gauges for a particular
dimension.
INSTRUMENTS/MATERIALS REQUIRED:
(1) Set of slip gauges
(2) Surface plate
(3) Magnetic base holder
(4) Steel foot rule
INTRODUCTION:
A set of slip gauges consists of a number of rectangular steel blocks suitably
hardened with ground and lapped working faces. They are used conveniently for
building up lengths by combination of number of blocks. The measuring faces of the
two combined gauges adhere together which is known as wringing . Gauge blocks
are meant to be used as reference slandered and direct linear dimensions of
industrial components. They are classified according to their accuracy viz. C, B,A,
AA grades. The different sets are available for use.
PRECAUTIONS:
(1) Protect slip gauges from dust & dirt.
(2) Keep slip gauges always closed when not in use.
(3) Remove protective coating with petrol and wipe with clean soft linen cloth before
use.
(4) Do not touch lapped faces of gauge blocks.
(5) Avoid unnecessary handling of slip gauges.
(6) Immediately after use each gauge block should be wiped clean and replace them
in proper place witch coating of petroleum jelly.
(7) Use slip gauge accessories for marking out tools, measuring plug and ring
gauges inspection of gauges and precision instruments.
(8) Never drop slip gauges.
(9) Never strike slip gauges with other metallic objects.
PROCEDURE:
(1) Take all precautions for gauge blocks before, during and after use.
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(2) For building up required height, wring the smaller number of slip gauges.
(3) For wringing the two gauge blocks, first bring them in contact in right angles to
one another and then turn them through 90.
(4) For the required dimension s(height /length) use the largest possible block in
each step to reduce the number of blocks used to minimum.
ILLUSTRATION:
Build up dimension 48.755mm from standard set of slip gauges.
SOLUTION:
(1)Required dimension is 48.755mm. Use metric set of M112 pieces & 1mm base.
(2)Select the block to eliminate the digit 1.005 i.e 1.005
(3) Select the block to eliminate the digit 0.05 i.e 1.25.
(4) Select the block to eliminate the digit 0.5 i.e 21.50
(5) Select the block to eliminate the digit 25 i.e 25.00
EXERCISE:
Build up the dimension of 58.5835 from the standard set of slip gauges and show
them by figure.

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PRACTICAL NO: - 05
TITLE: Angular measurement Using Combination Set,bevel protector ,Sine bar and
Angle Dekkor.
AIM:a) To measure the angle between two faces of a given component using
combination set and Bevel protractor.
b) To measure the taper angle of a given component using sine bar.
EQUIPMENT AND ACCESSORIES REQUIRED:
1) Bevel protractor with vernier and actual angle attachment (150/300 mm blades),
2) Sine bar (100 mm size), 3) Surface plate, 4) Slip gauges, 5) Dial gauge (0.01 mm
least count), 6) Slotted angle plate, 7) Bolts for locking sine bar to angle plate, 8)
Clamps for locking component to sine bar.
THEORY AND DESCRIPTION:
(A) COMBINATION SET:
The combination square set evolved from the try square, small , fixed blade
square. A Combination set consists of a blade and a square head. Size is detrained
by the length of the head. A head may be either plain or hardened and has a clamp
that locks the blade into any position, a spirit level and a scriber. Three measuring
heads are attached to the stainless steel rule, allowing versatile measurement on
various types of work pieces.
(1) Square head: It is used to set the rule at 90 or 45 to an edge of a work pieces.
(2) Center head: it is used to locate centers of round work pieces.
(3) Protractor head: it is used to set the rule at desired angle to an edge of a work
piece. Also it is used for measuring angles.
Procedure:
(1) Attach the square head to the steel rule and check the adjustment at 90and 45
(2) Attach the center head to the steel rule and find the center point of the given job
and its radius.
(3) Attach the protractor head to the steel rule and measure the angles in the given
job.

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FIG: COMBINATION SET

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(B)BEVEL PROTRACTOR:
It is the simplest instrument for measuring angle between two faces of component. It
consists of a base plate attached to the main body and an adjustable blade which is
attached to a circular plate called turret containing vernier scale. The adjustable
blade is capable of rotating freely about the centre of the main scale (graduated
around a complete circle from 0 to 90, 90 to 0 and 0 to 90, 90 to 0) engraved
on the body of the instrument and can be locked in any position. An acute
attachment is provided at the top as shown in fig (1.1) to measure acute angles. The
base of the base plate is made flat so that it could be laid flat upon the work and any
type of angle measured. It is capable of measuring from 0 to 360.
The vernier scale has 24 divisions coinciding with 46 main scale divisions (23 on
either side) as shown in fig (1.2). The vernier scale is graduated to the right and left
of zero up to 60 minutes, each of the 12 graduations representing 5 minutes. Since
both the protractor dial and vernier scale have graduations in both directions from
zero, any angle can be measured, but it should be remembered that the vernier must
be read in the same direction from zero as the protractor either left or right. If the
zero graduation on the vernier scale coincides with a protractor graduation, the
number of degrees read between the zeros on the 5 minutes, must be added to the
number of degrees read between the zeros on the protractor dial and vernier scale.
Magnified view of main scale is shown in fig (1.2a).

POCEDURE:
Angle measurement by Bevel protractor:
1. The base plate of the bevel protractor is placed on the top horizontal surface of
the component.
2. Blade locking nut is loosened and by rotating the blade about the centre of the
main scale, the working edge of the blade is made to coincide with the inclined
surface of the component.
3. Blade is locked in that position by tightening the nut.
4. Vernier scale division coinciding with main scale division is noted.
Inclination of the surface with respect to horizontal is calculated as follows:
Angular reading = (Vernier scale division 5 minutes) + Main scale division in
degrees.

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BEVEL PROTRECTOR:
Observation Table
SR
NO

Main scale reading( M.S )

Vernier Scale reading( V.S )

Total reading
=M.S + ( L.C * V.S )

(C) SINE PRINCIPLE AND SINE BAR:


The Sine principle uses the ratio of two sides of a right angle triangle in deriving a
given angle. The measurement is usually limited to 45 from loss of accuracy point of
view. The accuracy with which the sine principle can be put to use is dependent in
practice, on some form of linear measurement. The sine bar in itself is not a
complete measuring instrument. Another datum such as surface plate is needed, as
well as other auxiliary equipment, notably slip gauges, and indicating device to make
measurements. Sine bars used in conjunction with slip gauges constitute a very
good device for the precise measurement of angles. Sine bars are used either to
measure angles very accurately or for locating any work to a given angle within very
close limits.
Sine bars are made from high carbon, high chromium, corrosion resistance steel,
hardened, ground and stabilized. Two cylinders of equal diameter are attached at the
ends.
The axes of these two cylinders are mutually parallel to each other and also parallel
to and at equal distance from the upper surface of the sine bar. The distance
between the axes of the two cylinders is exactly 5 inches or 10 inches in British
System and 100, 200 and 300 mm in metric system.
The various parts are hardened and stabilized before grinding and lapping. All the
working surfaces and the cylindrical surfaces of the rollers are finished to surface
finish of 0.2 m Ra value or better. Depending upon the accuracy of the centre
distance, sine bars are graded as of A grade or B grade of sine bars are guaranteed
accurate up to 0.01 mm/m of length. There are several forms of sine bars, but the
one shown in fig (1.3) is not commonly used. Some holes are drilled in the body of
the bar to reduce the weight and to facilitate handling.
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The accuracy of sine bar depends on its constructional features:


1) The two rollers must have equal diameter and true cylinders.
2) The rollers must be set parallel to each other and to the upper face.
3) The precise centre distance between the rollers must be known.
4) The upper face must have a high degree of flatness.
USE OF SINE BAR:
a) Measuring known angles or locating any work to a given angle:
For this purpose the surface plate is assumed to be having a perfectly flat surface so
that its surface could be treated as horizontal. One of the cylinders or rollers of sine
bar is placed on the surface plat and other roller is placed on the slip gauges of
height h as shown in fig (1.4). Let the sine bar be set at angle . Then Sin = h/L.
Where, L = Distance between the centre of rollers.
Thus knowing , h can be found out and any work could be set at this angle as the
top face of sine bar is inclined at angle to the surface plat. The use of angle plates
and clamps could also be made in case of heavy components for better results; both
the rollers could also be placed on slip gauges of height h 1 and h2 respectively. Then
Sine = (h2 - h1)/L
b) Checking of unknown angles:
Many a times, angle of components to be checked is unknown. In such a case, it is
necessary to first find the angle approximately with the help of a bevel protractor. Let
the angle be . Then the sine bar is set at an angle and clamped to an angle plate.
Next, the work is placed on sine bar and clamped to an angle plate as shown in fig
(1.5) and dial indicator is set at one end of the work and moved to the other, and
deviation is noted. Again slip gauges are so adjusted that dial indicator reads zero
across work surface.
If deviation noted by the dial indicator is h over a length of L of work, then height of
slip gauges by which is should be adjusted is equal to hL/L1
POCEDURE:
Angular measurement by sine bar:
1. The sine bar is made to rest on surface plate with rollers contacting the datum
(Surface plat)
2. Place the component on sine bar and lock it in position.
3. Lift one end (roller) of the sine bar and place a pack of slip gauges, underneath
the roller. The height of the slip gauges (h) should be selected such that the top
surface of component is parallel to the datum plate (Surface plat). The parallelism
can be assessed by making the stylus of a dial indicator mounted on a dial gauges
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stand in contact with the upper surface of component and sliding the stylus along the
component surface. If both the surfaces are perfectly parallel, the pointer on the dial
gauges shows the same reading throughout the travel of the dial gauge stylus. If the
surfaces are not parallel then the height of slip gauge back (h) can be altered and
procedure for checking parallelism can be repeated.
Record the final height of slip gauge pack used for achieving parallelism
Calculate inclination = Sine -1 (h/L)
PRECAUTIONS:
1. The sine bar should not be used for angle greater than 60 because any possible
error in construction is accentuated at this limit.
2. Accuracy of sine bar should be ensured.
3. As far as possible longer sine bar should be used since many errors are reduced
by using longer sine bar.

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OBSERVATION TABLE:
L = ------ mm
SR
Hight
NO
h1

Hight
h2

= sin-1 (h1 h2 /L )

QUIZ:
1. Differentiate vernier scale and main scale of a Bevel Protractor.
2. How do you measure the angle of a component using Bevel protractor?
3. What is sine principle?
4. How do you measure the angle of a component using sine bar?
5. Which material is used for sine bar?
6. What are the constructional features on which accuracy of sine bar depends?
7. What is the distance between the axes of two cylinders in British system and
metric system?
8. Why are rollers preferred to support the sine bar?
9. Why is a sine bar longer length preferable to the one of a shorter length?

CONCLUSION:

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PRACTICAL NO: - 06
AIM:- Study and measurement of roundness, straightness and flatness.
Objective: After completing this experiment, the student will be able to use dial
gauges for the roundness measurement of a circular bar, measure
straightness of a given job using slip gauge and flatness of a flat
surface using dial indicator.
(A)ROUNDNESS MEASUREMENT:
Equipment/instruments:
(1) Dial gauge
(2) V block
(3) Surface plate
INTRODUCTION:
Roundness can be defined as the radial uniformity of the surface part from its
centerline. There are three main irregularities in the roundness i.e. ovality, lobbing
and no specific form. Error in roundness can be eliminated/ reduced by grinding.

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PROCEDURE:
(1)
(2)
(3)
(4)

Clean the surface plate, v block and given job.


Divide the circular job into 12 or 8 equal parts with pencil point.
Place the job on the v block and set the dial gauge on the job as shown in fig.
Adjust dial gauge plunger by applying some pressure and then set the gauge to
zero.
(5) Now rotate the job and take reading of the dial gauge at point 2 and tabulate the
reading.
(6) Repeat the same procedure for all the remaining points.

STRAIGHTNESS & FLATNESS


EQUIPMENT/MATERIAL:
(1)
(2)
(3)
(4)

Straight edge
Slip gauge
Surface plate
Dial indicator with magnetic stand

INTRODUCTION:
Guide ways of a lathe spindle of a machine, surface of measuring table and many
other similar situations where if reference surface is not straight or uniformly linear, it
produces defective marketing or product. Hence the straightness is required to be
checked. Naturally, the straightness of a straight edge and surface plate should be
very high, because they are considered as standards compared to other instruments
in laboratory or work shop. The bed or table of a machine should be a perfectly flat
surface. It is required in machine tool that one part sub-assembly is moving or sliding
on another reference surface is not flat, the product produced will be defective. This
will lead to wastage of man power and material. Therefore, it is necessary to check
the flatness of such surfaces.
(B) STRAIGHTNESS MEASUREMENT:
PROCEDURE:
(1) Clean the surface plate and place the job on it.
(2) Mark two point A and B at 0.554L distance on the straight edge and divide them
into two equal parts as shown in figure. Remaining length of the straight edge
should be kept approximately equal on both sides.
(3) Put the straight edge on slip gauge, keep 10 mm slip gauge below A and 20 mm
slip gauge below B.
(4) Insert the required slip gauges below point number 1 of straight edge and note
the reading in table-1.
(5) Repeat the above procedure for point 2 to 9.
(6) Plot the graph of error v/s position.
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(C) FLATNESS MEASUREMENT:


PROCEDURE:
Clean the surface plate and place the job on the surface plate.
(1)
(2)
(3)
(4)
(5)
(6)

Divide the surface of the flat surface into six blocks by drawing vertical and
horizontal lines on it by soft pencil as shown in figure.
Put the stand on the surface plate after fixing dial indicator in the stand.
Adjust the plunger on point 1 with little pressure.
Adjust the pointer to zero.
Now move the stand and keep the plunger on points 2,3,4,..,12etc. and note
the reading each time. It may be positive or negative.

PRACTICAL NO: - 07
TITLE: -Go and No Go Type Plug, Snap and Ring Gauges.

AIM:- Inspection of diameter using Go and No Go type plug and ring gauges and
thickness using gap or snap gauges.

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GAUGES INTRODUCTION:
Gauges are scale less inspection tool at rigid design, which are used to check the
dimensions of manufactured parts. They also check the form and relative position of
the surface of the parts. They do not determine the actual size or dimension of parts.
They are only used to determine whether the inspected part has been within the
specified limits.
The gauges consist of two sizes corresponding to their max and min limits. For
gauging hole limits plug gauges and for gauging shaft shape gauges are used.
Gauges are easy to employ and can be used in many cases by unskilled operators.
For checking the component with a gauge it is not necessary to make any calculation
and to determine the actual dimensions of the part, the time involved for checking is
considerably reduced. For these reasons in mass production they are used.
PLAIN GAUGES:
They are used for checking holes and shafts. Gauges are classified as:
1. According to their type:
Standard and limit gauges.
Limit gauges.
2. According to their purpose:
Workshop.
Inspection.
Master or reference gauges.
3. According to the form of tested surface:
Plug gauges for checking holes.
Snap and ring gauges for checking shafts.
ADVANTAGES OF FIXED GAUGES:
1. They are free from errors due to drift and the original adjustment, non-linear
response, effect of power supply variation and other extraneous factors which
necessitate regular calibration and occasional correction on comparator type
gauges.
2. These provide positive dimensional information.
3. These are portable and independent of power supply avaibility.
4. These involve no other auxiliary equipment and set ups.
5. These can be design to inspect combinations of several dimensioncorresponding
lengths, diameters and angles.
6. These provide uniform reference standards.
7. These are not expensive.
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8. Comparator has to be set form time to time using master fixed gauges.
TYPES OF GAUGES:
STANDARD GAUGES:
If a gauge is made as an exact copy of the mating part of the component to be
checked, it is called standard gauge. It can not be checked to interference fit. It has
limited applications.
LIMIT GAUGES:
They are widely used in industries. As there are two dimensional limits high and low
accordingly they are known as NO and NO-GO gauges.
PLAIN PLUG GAUGES:
Generally the gauging members of plain gauges are made of suitable wear
resistance steel and the handle can be made of any suitable steel. They are normally
of double ended type for size up to 63mm and of single ended type for size above
63mm.
The various types of plain plug gauges are shown below:
(1) For size up to 10 mm GO and NO-GO type. (Solid type).
(2) GO and NO-GO type gauges for size over 10 mm and up to 30 mm. (Taper
inserted type).
(3) (a)GO and NO-GO type gauges for size over 30 mm and up to 63 mm.(fig : 3)
(b)GO and NO-GO type gauges for size over 63 mm and up to100 mm.(fig : 3)
(4) GO and NO-GO type gauges for size over 100 mm and up to 250 mm.(fig : 3)
(5) In this type, gauges with the gauging portion integral with the handle are replaced
with renewable end. (Renewable type).
(6) For relatively short through hole. It has both the ends on one side of gauge as
shown in fig. (Progressive type)
(7) To avoid jamming of the plug gauge inside the hole they are used. It is of elliptical
shape and so it touches the hole with major axis end points. The chamber behind
the pilot lifts the gauges into link, making jamming impossible and advantages is
that it can be handle with less care.(Pilot plug gauge).See fig

PLAIN RING GAUGES:

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Plain ring gauges are generally manufactured as individual Go and No-Go rings.
Special ring gauges can be manufactured with both Go and No-Go diameters on a
single ring if requested. Standard plain ring gauges below 65 mm [2.5"] are
manufactured from hardened steel blanks kept in stock and can be delivered within 2
weeks.
The various types of these gauges are as follows:
(1) For fig : 9 dimension d2 varies from 22mm to 112 mm. Correspondingly b varies
from 5mm to 22 mm and c from 0.4mm to n1.6 mm.
(2) For fig : 10 dimension d2 varies from 125 mm to 355 mm. corresponding to
d1=120 mm to 355mm, dimension d2 varies from 100 mm to 280 mm,b1 from 12
mm to 18 mm, c from 2.5 mm to 4 mm, r from 3mm to m6 mm, t from 3 m to 8
mm.
(3) For fig : 11 dimension d2 varies from 22 mm to 112 mm with d1 from 3 mm to
5mm and 66 mm to 709 mm respectively, corresponding b1 varies from 3 mm to
8 mm, c from 0.4 mm to 1.6 mm.
SNAP GAUGES:

Thread and plug gauges

Thread and pluggauges

These images illustrate an alternative type of gauge. The snap gauge has four anvils
or jaws, the first one or pair (outermost) are set using the upper limit (tolerance) of
the part and the inner set adjusted to the lower limit of the part.

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The usage of this gauge may be more intuitive than the plug type. A correctly
machined part will pass the first set of jaws and stop at the second end of test. In
this manner a part may be checked in one action, unlike the plug gauge that needs
to be used in the correct sequence and flipped to access the second gauge.
The left image is a plain snap gauge used to measure outside distances (diameters),
the right hand image shows two views of a thread snap gauge. it is very useful one
for mass production
(1) RIB TYPE SNAP GAUGES:
Double type snap gauges can be conveniently used for checking size in the range of
3 to 100 mm and single ended progressive type snap gauges are suitable for range
of 100 mm to 250 mm with gauging surface suitably stabilized, grounded and
lapped.(see fig.)
(2) PLATE SNAP GAUGES :
Double ended type plat snap gauges are used for sizes in the range of 2 mm to 100
mm and single ended progressive size range of 100 mm to 250 mm with gauging
surface properly hardened, stabilized ground and lapped. They are reasonably flat
and all sharp corners and edges are removed.
ADJUSTABLE TYPE GAP GAUGES:
In this gauges gauging anvils are adjustable end wise in the horse shoe frame. They
are set with the help of slip gauges to any particular limit required. It possible to
made gauges within about 0.002 mm of desired size and so their use enable faller
advantages to be taken of manufacturing tolerance. The adjustably also ended GO
anvils to be taken up any time. If anvils faces lose their flatness with use. They can
be reground quite easily. For designing of gap gauges some design consideration.
COMBINED LIMIT GAUGES:
In the case of gauging of cylindrical holes, it is possible to combined both GO and
NO GO dimensions of a plug gauges and thus a single gauge doing the checking of
both lower and upper limit.
POSITION GAUGES:
They are commonly used and designed on based of shape of work. They are used
for checking the position of some feature on the work relative to another reference
point or surface. Fig shows a position gauge for checking recess with respect to
some flat surface and fig shows location of parallel surface to the reference surface
by means of gauge.

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CONTOUR GAUGES:
These are employed for checking the dimensional accuracy and shape of irregular
work. They are made of similar profile as that of work. e.g. radius gauges are
employed for checking the shape of fillets.
MISCELLANEOUS GAUGES:
They are used for not only shaft and hole checking but can be designed for all type
of application for checking purposes in production shop and checking.
RECEIVER GAUGES:
They are designed to simultaneously check a number of features of work pieces.
They are often used for checking components before assembly.
PROFILE GAUGES:
They are used to check the form of the components. Profiles are difficult to be
checked by limit gauges and it is usual practice to use fixed gauges for profile
checking.
GAUGE DESIGN:
To a greater or lesser extend, every gauges is a copy of the part which mates with
the part of which gauges are designed. For example, in the design of bushing gauge
is a copy of opposed part shaft to which bushing is mate.
TAYLORS PRINCIPLE:
According to GO and NO GO gauges should be designed to check maximum and
minimum material limits which are checked as below:
GO LIMIT:
This consideration is applied to that limit of the two limits of a size which corresponds
to the maximum material limit consideration.
NO GO LIMIT:
This consideration is applied to that limit of the two limits of a size which corresponds
to the minimum material limit consideration. i.e. lower limit of shaft and upper limit of
a hole.Fig. Shows GO plug gauges and GO snap gauges.

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IMPORTANT POINTS FOR GAUGE DESIGN:


(1) The form of GO gauges should exactly coincide with the form of opposed parts.
(2) GO gauges are complex gauges which enables several related dimensions to
be checked simultaneously.
(3) In inspection, GO gauges must always be put into conditions of maximum
impossibility.
(4) NO GO gauges are gauges for checking a single element of feature.
(5) In inspection, NO GO gauges must always be put into conditions of maximum
possibility.
LIMIT GAUGES:
The various types of limit gauges used for gauging internal diameters of holes are:
(1) FULL FORM CYLINDRICAL PLUG GAUGES:-The gauging surface is in the
form of an external cylinder. Generally a small
groove cut near the leading end of
the gauges and the remaining short cylindrical surface is reduced in order to act as a
pilot. The method of attaching gauges to handle should be such as not to affect the
size and form of gauge by producing undesirable stress.
(2) FULL FORM SPHERICAL PLUG OR DISK GAUGES:- This has gauging surface
in the form of a sphere from which two equal segments are cut off by planes normal
to the axis of the handle.
(3) SEGMENTAL CYLINDRICAL BAR GAUGES:- It has the gauging surface in one
of the following two forms: External cylindrical form from which two axial segments
are made by lowering down the surface of two planes as shown in fig.
(4) SEGMENTAL SPHERICAL PLUG GAUGES:- It is similar to full form spherical
plug or dick gauge but two equal segments cut off by planes parallel to the axis of
the handle in addition to the segments cut off by planes normal to the axis of handle
as per fig..
(5) SEGMENTAL CYLINDRICAL BAR GAUGE WITH REDUCED MEASURING
FACES:- It is similar to segmental cylindrical bar gauge but has reduced measuring
faces in a plane parallel to the axis of the handle as shown in fig..
(6) ROD WITH SPHERICAL ENDS:- It has spherical surfaces which form part of one
single sphere.
THE STANDARD LIMIT GAUGES
DIAMETERS OF SHAFTS ARE:

USED

FOR

GAUGING

EXTERNAL

FULL FORM CYLINDRICAL RING GAUGE:


It has auging surface in the form of an internal cylinder and whose wall is
enough to avoid deformation under normal condition.

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thick

MECHANICAL MEASUREMENT AND METROLOGY

GAP GAUGES:
It generally has one flat surface and one cylindrical surface the axis of two surfaces
being parallel to the axis of the shaft being checked. The surface contributing the
working size may both be flat or both cylindrical also.
PLUG GAUGES:

Hardened and ground plug gaugeReplaceable thread and plug gauges


These gauges are referred to as plug gauges; they are used in the manner of a plug.
They are generally assembled from standard parts where the gauge portion is
interchangeable with other gauge pieces (obtained from a set of pin type gauge
blocks) and a body that uses the collet principle to hold the gauges firmly. To use
this style of gauge, one end is inserted into the part first and depending on the result
of that test, the other end is tried.
In the right hand image, the top gauge is a thread gauge that is screwed into the part
to be tested, the labeled GO end will enter into the part fully; the NOT GO end
should not. The lower image is a plain plug gauge used to check the size of a hole,
the green end is the GO, and red is the NO GO. The tolerance of the part this gauge
checks is 0.30mm where the lower size of the hole is 12.60mm and the upper size is
12.90mm; every size outside this range is out of tolerance. This may be initially
expressed on the parts drawing in a number of styles, three possibilities may be:12.75mm +/- 0.15mm
12.60mm +0.30 -0.00
12.90mm +0.00 -0.30
PLAIN:
It is a full form of GO gauge representing a plain or tapped end shank. It is provide
with one ring marked on the gauge plane and another ring to indicate the minimum
depth of internal taper. The dimension of gauging portion represents basic size. The
distance between two ring marks Z correspond to permissible deviation of gauge
plane position for the particular taper. It can test internal taper also.

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TANGED:
It is a full form of GO gauge representing the virtual size of the shank of basic
dimension having tang which is one of the top limit of its thickness and eccentric by
the maximum permissible amount. It is provide with one ring marked on the gauge
plane and another ring to indicate the depth of internal taper.

RING GAUGE:
PLAIN:
This gauge represent on internal taper of basic size. It is used for verifying the taper
of tapped or plain and shank. As the ring gauge is inserted to be used for verification
of internal taper, the dimension of gauging portion represent an internal taper basic
size. For inspecting external taper, the ring gauge is inserted with light pressure at
the extreme position the small end of taper shank under test should lie flush or short
of the face of the ring gauge on the small end.
TANGED:
This gauge represents an internal taper of basic size. A limit step is provided at the
small end of taper which verifies the length of shank form the gauge plane and also
combined effect of tang thickness and its offset. A step is provided to verify, the tang
slot will accept a shank even worst case. For testing, the external taper of the tanged
and shank the ring gauge will insert light pressure.

CONCLUSION:-

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PRACTICAL NO: - 08
TITLE: Profile Projector & Tool Makers Microscope
AIM:- Measurement of Profile using Profile projector and Tool Makers Microscope.
[A] PROFILE PROJECTOR:-

FEATURES:1. Medium sized model that features high versatility and easy operation.
2. Digital readout projector for angular measurement.
3. Screen glass carries the chart clips.
4. Easy to read digital XY-coordinate counters located near the projection screen to
minimize eye movement.
5. Floating type table for speedy measurement.
DESIGNATION OF PARTS:1. Base /body
2. Image screen
3. Driver for vertical and complete
assembly
4. Lamp casing for diastolic and
episcopic lighting
5. Bulb holder with a wire
6. Tighting screw
7. Condenser lens for diastolic and
epidiascope
8. Objective lenses with socket and
turret
9. Objective glass type

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10. Micrometer heads and slide


11. Panel board
12. Spindle for V-model
13. Swith for lighting
14. Fuse
15. Regulator for lighting intensity
16. Socket input
17. A & B socket outputs
18. Socket inputs
19. Name plate
20. Vernier scale
21. Episcopic mirror

MECHANICAL MEASUREMENT AND METROLOGY

SPECIFICATION OF PROFILE PROJECTOR:Model HPP 310


Screen dia. 300mm
Work stage 350 x 250mm
Travel 220 x 110mm
Magnification:
Standard 10X 20X
Optional 25X 50X
SPECIFICATION OF HALOGEN PROJECTION LAMP:Power
Voltage
Height of filament
Socket with two contacts
Distant between two contacts
Type Philips no.
Osram type no.

- 150 watt
- 24 volt
-32 mm
- 10 mm
- 6.35 mm
- 7158
- 64640

CENTERINGTHE DIASTOLIC LAMP:1.


2.
3.
4.
5.

Draw the diagonals accurately with a pencil on a trans paper.


Remove the objective and condenser lamp.
Switch the regulator to half brilliance.
Slacken clamp screw 8 to enable the lamp socket to be moved in direction B-B & C-C.
Move lamp socket in direction A-A/B-B & C-C until the image of filament is shap &
central on the screen.
6. Tighten the clamp screw and grab screw 39.
7. Mount objective and condenser lens at its position.
SETTING UP THE SURFACE ILLUMINATION:1.
2.
3.
4.
5.
6.

Mount the required lense.


Bring the proper height of light beam.
Switch on the light & moves mirrors centrally.
Replace the piece of paper.
The clarity can be improved.
Try to get the sharp and clear image.

THE MAGNIFICATION:

For accurate reading use magnifying glass.


Check can be made with slip gauge arbors of accurate dimension etc by keeping it on
the table and measure the image on the paper.
We accurately set the magnifications, but a result of vibration on which they have been
subjected during transport proportional to travel.

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PROCEDURE:

Following type of steel screws is used for inspection


First measure the dimension using screw thread micrometer screw.
Then check the dimension using profile projector.

Fig. Threaded Screw


The following parameters were assessed:
1 - Dimensions:
a. body diameter (proximal non-threaded portion);
b. inner diameter;
c. thread fillet height;
d. step length;
e. thread apex lengths;

Fig. Metrologic evaluation of the screw

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[B] TOOL MAKER MICROSCOPE:

It is based on the principle of optics. The microscope consists of heavy hollow bases;
accommodates the illuminating unit underneath & above this, on the surface of the
base, the work table carriage is supported on the balls & controlled by micrometer
screw.
Projecting up from the near base is a column which carries the microscope unit & inter
changeable eyepiece.
Light from source lamp reflected as parallel beam by prison at the end of tube so image
is created on the translucent screen. Magnification can be from 10X to 100X.
Linear movement of the table is controlled by micrometer screw having a movement up
to accuracy 0.0025mm.
For the most effective manipulation magnified image of the work compared through the
eyepiece superimposed on a prepared background engraved on a glass disc on an
eyepiece. The operator unit is prepared with radial
and cross setting lines. This may be rotated by a
knurled screw for setting any of line with work or
image and reading of the protector may be made to
1 minute.

THE CHIEF APPLICATION OF THE TOOL ROOM


MICROSCOPE ARE AS FOLLOWS:
1. The determination of relative position of various
points on work.
2. Measurement of angel by using a protector
eyepiece.
3. Comparison of thread forms with master profiles
engraved in the eyepiece, measurement of pith and
effective diameter.

SPECIFICATION OF TOOL MAKERS MICROSCOPE:Work stage


Travel
Magnification:
Standard
Optional

- 150 X 150 mm
- 50 X 50 mm
- 30 X standard
- 30 X standard

SPECIFICATION OF HALOGEN LAMP:Power - 50 watt


Voltage
Height of filament
Socket with two contacts
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- 12 volt
- 12 mm
- 8 mm

MECHANICAL MEASUREMENT AND METROLOGY

Distance between two contacts


Type of G.E. no.

- 4 mm
- 34718

PREPARING FOR WORK:Tool makers microscope requirement is as same as profile projector discussed in [A].
SETTING UP:It requires 50cm free space all around and single phase lighting current of 220 volts.
WORK-ROOM REQUIREMENT, CENTERING AND SURFACE ILLUMINATION:All the work room requirements, centering of lighting position and surface illumination
technique as same as in case of profile projector discussed in section [A].

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PRACTICAL NO: - 9
TITLE: - Surface Roughness Measurement
OBJECTIVE;
1. To measure the surface roughness of the given specimens using roughness tester
2. To show the variation of surface roughness as a function of cutting conditions i.e.,
speed, feed, depth of cut and tool geometry etc
MEASURING INSTRUMENTS AND MATERIAL RIQURIED:
1.
2.
3.
4.

Surface roughness tester (SJ- 201)


Precision roughness specimen, Test specimens, Calibration stage
Height gauge, Adapter for the height gauge, support
Nose Pieces, Digimatic data processor (DP-1 HS)

TERMINOLOGY AS PER INDIAN STANDARD:


Surface roughness: It concerns all those irregularities which form surface relief and which
are conventionally defined within the area where deviations of form and waviness are
eliminated.
PRIMARY TEXTURE (ROUGHNESS):
It is caused due to the irregularities in the surface roughness which results from the
inherent action of the production process. These are deemed to include transverse feed
marks and the irregularities within them.
SECONDARY TEXTURE (WAVINESS)
It results from factors such as machine or work deflections, vibrations, chatter, heat
treatment or warping strains, waviness is the component of surface roughness upon which
roughness is superimposed.
CENTRE LINE:- The line about which rough is measured.
LAY:-It is the direction of the predominant surface pattern: ordinarily determined by the
method of production used.
TRAVERSING LENGTH: It is the length of the profile necessary for the evaluation of the
surface roughness parameters.
SAMPLING LENGTH (I):Is the length of profile necessary for the evaluation of
irregularities to be taken into account. This is also known as the cut off length as regard
to the measuring instruments. It is measured in a direction parallel to the general direction
of profile.

THEORY:
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Surface texture is deemed to include all those irregularities which, recurring many times
across the surface, tend to form on it a pattern or texture. The irregularities in the surface
texture which result from the inherent action of the production process is called roughness
or primary texture. That component of surface texture upon which roughness is super
imposed is called waviness or secondary texture. This may result from such factors as
machine or work deflections, vibrations, chatter, heat treatment or warping strains. The
direction of the predominant surface pattern, ordinarily determined by the production
method used is called lay. The parameters of the surface are conveniently defined with
respect to a straight reference line. The most widely used parameter is the arithmetic
average departure of the
Filtered profile from the mean line. This is known as the CLA (Centre Line Average) or
Ra (roughness average)
Arithmetic mean deviation of the Profile, Ra
Ra is the arithmetic mean of the absolute values of the profile deviations (Y i ) from the
mean line.
N
Ra = 1/N Yi
I=1
Root mean- square deviation of the Profile, Rq :
Rq is the square root of the arithmetic mean of the squares of profile deviations (Y i ) from
the mean line.
N
1/N Yi2
I=1
Maximum height of the profile, Ry:
Ry is the sum of height Yp of the highest peak from the mean line and depth Y v of the
deepest valley from the mean line.
Ry = Yp + Yv

OUTLINE OF SURF TEST SJ- 201


The surf test -201 is a shop-floor type surface roughness measuring instrument, which
traces the surfaces of various machines parts, calculates their surface roughness based
on roughness standards, and displays the results.

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Surf Test SJ-201 Surface roughness measurement principle:


A pick-up which is usually called as the Stylus attached to the detector unit of the surf
test SJ- 201 will trace the minute irregularities of the work piece surface. The vertical stylus
displacement during the trace is processed and digitally displayed on the liquid crystal
display of the surf test SJ- 201. The measurement principle of surf test SJ- 201 is show in
fig. The instrument consists of the display unit and drive/detector unit is designed to be
removable from the display unit. Depending on the shape of the work piece, it may be
easier to perform measurement without mounting the drive/detector unit to the display unit.
Name of each part on the display unit is shown in fig. The detector in turn can be detached
from the drive unit. Each time a measurement task has been completed with the surf test
SJ-201, it is recommended that the detector be detached from the drive unit and stored in
a safe place.

Fig. Terminology as per Indian Standard

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Fig. Measurement Principle of Surftest SJ-201


LIST OF SURF TEST SJ-201 OPERATION MODE:
The surf test SJ-201 has various operation modes including the measurement mode,
calibration mode, condition setting mode, RS-232C communication mode, and detector
retraction mode.
MEASUREMENT MODE:
Starts and stops measurement, calculates and selects measurements parameters to be
displayed, and performs SPC output.
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CALIBRATION MODE:
Sets the calibration value prior to measurement and performs calibration measurement.
CONDITION SETTING MODE:
Sets and modifies measurement conditions. This mode has 11 sub-modes as shown in
chart.
RS 232C COMMUNICATION MODE:
Used for communication with a personal computer.
DETECTOR RETRACTION MODE:
Retracts the detector as required.
Relationship between the operation modes and available keys is shown in Table.
MEASUREMENT OF SURFACE ROUGHNESS:
Surface roughness measurement with the surf test SJ-201 includes
1. Mounting/ dismounting the drive unit/ detector, and cable connection, etc. according to
the feature of the work piece to be measured.
2. Selection of power supply i.e., either the AC adaptor or built-in battery.
3. Modifying the measurement conditions as necessary.
4. Calibrating surf test SJ-201 to adjust the detector gain for correct measurements.
5. Measuring the roughness specimen and display the result.
6. Outputting the measurement data or perform communication with a personal computer
via the RS- 232C interface.
PROCEDURE:
MODIFYING MEASUREMENT CONDITIONS:
Table shows the measurement conditions that can be modified by the user. If they are not
modified, then measurement will be performed according to the default values,
measurement conditions are modified according to the surface roughness parameters, the
amplitude of roughness, the conditions of the objective area of measurement, etc.
The surf test SJ-201 can obtain each roughness parameter based on the new JIS, old JIS,
DIN ISO and ANSI standards. Evaluation according to any one of the standards may be
obtained from Reference information (Users manual)

CALIBRATION OF MEASURING INSTRUMENT:


The process of calibration involves the measurement of a reference work piece (precision
roughness specimen) and he adjustment of the difference (gain adjustment), if there is any

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Fig. Name of each part on the display Unit


between the measured value and the reference value(precision roughness specimen).
With out properly calibrating the instrument, correct measurements cannot be obtained.
Calibration of surf test SJ- 201 with the supplied precision roughness specimen must be
performed with the default values mentioned in table.
1. Precision roughness specimen and calibration stage are placed on a level table.
2. Surf Test SJ-201 is mounted on the calibration stage.

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3. Surf Test SJ-201 is set so that the detector traversing direction is perpendicular to the
cutter mark of the precision roughness specimen. It should be confirmed that the
detector is parallel to the measured surface as shown in fig.
4. If [CAL/STD/RANGE] key is pressed in the measurement mode, the calibration mode is
entered and current calibration value is displayed. In this stage the calibration value
can be modified, if the displayed value is different from that marked on the precision
roughness specimen.
5. [n/Ent] key is pressed after confirming the displayed value, so that the entered
calibration value is set.
6. [START/STOP] key is pressed to begin the calibration measurement. The symbol is
displayed while the detector is traversing and the measured value will be displayed
when the measurement has been completed.
7. [n/Ent] key is pressed so that the calibration factor is updated, completing the entire
calibration operation.
8. [MODE/ESC] is pressed. This restores the measurement mode and retains the
calibration factor obtained in the previous operation.
ACTUAL MEASUREMENT OF ROUGHNESS SPECIMEN:
Surf Test SJ-201 is placed on the work piece, if the work piece surface is large enough.
For measurement to be successful, it should be performed on a firm base that is insulated
as well as possible from all sources of vibration. If measurement is performed being
subject to significant vibrations, results, may be un reliable.
1. Work piece is poisoned so that the measured surface is level.
2. Surf Test SJ-201 is placed on the work piece, In this operation SJ-201 is supported by
to reference surfaces at the bottom of driving unit. It must be confirmed that the stylus
is in proper contact with the measured surface and the detector is parallel to the
measured surface.
3. [START/STOP] key is pressed in the measurement mode, the detector starts traversing
to perform measurement.
4. After the measurement has been completed, the measured value is displayed on the
LCD.
5. [PARAMETER] key is pressed until the desired parameter value is displayed on the
LCD.
OUTPUTTING MEASUREMENT RESULT:
1. The Surf Test SJ-201 is connected to a Digimatic data processor (DP-1HS) to output
the measurement results (including the unit of measurement) as SPC data.
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2. DP-1HS is turn to ON position.


3. [PARAMETER] key is pressed until the objective parameter for output is displayed.
4. POWER/DATA] key is pressed so that the measurement result will be outputted from
the Surf Test SJ-201 to the DP-1HS.

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PRECAUTIONS:
i) Never touch the stylus, otherwise it may be damaged.
ii) Do not hold the detector when detaching the drive/ detector unit. Otherwise, the
detector may be damaged.
iii) Confirm that the detector is parallel to the measured surface.
iv) Confirm that the stylus is in proper contact with the measured surface.
v) Calibration of SJ-201 with the precision roughness specimen must be performed with
the default values that have been used for calibrating the roughness specimen.
CONCLUSION:-

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PRACTICAL NO: - 10
TITLE: - Pressure Measurement using pressure Transducer and calibration of pressure
gauge with dead weight pressure gauge.
AIM: - Pressure Measurement using pressure Transducer and calibration of pressure
gauge with dead weight pressure gauge.
INTRODUCTION OF TEST SET UP:The Instrumentation Tutor is meant for measurement of pressure trough Pressure cell. The
Tutor is very useful for study of pressure through pressure Cell. The circuit diagram is
given on the top cover on the tutor to understand the measurement parameter at a glance.
All the different test point are also provided on top cover with giving their heading to
facilitate the student to understand without any operation instruction by any person.
Range
Resolution
Display
Excitation
Analog output
Power source
Top Panel:
1. Display
2. Inputs
3. Cal check

4. Zero pot
5. Span pot
6. ON/OFF switch
7. Fuse
8. Light LED
9. Test point

: 10 kg/cm2
: 0.1 kg/cm2
: 3-1/2 digit
: 5.00Volt, DC
: 2Volt, DC
: 230 V +/-10%,50 HZ

: 3-1/20digit
: Pressure cell
: On pushing the red switch you will observe
the adjusted calibration on the display.The
present calibration adjustment is 8.3
: Provided for zero adjustment
: : : Provided for calibration
: To ON/OFF the system
: 0.5 milliamps
: Indicates the power supply when the
When is in ON position.
a) display card supply +/-5V
There are three terminals
Red
:+5V
Green
: Common
Black
: -5V
b) Pressure cell signal conditioner card supply
+/-12V
There are three terminals for
Red
: +12V
Green
: Common

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Black
: -12V
c)Analogue output 2V full range of Pressure cell
Red
: High
Green
: Low
d) Pressure cell full bridge
When the system is in OFF position the RED and
Green points are for Excitation 350 ohms.
The Yellow and Black pints are for Signal 350 ohms.
When the system is in ON position,
Red
: E+
Green
: EExcitation
: 5V fixed
Signals :
Yellows
: +
Black
: Signal maximum pressure 10 kg/cm 2 6.6mVs
NOTE- All the test points can be measured through multimeter and/or Cro.
OPERATING PROCEDURE:
1. TO connect the pressure cell at the 9 pin connector.
2. Power ON the switch. The front RED LED glow with which indicates the power available
on the instrument.
3. Give some time to stabilize the instrument for stabilization (warm up time).
4. Balancing the pressure Cell by through the corresponding ZERO ten turn timpot.
5. Set the gain of Pressure cell by SPAN ten turn trimpot.
6. Then to push the micro switch to ascertain the reading position of CAL. The present CAL
position in the instrument is 8.3
7. For example :
To apply the pressure on pressure cell say 10 Kg/cm 2. You will observe some reading
on the display say something like 9.6 or so. Now you have to adjust this reading say
10.0 by rotating the span pot and to stop rotating with the desired 10.0 counts are
visible.

PRECAUTIONS:
1. To get the good performance from the Tutor you have to maintain room temperature.
2. To check the power source. It should be 230V+/- 10%, 50 HZ. To avoid over voltage
hazards.
3. To get best performance, you have to put the instrument at dust proof and Humidity
free environment.
4. Do not try to open the instrument or repair it. Contact manufacturer in case Of any
fault/difficulty.
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THEORY:
New-tech pressure transducers employ foil type strain gauges bonded to the pressure
sensitive diaphragm. The transducer is a single body piece machined from special steel,
treated for maximum stability.
CONTROL POTS:
-

Zero adjust for trimpot


Span adjust for trimpot
Excitation : 5Volts DC
Cal check : _________

OBSERVATION TABLE:
Sr.
No.

Pressure Applied
(in kg/cm 2)

Display
(in kg/cm 2)

1 No pressure
2
2
3
4
4
5
6

6
8
10

CONCLUSION:

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Reading Signal
(in mV)

Output
( in Volts)

MECHANICAL MEASUREMENT AND METROLOGY

PRACTICAL NO: - 11
TITLE: - Temperature Measurement using Thermocouple.
AIM: To Measure The Temperature Using Thermocouple (Range: Up To 100 C IronConstantan)
.
INTRODUCTION OF TEST SET UP:
The New-Tech temperature calibrator is meant for measurement of temperature
through thermocouple. The calibrator is very useful for study of temperature through
thermocouple sensor. The circuit diagram is given on the top cover on the calibrator to
understand the measurement parameter at a glance. All the different test points are also
provided on the top cover with giving their headings to facilitate the user to understand
without any operation instruction by any third person.
Thermocouple Range
Resolution
Analogue output
Top Panel:
1. Display
2. Inputs
3. Zero pot
4. Span pot
5. ON/OFF switch
6. Fuse
7. Light LED when
8. Test point

: 100
: 0.1
: 2 Volts DC
: 3-1/2 digit LED
: Thermocouple sensor (Iron Constantan)
: Provided for zero adjustment
: Provided for calibration
: To ON/OFF the system
: 0.5 milliamps
: Indicates the power supply it is in ON position.
: a) Display card supply +/- 5V
There are three terminals:
Red
: + 5V
Green : Common
Black : -5V
:b)Thermocouple Signal Conditioner
Card supply +/- 5V
There are three terminals for:
Red
: +12V
Green
: Common
Black
: -12V
:c) Analogue output 2V full scale display
Red
: +VE
Black
: -VE
:d) Sensor input point
When the system is in OFF
you can measure the resistance of sensor

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EQUIPMENTS USED:
1. Thermocouple
2. Thermistor
3. Bimetallic temperature gauge
4. Mercury type thermometer
5 .Pyrometer
PRINCIPLE:
The principle on which various temperature measuring devices work is shown below:
(1)Principle of expansion e.g mercury thermometer range:-40to400 c
(2)Principle of Electrical resistance e.g. resistance thermometer range:
-240 to 980c
(3)Change of physical state e.g. bimetallic thermometer range: -73to540 c
(4)Change in chemical state e.g. thermistor range: -100 to260 c
(5)Change in radiation e.g. pyrometer range: -20 to 5760 c
THERMOCOUPLE:
Thermocouple is an instrument to measure temperature which works on thermoelectric
effects. In its construction two dissimilar conductors electrically insulated except at hot
junction where conductors may either be soldered or welded together. A refractory and
metal protective cover is provided to protect the thermocouple from injurious furnace
gases and to prevent from mechanical damages. The leads allow the measuring
instrument to be placed at considerable distance from thermocouple. The cold or the
reference junction provided by the instrument is used for measuring e.m.f. The hot
junction point is placed into a hot well i.e. the system to be measured. Due to difference of
temperatures at hot and cold junction points, an e.m.f. is generated and electric current
flows through the circuit. The value of this generated current can be read on the calibrated
meter in terms of temperature.

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THERMISTOR:
Thermistor is a contraction of term Thermal Resistor. They are essentially
semiconductors which behave as resistor with a high negative temperature coefficient. As
the temperature increases, the resistance goes down and as the temperature decreases,
the resistance goes up. This is just opposite to the effect of temperature changes on
metals. A high sensitivity to the temperature changes makes the thermistors extremely
useful for precision temperature measurement, control and compensation in the
temperature 100C to 300 C. Thermistor is composed of sintered mixture of metallic
oxides. These oxides are milled, mixed in appropriate proportions, are pressed into
desired shape with appropriate binders and finally sintered. Thermistor may be shaped in
the form of beads, disks, washers, rods etc. Thermistors may be used bare but are
usually glass coated or positioned under a thin metal cap.

BIMETALLIC TEMPERATURE GAUGE:


A bi-metal strip consists of two pieces of different metals firmly bonded together by
welding. For a bimetal in the form of a straight cantilever beam, temperature changes
cause the free end to deflect because of the different expansion rates of the components.
This deflection can be correlated quantitatively to the temperature change. Apparently
when one end of the strip is fixed, the position of free end is a direct indication of the
temperature of the strip. Bimetallic elements can be arranged in the flat, spiral, the single
helix and the multiple helix configurations. It is inspective, simple, compact and robust in
construction. It can be applied in temperature range of -73 to 540C.

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PYROMETER:
Pyrometers can be either radiation or optical. A radiation pyrometer can be sensitive to the
whole spectrum of wave lengths or to only part of it. The first part is called total radiation
pyrometer while the latter part is called optical pyrometer.
The total radiation pyrometer measures the energy radiated by the object while the optical
pyrometer depends upon the matching of the brightness of a calibrated lamp filament with
that of the heated object. The temperature is inferred from the total heat energy which is
caused to impringe on a thermocouple or a series of thermocouples which comprise a
thermopile. The radiated energy is converted into an electromotive force by the thermopile.
This potential may then be measured in any one of a number of ways.
Optical pyrometer employs principle of color and brightness which are an indication of its
temperature. As the color becomes brighter bluer light and less red light is likely to be
present. The optical pyrometer measures temperature of a hot body from a determination
of the brightness of the surface under measurement. It has wide application as portable
instrument. The reference filament in the pyrometer is made to match the brightness
created by the radiated energy from the unknown temperature source. the intensity of the
two light sources viewed in the pyrometer is manually matched. The brightness of the lamp
filament can be adjusted by manipulating an electrical resistance in series with it.

OPERATING PROCEDURE
1. To connect the T/C sensor at the 9 pin connector.
2. Switch ON the system the power indicator. The RED LED on the front panel will glow.
3. Give the 0 C temperature to the T/C by keeping it into the ice, adjust the 000 reading on
the display by adjust through zero Pot.
4. Keep the T/C into the boiling water and adjust the display reading 100 by adjusting
through span pot 100C is calibrated.
5. Keep the T/C in room temperature. The indicator will display room temperature.
PRECAUTIONS
To get the good performance from the calibrator you have to maintain room temperature.
To check the power source, it should be 230V+/-10%, 50 Hz to avoid over voltage
hazards.

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To get best performance you have to put the instrument at dust proof and humidity free
environment.
Do not try to open the instrument or repair it. Contact manufacturer in case of any
fault/difficulty.
THEORY:
The thermocouple is a thermoelectric device that converts thermal energy in electrical
energy. The thermocouple is used as a primary transducer for measurement of
temperature, converting thermocouple changes directly into emf.
CONTROL POTS:
0 C (IC point) adjust by zero trimpot.
100 C (Boiling point) adjust by span trimpot.
OBSERVATION TABLE:
Sr.
No

Temperature

Display reading C

1
2
3
4
5
6
7

CONCLUSION:

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Analogue
output Volts

MV output of Iron
Constant
Thermocouple

MECHANICAL MEASUREMENT AND METROLOGY

PRACTICAL NO: - 12
TITLE: - RPM Measurement using Opto-Coupler Pick Up and Tachometer.
AIM: - To measure the RPM using Opto-coupler pick up (Stroboscope) and Tachometer .
.
INTRODUCTION OF TEST SET UP:
The instrumentation Tutor is meant for measurement of RPM through Opto-coupler
Pickup. The Tutor is very useful for study of RPM through Magnetic Pickup. The
measurement parameter at a glance. All the different test point are also provided on top
cover with giving their heading to facilitate the student to understand without any operation
instruction by any third person.
Range
: 2000 rpm
Resolution
: 1 rpm
Speed
: 6000/sec
Resolution
: 1mm/sec
Top Panel:
1. Display
2. Inputs
3. Single turn pot
4. ON/OFF switch
5. Fuse
6. Light LED
8. Test point

: 3-1/2 digit LED


: Opto coupler transducer
: Motor speed control adjustment
: To ON/OFF the system.
: 0.5 milliamps
: Indicates the power supply when the when Is in ON
position.
a) Display card supply 5+v
There are two terminals :
Red
: +5V
Black
:
b)Signal conditioner card supply +5V
There are two terminals for :
Red
: +5V
Black
: Ged
c) sensor output to measure CRO
Red
: High
Black
: Low
Square wave in CRO

OPERATING PROCEDURE:
1. To connect the Magnetic pick up at the 9 pin connector.
2. Power ON the switch. The front REDLED glow with which indicates the power available
on the instrument.
3. Give some time to stabilize the instrument for stabilization (warm up time).
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4. Display show 0000 reading.


5. Motor ON minimum to maximum. Maximum RPM 2820.
PRECAUTIONS:
To get good performance from the Tutor you have to maintain room temperature.
To check the power source, it should be 230V+/-10%, 50HZ. To avoid over voltage
hazards.
To get best performance, you have to put the instrument at dust proof and Humidity
free environment.
Do not try to open the instrument or repair it. Contact manufacturer in case of any
fault/difficulty.
THEORY:
When a current carrying conductor is placed in magnetic field such that the field is at right
angles to the direction of the current, an electric field (sometimes called hall field) EH is
produced in the conductor at right angles to both the current and the magnetic field.
OBSERVATION TABLE:
Sr. NO

RPM

1
2
3

Minimum RPM
Centre
RPM
Maximum RPM

CALCULATION FORMULA:
RPM = (Frequency x Diameter of dick) / No. of teeth
Diameter of Disk = 55 mm
Periphery of Disk = D = 3.14 x 55 = 172.7
No. of teeth = 60 Nos.
Frequency = 900
Speed = (Frequency x Peppery of disk) / No. of teeth
Speed = (900 x 172.7) / 60 = 2590
RPM = Speed / 3.1415
CONCLUSION:

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Display reading

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