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HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

MECHATRONIC ENGINEERING ADVANCED PROGRAM

REPORT
EXPERIMENT 5
DIAMETER AND FORM ERROR MEASUREMENT

Name : Phạm Cao Khải

Student ID : 20185265

Class : 717611

Instructor : Nguyễn Thành Trung

I. Abstract:
Testing dimensional accuracy plays a very important role in inspection
process. This experiment devotes to check diameter in a cross-section, along
profile longitudinal axis and roundness of a cylinder-shaped product – a gear box’s
transmission line shaft. For this purpose, the Dial Indicator is chosen because of its
high resolution and ease of manipulation.
It raises one hypothesis that deviation of diameter follows Student
distribution. The experiment result confirms the hypothesis as well as helps us
determining the sample’s quality.
II. Content
1. Principle

Dial indicators, also known as “dial gauges” and “probe indicators”, are
instruments used to accurately measure small linear distances, and are frequently
used in industrial and mechanical processes. They are named so because the
measurement results are displayed in a magnified way by means of a dial.

A special variety of the dial indicator is the dial test indicator (DTI) which is
primarily used in machine setups. The DTI measures displacement at an angle of a

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lever or plunger perpendicular to the axis of the indicator. A regular dial indicator
measures linear displacement along that axis.

Dial indicators may be used to check the variation in tolerance during the
inspection process of a machined part, measure the deflection of a beam or ring
under laboratory conditions, as well as many other situations where a small
measurement needs to be registered or indicated. Dial indicators typically measure
ranges from 0 to 300 mm (0 to 12.0 inch), with resolution of 0.001 mm to 0.01 mm
(metric) or 0.00005 in to 0.001 inch (imperial)

By using Dial Indicator, we have some advantages: high resolution (0.001

mm), easy manipulation (owing to accompanied jig system)

2. Equipment
a) Dial Indicator
b) Block gauge (30mm)
c) Jig system: 1 support and 2 short V-block (2 types)

Jig System 2

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 d) Specimen : cylinder as figure

3. Practice
3.1. Calibration of the Dial Indicator

o Put the cylinder on V-blocks then adjust position of the V-blocks and
the cylinder so that the spindle is just above measured dimension (A
or B). Turn the cylinder until the pointer shows the max value.
o Replace cylinder with the standard sample.
o Rotate the top knob until the pointer coincides with line zero of
display. Then put the cylinder back again.

3.2. Carry out the experiments

3.2.1. Cylinder diameter (with Jig system 1)

o Rotate the cylinder slowly about its axis and stop at 5 different
positions. Write down these 5 values indicated by the pointer.
o Repeat these steps with the other dimension.

3.2.2. Roundness (with Jig system 2)

o Rotate the cylinder slowly about its axis. Write down the
maximum and minimum values indicated by the pointer.
o Repeat these steps with the other dimension.

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4. Observations and Result

4.1. Observations
4.1.1. Cylinder diameter deviation in a cross-section

Choosing 5 different position of cylinder, we collected 5 values

which are slightly different to each other. These values, in m, are
deviation of cylinder diameter compared with the standard sample.

4.1.2. Roundness error

We observe the same occurrence as the 1st experiment

(Cylinder diameter deviation in a cross-section). But we just notice
the maximum and minimum values when the shaft is rotating.
4.2. Result
4.2.1. Data
Deviation indicator
Times x
(m)
A B
1 30.017 30.015
2 30.014 30.018
3 30.016 30.021
4 30.018 30.019
5 30.015 30.017
Measure the cylinder diameter in a cross-section
Allowable dimensions are: max = 30.023 mm; min = 30.002 mm

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 Roundness measurement
A B
Measured value indication (m)
xmax 30.005 30.002
xmin 29.995 29.997
Measurement of roundness error
Allowable roundness error is 0.01 mm

4.2.2. Calculations
a) Cylinder diameter deviation in a cross-section

Times Size allows

(mm)
A( x i ¿ B( x i ¿
1 30.017 30.015
2 30.014 30.018 max =30.023(mm)
3 30.016 30.021
4 30.018 30.019 min =30.002(mm)
5 30.015 30.017
- A
5

=∑
xi
o Mean value: 1 = 30.016 (mm)
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o Sample standard deviation: S x =

n−1 √ 4 √
∑ ( x i−x )2 = ∑ ( x i−x )2 =¿ 0.002 (mm)
→ A=30.0 16 ± 0.0 02∈(30.002 ; 30.023)→ A is acceptable
- B
5

o Mean value: = ∑
1
xi
=30.018 (mm)
5

o Sample standard deviation: S x =

n−1 √ 4
→ B=30.0 18± 0.002 ∈(30.002;30.023)→ Bis acceptable
√
∑ ( x i−x )2 = ∑ ( x i−x )2 =¿ 0.002 (mm)

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 b) Deviation in roundness

o Deviation of roundness of A is ∆ x=0.002( mm)

⇒ Deviation of roundness of A is30.000 ± 0.002 (mm)
o Deviation of roundness of B is ∆ x=0.001( mm)
⇒ Deviation of roundness of Bis 30.000 ± 0.001 (mm)