Mechanical Measurement Laboratory

I.AR MANUAL

TE Mechanical

Department of Mechanical Engineering,

All IndiaShri Shivaji Memorial Society's

College of Engineering,Pune-01.

[2021-2022]
 AISSMS
COLLEGE OF ENGINEERING
Approved by AlCTE, New Delhi, Recognized by
MNCY 191
Govt. of Maharashtra, Amiliatod to Savitribai Phulo Pune University
and recognized and UGC PU PNI
2() 12(B) by (Id.No. Engg./ 093 (1992)
Accredited by NAAC with 'A+ Grade

Index

SR. CONTENT PAGE DATE OF COMPLETION

NO. NO.
Linear and Angular measurement:
Demonstration and calculations using vernier
calliper, screw gauge, dial gauge, height gauge,
etc. and cause and
plotting effect diagram for
their errors in

measurement with the help of OER software's

Limit Gauges: Concepts, uses and
applicationsof
Go-No-Go Gauges, Taylor's principle and design
of

gauges.([Numerical and studentactivity)._

Surface roughness measurement of a given
sample using surface tester.

Determination of geometry and dimensions of

given composite object/singlepoint tool, by using|
optical projector.
5. Verification of dimensions and geometry of giveen

component using mechanical comparator

6. Measurement of gear tooth thickness by using

gear tooth vernier caliper.
7. Speed Measurement and calibration of photo and
magnetic speed pickups for the measurement of
speed by using Stroboscope.
8. Calibration of Pressure gauge by using Dead

weight
9. Study of co-ordinate measuring machine.
 Experiment No: 1 Date:

Linear and Angular Measuring Instruments

Aim: Determination of lincar and angular dimensions of given composite part using
precision/non precision nmcasuring instrumcnts.

Apparatus: Stccl Rulc, Vernier Caliper, Vernier Height Gauge, Micrometer,

Digital Micromcter, Sine Bar, Universal bevel
protractor.

Introduction:
Steel Rule: It is also known as scale. It is the line
measuring device. It is the
Simplest and common measuring instrument used for
inspection. It works on the
basic measuring technique of
company on unknown length to the one previously
calibrated. It consists of a strip of hundred steel
having line graduation etched
engraved on internal of fraction of standard unit of
length, depending upon the
internal at which
graduations are made. The scale can be manufactured in different
sizes and styles. It may be 150 mm, 300
mm, 600 mm
or 1000 mm long.
Vernier Calliper:The principle of vernier is that when two
scalesor divisions slightly
different in size are used, the difference between
them can be utilized to enhance the
accuracy of measurement. The Vernier Calliper essentially consistsof two steel rules
and these can slide along each other. The details are shown in below fig.

Jgppon TDhmogson]nquvqungarHUyrggo

-a
1. Outside jaws: used tomeasure external diameter or width of an
object.
2. Inside jaws: used to measure internal diameter of an object.
3. Depth probe: used to measure depths of an
object or a hole.
4. Main scale: gives measurements of
up to one decimal place (in cm).
5. Main scale: gives measurements in fraction(in
inch).
6. Vernier gives measurements up to two decimal
places(in cm).
7. Vernier gives measurements in
fraction(in inch).
Least
count Main Scale Division(MSD)-
Vernier Scale Division(VSD) OR
Least count Value of 1
MSD/Total no. Of VSD
1 MSD = Imm, total =
no. VSD 50, thereforc LC 0.02 mm. =

Suppose 50 vernier scale division coincide with 49 divisions on main scale, and
1 msd=l
mm. Then 1 VSD = 49/50 of MSD = 49/50 mm,
Therefore LC 1-49/50- 0.02 mm.
is just as
Alternatively,
it
easy to read the 13 on the main scale and 21l on
Vernier scale.The correct measurement being 13.42mm.

13 21 13 + 21x0.02
IMPERIAL SCALE DivisiONS
13 0.42
13.42mmn (final answer)
udn0001
o ,i By

2
JunlunlHUHAm
METRIC SCALE -21 DViSIONS-
MAIN METRIC SCALE HUNDREDTHS OF mm

Example l.

19 32 DIVISIONS

19+32 X 0.02
19+0.64
4 5
nlnlnulyHHHdttHktHtHaHtHlHaHtHAHHAlul 19.64mm (final answer)

34 DIVISIONS
MAIN METRIC SCALE HUNDREDTHS OF mm
Example 2

Vernier Height Guage:

This a
is also
of a
sort vernier caliper equipped with
a specialbase back and other
the suitable for height measurement.
attachments which make instrument
the is provided to carry a removable
Along with sliding jaw assembly arrangement
clamp. The upper and the lower surface of the measuring jaw are parallel to the base
so it can
that be used for measurement over or under the surface.The vernier height
is used toscribe lines of certain distance above surface. However, dial
guage merely
indicator can be attached in the clamp and many useful measurements can be
 when dil tipjust touches the surfaces.
exactly madc as it cxactlygives the indication cssential.
usc of surfacc platcs as datum surface is very
For all thesc mcasurements,
Vernier Depth Gauge:

Beam
graduations

Main scale

Beam-

Fine adjustment
screw

Vernier scale
Locking
Screws Measuring law
-Scriber

Slider

TIL
Base
A vernier depth gauge is used to measure the depth of holes, recesses and distance
from a plane surface to a projection.
In Figure shown a vernier depth gauge in use. The vernier scale is, fixed to the main
body of depth gauge, and is read in the same way as vernier calipers. Running
the end of which provides the datum
through the depth gauge body is the main scale
surface from which the measurements are taken. The depth gauge is carefully made
so that the beam is perpendicular to the base in both directions. The end of the beam

Fine adjustment screws

Screw H-Locking

Main scale Vemier scale

Measuring face

P777777777
 1SSquare and flat, like the end of a steel rule and the base is flat and true, free from
cunes or waviness.

Micrometer:
The micrometer esscntially consists of U shapcd frame. The component to be
measured is held between fixed anvil and movable spindle.The spindle can be moved
With the help of thimble. There are two scales on micrometer, a main scale and a
Circular scale.Tlhe barrel is graduated in unit of 0.5 mm whereas thimble has got 50
divisions around its periphery.One revolutionof thimble moves 0.5 mm which is the

(
lead of the screw and also the pitch.

Locknut
Anvil

Spindle-

Z Thimble Rachet

0-25
mm Frame

Digital Micrometer:
1) It is used where high accuracy is required.
2) It is based on electronic technology.
3) It can be zeroed at any position, which greatlyspeeds the process of inspection.

Sine Bar: A sine bar

isa tool used to measure angles in metalworking. It consistsof a hardened, precision
ground body with two precision ground cylinders fixed at the ends. The distance

Holes for reducing

Upper surtace the weight and material Surtace
parallel to lines

Roller or
plugs

between the centers of the cylinders is precisely controlled, and the top of the bar is
parallel to a line through
the centers of the two rollers as shown in above Figure
The dimension between the two rollers is chosen to be a whole number (for easeof
later calculations)and forms the hypotenuse of a triangle when in use. Generally,
the centre distance between two cylindrical rollers is 10 inch or 100 sine
bar. mm
The important condition for the sine bar is that the surface of sine bar must be
parallel to the center lines
of the plug.
Principle of Working:
As shown in Figure the taper angle 0 of the job WX YZ is to be measured by the sine
bar. The job is placed over the surface plate. The sine bar is placed over the job with
plug or roller of one end of the bar touching the surface plate. One end of the sine
bar is rested on the surface plate and the other end is rested on the slip gauges.

Slip

gauge
O 0 Sinebar

Surtace plate

Job

The angle of the job is then first measured by some non-precision instrument, such
as bevel protector. That angle gives the idea of the approximate slip gauges required,
at the other end of sine bar. And finally the exact number of slip gauges are added
equal to height h, such that, the top most slip gauges touches the lower end of the
roller. The height of the slip gauges required is then measured. Then the taper angle
can be measured by making sine bar as a hypotenuse of right angle triangle and slide
gauge as the opposite side of the triangle as shown in Figure.
h Heightin mm
L Center distance in mm

Opposite Side h
Sin 0 L
Hypotenuse

Taper Angle 6 =Sin-1 4L

Sine Centers: It is the extension of sine bars where lwo ends are
provided on
which centers can be clamped, as shown in Figure. These are useful for
testing ol
conical work ccntcred at each end, up to 60°. The centers
ensurc correct alignment
as for sine bar. The dial
of the work piece. The procedure of setting is the sume
indicator is moved on to the job till the rcading is same at the extreme position.

Job

Dial

Indioator

Slip gaugess

Universal Bevel Protractor:

A Bevel Protractor, a graduated circular protractor having a pivoted arm and used
for measuring or marking off angles, is shown in figure below. Sometimes vernier
scales are attached to give more accurate readings.

Magnitying lense
,Working edge

Blade locking nut

Acute
Fine
angle attachment
adjustment screw

Locking nut

Scale
Stock

Vemier scale

Body Working edge

It is used measure angles accurately to 5 minutes. It is finely made tool with dial,
to

graduated degrees, a base and a sliding blade. The blade can be locked against
in
dial by tightening the blade clamp nut. The blade and dial can be rotated as one unit
to any position and locked by tightening the dial clamp nut for accurate
measurement, a vernier or a fine adjustment device, is fitted on the dial. The dial is
graduated into, it reads, , The vernier scale is divided into twelve equal parts on each
side of zero,every third division is numbered 0, 15, 30,45, 60 representing minutes.

V Block:
that are very precisely 100mm square.
The Vee-block is essentially tool steel blocks
Standard Vee-blocks come as 45 degree block, i.e. the vee-sides slope 45 degree from
horizontal or vertical, the included
angle of the vee being of course, 90 degrees. But
blocks with different angles and
shapes are also available. For special purpose such
as checking triangle cffects or for taps and other three-fluted tools, 60 degree Vce-
Dlocks are also available. The included
angle of the vee then is 120 degrees. The
major purposc of the Vee-blocks is to hold cylindrical picces, or move to the
point, to
establish precisely the centre line or axis of a
cylindrical piece. In using a vee-block,
t 1s very essential that the
cylindrical piece should rest on firmly on the sides of the
vee and not on the
edges of the vee.

H &G Magnetic V Block

and ground, Used for grinding, light Milling, Driling and
1. Allsides are hardened
inspection of round and square jobs
2. mm
Accuracy for Flatness, squareness and parallelism within 0.005 upto 150 L
and 0.010 mm for 200 L
3. Hardness above 60 RcC
4. Supplied in matched pair Uniform and
Strong magnetic pull to all three magnetic
surface Top, Bottom and V Faces
5. Easy ON OFF facility

Surface Plate
For
majority of dimension measurement and establishment of geometric accuracies,
and flat surface is
a reference datum plane required. The instrument and jobs are
kept on this
surface
for measurement and also the surface is used for direct
comparison and acts a master for checking of flatness and other characteristics of
perfectly flat plane of reference is available on
work surface. This important
methodical device known as surface plate.

Types of surface Plate:

1) Cast Iron Surface Plate. 2) Granite Surface Plate.

3) Glass Surface Plates.

Procedure:
For Vernier Calliper/Micrometer/Height gauge
1.Check the zero ofmain and vernier scale to be coinciding.
2. Read the instrument for at least three random vernier positions.
3. Measure the samples at indicated places and record as per the format

For Sine Bar/Bevel Protractor:

1. Study the bevel protractorand identify its main parts.
2. Introduce the adjustable blade in the slot of body and clamp it with the help
of knob in the convenient position.
3. Place the working edge of the stock on one surface of the job and rotate the
turret holding the blade so that the working edge of the blade coincides with
another surface of thejob. Fix the turret and read the angle. And now measure
the angles of the sample pieces with the bevel protractor and record the
reading.

Observations:
1. = =
Length of sine bar L 204 mm
2. Size, h=
3. Specimen angle with vernier bevel protractor =
4. Centre distance 200= mm
=
5. 0 Sin-1 =
6. Angle of specimen =
7. Least count of dial indicator=0.01 mm
Observation Table:
1) Vernier Caliper:

|Sr. Main Vernier Scale Least Total

Scale Reading
No. Reading Count Readinglmm)

2) Vernier Height Gauge

 Sr Vernier Scale Least Total
Main Scale Reading
No. ReadinB_ Count Readinglmm)_

3) Vernier Depth Gague

Sr. Vernier Scale Least Total
Main Scale Reading
No. Reading Count Readinglmm)

4) Micrometer
Sr. Vernier Scale Least Total
Main Scale Reading
No. Reading Count Readingimm

5) Bevel Protractor:
Sr Vernier Scale Least Total Reading
Main Scale Reading
No. Reading Count (Deg.)

6) Sine Bar:

Angle of Specimen:

Conclusion:
Hence, we have studied various types of linear and angular measuring instruments.

Experiment No:1A Date:

 Error Determinationof Measuring Instruments

Aim: Error Determination of Lincur/ Angular Mcasuring Instruments.

Apparatus:

1. Vernier
Caliper
2. Micrometer
3. Slip Gauges

Theory:
It isnever possible to measure the true value of a dimension there is always somne
error.The error in measurement is the difference between the measured value and
the true value of the measured dimension.

Error in measurement Measured value True value

The error in measurement may be expressed or evaluated either as an absolute error
or as a relative error.

Absolute Error:
True absolute error: It is the algebraic difference between the result of measurement
and the conventional true value of the quantity measured.
Apparent absolute error:If the series of measurement are made then the algebraic
difference between one of the results of measurement and the arithmetical mean is
known as apparent absolute error.
Relative Error:
It is the quotient of the absolute error and the value of comparison use or calculation

of that absolute error. This value of comparison may be the true value, the
conventional true value or the arithmetic mean forseriesof measurement.
The accuracy of measurement, and hence the error depends upon so many factors,
such as:
Calibrationstandard
- Work
piece
- Instrument
- Person

- Environment etc.

No matter how modern is the measuring instrument, how skilful is the operator, how
accurate the measurement process, there would always be some error. It is therefore
attempted to minimize the error. To minimize the error, usually a number of
observations are made and their average is taken as the value of that measurement.
If these observations are made under identical conditions ie., same observer, same
instrument and similar working conditions excepting for time, then, it is called as
Single Sample Test'.
however, repeated measurements of
conditions, such as
a given property using alternate test
different observer and/or different instrument are made, the

procedure is called as 'Multi-Sample Test'. The multi-samplc test avoids many

controllable crrors e.g., pcrsonal crror, instrument zero error etc. The multi-sample
test
is costlier than the single sample test and hence later is in wide use. In practice
good number of observations is made under single sample test and statistical
techniques are applied to get results which could be approximate to those obtainable
from multi-sample test.

Types of Errors:

.Systematic Error: These error includes calibration errors, error due to variation
in
the atmospheric condition,variation in contact pressure etc. If properly analysed,
these errors can be determined and reduced or even eliminated hence also called
controllable errors. All other systematic errors can be controlled in magnitude and
Sense except personal error. These errors results from irregularprocedure that is
consistent in action.These errors are repetitive in nature and are of constant and
similar form.

2. Random Error: These errors are caused due to variation in position of setting
and work-piece errors. Due to displacement of level joints of instruments,
standard
due to backlash and friction, these error are induced. Specific cause, magnitude and
sense of these errors cannot be determined from the knowledge of measuring system
or of measurement. These errors are non-consistent and hence the name
condition
random errors.

3. Environmental Error: These errors are caused due to effect of surrounding

temperature, pressure and humidity on the measuring instrument. External factors
like
nuclear radiation, vibrations and magnetic field also leads to error. Temperature
where high precision is required.e.g. while using slip gauges,
plays an important role
due to handling the slip gauges may acquire human body temperature, whereas the
work is at20°C. A 300 mm length bar will go in error by 5 microns which is quite a
error.
considerable To avoid errors of this kind, all metrology laboratories and
standard rooms worldwide are maintained at 20°C

4. Alignment Error (Cosine Error): This error is based on Abbes principle of

that the line of measurement of the measuring component
alignment which states
should coincide the scale or axis of the measuring instrument. These
with measuring
errors are caused due to non- alignment of measuring scale to the true line of
dimension being measured. Cosine errors will be developed generally while
measurement of a given job is carried out using dial gauge orusing steel rule.
The axis or line of measurement of the measured portion should exactly coincide
with the measuring scale or the axis of measuring instrument, when the above thing
 Job
Steel rule
does not happen then cosine error will occur. To
measure the actual size of the job
L, using steel rule it is
necessary that the steel rule axis or line of measurement
should be normal to the axis of the
job as shown in Figure. But sometimes due to
non-alignment of steel rule axis with the job axis, the size of job 1 measured is

oa*o*samo*********** *******

different than the actual size ofjob L, as shown in Figure.

5. Elastic Deformation or Support Error: Long bars due to

improve support or due
to self weight may undergo deflection or As shown
may bend. in Figure, due to less
or high distance between the support, A long bar tends to deform.

* ****. ..
*******
...
*****
*****.. T *********neo**..

(a)

***

Such errors can be reduced the distance between the support point is
kept as 0.577
if

of the total distance of bar as shown in Figure.

 S 0.577L

6. Contact Error: The rings as show in is to be measured.

Figure whose thickness
Number of times, the contact of jaws work with
piece plays an important role while
measure in laboratoryor work shops. The followingexample shows the contact error.
If the jaws of the instrument are placed as shown in Figure the error 'e' is developed,

which is because of poor contact only.

Jaws of instrument

error

Work piece

7. Parallax Error (Reading Error): The position of the observer at the time of taking
a reading (on scale) can create errors in measurement. For this two positions of the
observers are shown (X and Y), which will be the defect generating positions. Position
Z shows the correct position of the observer i.e. he should take readings by viewing
eye position exactly perpendicular to the
scale

IINAI Scale

Wrong position
of observer Wrong position
of observer

Comect
poston
of observer
Uncertainty:

easurement uncertainty is a non-negative parameter characterizing the dispersion

O he values attributed to a measured quantity. The uncertainty has a probabilistic
and reflects incomplete knowledge of the quantity. All measurements are
basis
to
Subject uncertainty and a measured value is only complete if it is accompanied by
a statement of the associated uncertainty. Relative uncertainty is the measurement
uncertainty divided by the measured value.

of a measurement is found by repeating the measurement enough

he uncertainty
to aget good estimate of the standard deviation of the values. Then, any single
times
value has an uncertainty equal to the standard deviation. However, if the values are
then the mean measurement value has a much smaller uncertainty, equal
averaged,
to the standard error of the
mean, which is the standard deviation divided by the
square root of the number of measurements. This procedure neglects systematic
errors.

Uncertainty depends on both the accuracy and precision of the measurement

instrument. The lower the accuracy and precision of an instrument, the
larger the
measurement uncertainty is. Notice that precision is often determined as the
deviation of the repeated measures of a given value, namely using the same
standard
method described above to assess measurement uncertainty. However, this method
is correct only when the instrument is accu e. When it is inaccurate, the
uncertainty is larger than the standard deviation of the repeated measures, and it
appears evident that the uncertainty does not depend only on instrumental precision.
Percentage error can be calculated by,

Percentage Error (Uncertainty/ Measured Value)" 100

Observations:

1) Uncertainty Vernier Caliper =tl

of mm
2) Uncertainty Micrometer
of =t 0.5 mm
=
3) Least count of Vernier Caliper 0.02 mm
4) Least count of Micrometer= 0.01 mm
Observation Table:

1) Absolute Error

1) For Vernier Calipcr

Sr. Error
True Value (mm) Measured Value(mm)
No.

2) For Micrometer:

Sr. Error
True Value (mm) Measured Value(mm)
No.

2) Percentage Error:

Measured
% Error=
Sr. Error
Name of Device (Error/measured1
No. Value(mm) value)* 100

Conclusion:

Calculated Measured Value and find out various types of Errors, uncertainty,
and percentage
determination of uncertainty and calculation of absolute errors
errors.
Experiment No: 2 Date:

Design of Gauges Numerical

 Experiment No: 3 Date:

Identification of Surface Pattern & Measurement of

Surface Roughness

Aim: To measure surface roughness using surface roughness tester.

Apparatus:
1) Surface roughness tester,
2) Standard Specimen,
3) Slip Gauge.

Theory:
Surface roughness, often shortened to roughness, is a component of surface texture.

quantified by
It is the vertical deviationsof a real surface from its ideal form. If these

deviations are large, the surface is rough; if they are small, the surface is smooth.
Roughness is typically considered to be the high-frequency, short-wavelength
component of a measured surface. However, in practiceit is often necessary to know
both the amplitude and frequency to ensure that a surface is fit for a purpose.

Roughness plays an important role in determining how a real object will interact with
environment. Rough surfaces usually wear more quickly and have higher friction
its
coefficients than smooth surfaces. Roughness is often a good predictor of the
performance of a mechanical component, since irregularities in the surface may form
sites for cracks or corrosion.On the other hand, roughness may promote
nucleation
adhesion.

is often undesirable, it is difficult and expensive to control in

Although roughness
manufacturing. Decreasing the roughness of a surface will usually increase
exponentially its manufacturing costs. This often results in a trade-off between the
manufacturing cost of a component and its performance in application

Evaluation of Surface Roughness

1) C.L. A. Index: (R.)

The C.L.A index (Ra) means Centre Line Average index. To calculate the value of Ra,
from a graph, it is necessary to have a mean line. The mean line can be drawn along
 the direction of the surfacc profile and
dividing the profile in such a way that the
arca above the line
should approximately cqual to the arca under the line. Then
Suitablc length L is sclccted
which is callcd sampling length for the givcn surface.
Then average
hcight Ha is calculatcd as follow,

Ha Summnation of all area aobve and below line

Sampling Length

Then the C.L.A index can be calculated

by considering horizontal and vertical
magnification as,

= Ha
C.L.A. index
yxH x 1000um
Where, V =Vertical Magnification,
H Horizontal Magnification

Consider a surface having following surface

profile,

A Ha

Theaverage height Ha = (A1+A2+A3)+

L
(B1+B2)

(A1+A2 +A3)+(B1*DEx
Ra 1000microns
L

2) R.M.S. Average: (Rq)

R.M.S. average means Root mean square- number. It is the geometrical average of
the ordinates of the profile about the mean line. The mean line or centre line is
 located such that the sum of the areas albove the line is
approximately equal to sum
ot the areas below the line. If n
measurements are made from the mean line above
and below to the points on the surfacc
profilc, which arc denoted by Y,. Then the
RM.S. Value is the positive
square root of the arithmetic mean of the squares of the
Y, values in the set.

Ryms
For the surface profile given below, the R.M.S value can be calculated as,

Mean line

Rpms n

Rms =Rg = f+ys+Yn t...+yí

The R.M.S value is slightly greater than the Ra value for same profile. The ratio of
two depends upon the shape of theprofile. In general R.M.S value is equal to 1.11
times the Ra value.

Rq 1.11 Ra

Observations:
1) Ra value of Standard Specimen= 2.94 um
2)Measuring force= 4 mN
3) Stylus tip radius- 5 um
4) Cut-off Length=
Observation Table:

Sr. Actual Value Experimental Experimental

No Reading Over
(Ra) value (Ra) value(Rg)_
Standard Specimen 2.94 um
2 Standard Specimen
0.012-0. 16
(Lapped
Lapped Surface)
3 Slip Gauge 0.012-0.116

Conclusion:

Hence, we have studied surface roughess measurement, various devices used for
surface roughness measurement and evaluation of surface roughness. The results
of measuremnet are given in observation table.
Eperiment Nor 4 Date:

Determination of Geometry by using Profile Projector

Aim Determination of geometry & dimensions of given composite object using profile
prrect.

Bpparatus: Profile Projector, Test piece.

Specificatíons:
Srren diameter: 200mm,
Ae.rylic Sreen wíth 90° cross ine,
Standard magnification-10x, 20.
Dimensions
Height z Depth Width 800mm z420mm x 370 mm
Theory:

A projector is an optícal measurement tool that magnifies a sample's surface

profile
Seatures allow measurement on a linear/circularscale.A profile Projector is also
to
reserred to as an optical comparator, or even known ás a shadowgraph. A profile
projectorprojectsa magnified profile image of an area or feature of a work piece onto
a screen most commonly using diascopic illumination.Dimensions can be measuredd
directly on the sCTeen or compared to a standard reference at the correct
magnificatíon. For accuracy, it ís important that the magnification does not change
with perspective,í.e. its position or the view point of the operator. Telecentriclenses
are, therefore, híghly desirable.The screen often has a grid and this grid can often
be rotated through 360 degrees to align with an edge as displayed on the screen.
Point posítíons, measurements, and calculations may also be performed using a
simple diggtal read out device.A computer may be added to a profile projector system
for edge detectíon,thereby elimínating some human error.

Applications:
Profile projectors are robust measuring tools commonly used in machine shops,
qualíty assurance departments and occasionallyon assembly shop floors. They are
suitablc for measuring and quality control for a wide range of size and weights of
objects. The most basic use of a profile projector is to identify a point or edge on the
shadow and from this point to calculate a length. By magnifying the image, the
operator is less likely to make a mistake when deciding where the edge or point starts.
Profile images can also be used to make simple stop / go decision by, for example,

matching an image against a standard to determine whether a part has been made
correctly.
 Sctecn

Reflecting
misot

Micometed

JTable

Condensing
Lens

-Líght souYte

Fig 8.1 Profile Projector

Preparing forWork:
There are three basic requirements for perfect working of Profile
Projector is
A clean optical system
Accurately centered lighting
Careful focusing of the image
All optical parts must be
perfectly clean otherwise the projected image will appear
the glass of episcopic lighting mirror with the
dull without sharpness. Never touch
fingers as they are extremely sensitive.

Procedure:
1. Switch on the optical profile projector.
2. Place the clean workpiece on the glass of the profile
projector table.
3. Focus it properly by moving the housing wheel and moving the work table to
obtain the correct magnified image of the object.
4. Horizontal (X-axis) measurement can be taken on right hand side micrometer
and the vertical measurement from side micrometer.
5. To measure pitch take the distance between similar points on adjacent flank
t to or root on another adjacent threads parallel to the axis of the screw
threads. reference line
Por achieving this adjust the of the profile projectorto
corresponding point and note the micrometer readings between points.
6. Adapt similarprocedure for the measurement of the depth of screw.
7. For measurement of thread angle match the reference line betweern flanks and
note down the angle.
 8. lmage of
component can be compared with master template or chart.

Observation Table:

For Measuremcnt Sr. No. Initial Final

Difference
Reading Reading
1

2
1

2
1

Results:
1) Pitch Given Specimen
of

2) Angle of Given Screw Thread

3) Depth of Given Specimen

Conclusion:
Hence by using profile projector we have measured various parameters of screw
thread such as Pitch, Depth and Angle of screw thread. The results are given above.
Experiment No: 5 Date:

Verification of geometry by using Mechanical Comparator

Aim: Verification of dimensions & gconctry of given components using Mechanical

& Pnelmatic comparator

Apparatus: Dial Indicator,V-Block, Stand, Work-piece.

Theory:
The comparator is a device which takes a dimension of standard job as reference
dimension, and gives a reading to a pointer on a scale, the variation in such
dimension of the job to be compared.

Itoperates on the principle, that a very slight upward pressure on the spindle at the
contact point is multiplied through a system of gears and levers. It is indicated on
the face of the dial by a dial finger. Dial indicatorsbasically consists of a body with
a round graduated dial and a contact point connected with a spiral or gear train so
that hand on the dial face indicates the amount of movement of the contact point.
They are designed for use on a wide range of standard measuring devices such as
dial
box gauges, portal dial, hand gauges, dial depth gauges, diameter gauges and
dial indicator snap
gauge.

Dial indicator

Work space

12

Stand
V block

77777777777777 777777
They are available in dial 0.01 and some sensitive type of gauges has
graduations of
graduations of 0.002 mm. One of dial finger corresponds to a spindle
revolution
movement of 1 mm. The movement mechanism of the instrument is housed in a
case for it's protection. The large dial scale is graduated into 100 divisions. The
metal
indicator is set to zero by the use of slip gauges representing the basic size of part.

Procedure:

In this method the dial indicatoris placed above the work piece, as shown in
figure
above. The work piece whose roundness is to be measured is divided into 12 equal
parts. The work piece is then held in the V-block. The work piece is kept in such a
way that the dial indicator touches the work piece at position 1. The work piece is
then rotated to position 2 to position 12 successivelyand the variation in the surface
profile isnoted by the dial indicator. The procedure is repeated atleast three times to
get the higher accuracy and the average value of the reading is taken. Then a circle
of diameter
equal to 4 times the maximum value of the reading is drawn and then
the circle is again divided into 12 equal parts. Inside the circle a small concentric
Circle of suitablediameter (say 0.5 times of work piece diameter) is drawn.

The values of readings at various position are plotted between as small concentric
circle and maximum diameter circle. The points at various positions are joined by

straightlines to get the actual profile of the work piece. The error is then obtained by
measuring the radial distance between minimum circumscribing circle and
maximum inscribingcircle.

Observation Table

Sr. Indicator Indicator Indicator Averagee

No Angle 2 3
Reading1 Reading Reading Reading

2 30

3 60

4 90

5 120

6 150

7 180

8 210
 99 230

10 270

11 300

12 330

Conclusion:
Hence we have measured the roundness using the mechanical comparator.
Roundness of given work piece is shown in polar graph.
 Date:
Experiment No: 6
Measurement of Spur Gear Parameters

Gear Tooth Vernier, Span, Gear

Am
Rolling
Measurement of spur gear parameters using
Tester

Vernier Caliper etc.

Apparatus: Gear Tooth Vernier Caliper, Gear,

Theory:
the height on
This type of vernier Caliper with vertical slide which controls
is special

the gear tooth at which the measurements are taken. The gear tooth thickness can
be conveniently measured by a gear tooth vernier as shown in the fig. Since the gear
tooth thickness varies from the tip to the base circle of the tooth, the instrument
must be capable of measuring the tooth thickness at a specified position on the tooth.
The gear tooth vernier has two vernier scales. The vertical vernier scale is used to set
the depth (d) along the pitch circle from the top surface of the tooth at which the
width (w) has to be measured. While the horizontalvernier scale is used to measure
the width (w) of the teeth

3 56 10
HAR-

pitch circle
Fig. Gear Tooth Vernier Caliper
TERMINOLOGY OF GEAR TOOTH
Pitch circle diametcr (PCD): thc diameter of a circle which by pure rolling
It is

action would producc thc samc inotion on thc toothcd gear whccl. It is equal
toD = (NX OD)/(N+2)
Where, OD =outside diameter, N number ofteeth
ii. MODULE (m): It is defined as the length of the pitch circle diameter per tooth.
Module m=D/N and is expressed in mm.
iii. CIRCULAR PITCH (CP): It is the arc distance measured around the pitch circle
from the flank of one truth to a similarflank in the next tooth
CP= (1D)/T= (TTm)
iv. ADDENDUM: This is the radial distance from the pitch circle to the tip of the
tooth. It is equal to one module.
V. Clearance: This is the radial distance from the tip of a tooth to the bottom of
the mating tooth space when the teeth are symmetrically engaged. Its standard
value is 0.157m or 0.25m.
vi. DEDENDUM: This is the radial distance from the pitch circle to the bottom of
tooth space.
Dedendum =Addendum +Clearance m +0.157m =1 .157m.to 1.25m (metric
gearing system)
vii. TOOTH THICKNESs: This is the arc distance measured along the pitch fromn
the interceptswith one flank to the interceptswith the other flank of the same
tooth.

-Addendum circle

Addendum width
Face Top land

-Pitch surface element

Dedendum

Face Working depth

Flank Pitch circle

Tooth thickness
Circular pitch

Total depth Tooth space

Root
Clearance ordedendum circle
Clearance or
working depth circle
Procedure:
1. First find the Outer diameter (OD) of gear by vernier Caliper and also measure
no. of teeth(N)on
gear.
2. Calculate Pitch Circle Diameter (PCD)=D= (N* OD) /(N+2)
3. Find the addendum, clearance, pitch, module and dedendum as per the
formulae.

FOR CHORDAL TOOTH THICKNESS (using gear tooth calliper):

1.
Setthe chordal depth (addendum) on the vertical slide of the gear tooth vernier

and then insert the jaws the instrument on the tooth to be measured.
of
2.
Adjust the horizontalvernier slide by the fine adjusting screw so that thejaws
just touch the tooth.
3.
Read the horizontal vernier slide and note the reading. It gives the chordal
thickness of tooth.
4. Repeat the observations for the different teeth.
5.
Compare the values of different characteristics with the standard value and
set the percentage error.

Formulae:
Chordal Thickness: w =N.m Sin ()
90

Chordal Addendum: d ="(1+-Cos (

Observations:
1) Least count of Gear tooth vernier caliper:

2) Least count of vernier caliper:

Observation Table:
1)Chordal Addendum:
TheoreticalValue
Sr. No Practical Value d Error
W d
2)Chordal Thickness

TheoreticalValue
Sr. No Practical Value w Error
d W

Calculations:

Pitch Circle Diameter (D)=

Module (m) =
Chordal Thickness (w)=
Chordal Addendum (d)=

Conclusion:
The measurement of gear tooth parameters is done by gear tooth vernier caliper. The
errors in each case are found out by comparing theoretical value with practical value
given by empirical relations.
Experiment No: 7 Date:

Speed Measurement and calibration of photo and magnetic speed pickups for
the measurement of speed by using Stroboscope.

Aim: To measure the Spced by an optical method called as Stroboscope.

Apparatus:

1. Xenon Flash Lamp

2. Adjustable Motor

3. Marked Rotating Wheel

4. Stand for set up

5. Power Supply

Procedure:

1. Check the connections of the equipment.

2. Select the mode of operation on Xenon flash lamp (Hi/lo).

3. Make a mark on the rotating wheel.

4. Now switch on the Xenon flash lamp and adjust that the light exactly projected on the

rotating wheel.

5.
Adjust the speed of the motor such that ONE STATIONARY mark is visible on the wheel.
Note down the reading in the tabular column.

6. Now adjust the sped of the motor such that Two Stationary marks are visible and note the

readings.

7. Similarly for Three and more marks and note the readings.

Observation Table

S.No No.of images Reading on the Frequency

Xenon Flash Lamp

Conclusion- Study and measurement of speed is done by using optical method

Experiment No:8 Date:

Calibration of Pressure gauge by using Dead weight

Aim:To study the working of Bourdon calibration of the

Pressure Gauge and to check the
gauge in a deadweight pressure gauge calibration set up.

Apparatus used: Deadweight Pressure Gauge calibration set up, Bourdon tube Pressure
gauge.

Theory: These areused for measurement of pressure and vacuum and are suitable for all

clean and non-cloggingliquid and gaseous media. Bourdon gauge consists of a hollow metal
tube with an oval cross section, bent in the shape of a hook. It is made of phosphorous

bronze, glass beryllium or copper.One end of the tube is fixed and open at one end to
receive the pressure which is to be measured. The other end of the bourdon tube is free and

closed. The cross-section of the bourdon tube is elliptical. The bourdon tube is in a bent form
to look like a circular arc. To the free end of the bourdon tube is attached an adjustable link,

which is in turn connected to a sector and pinion as shown in fig. To the shaft of the pinion
is connected a pointer which sweeps over a pressure calibrated scale.

Scale

Bourdon
tube

Spring
Tip

Pinion Adjustable Link

Sector
Segment lever

Pivot

stop

Socket
 Fig.: Bourdon Tube Gauge

to the
Working Bourdon Pressure Gauge The pressure to be measured is connected
of the
walls of the
fixed open end of the bourdon tube. The applied pressure acts on the inner
-
bourdon tube. Due to the applied pressure, the bourdon tube tends to change in cross section
from elliptical to circular. This tends to straighten the bourdon tube causing a displacement
of the free end of the bourdon tube. This displacementof the free closed end of the bourdon

tube is proportionalto the

appliedAs the free end of the bourdon tube is connected
pressure.
to a link -section -pinion arrangement, the displacement is amplified and converted to a
motion of the pinion. As the pinion rotates, it makes the pointer to assume a
new
rotary

position on a pressure calibrated scale to indicate the applied pressure directly. As the
pressure in the case containingthe bourdon tube is usually atmospheric,the pointer indicates

gauge pressure. Advantages of Bourdon tube pressure gauge: 1. These Bourdon tube pressure
gauges accurate results. 2. Bourdon tube cost low. 3. Bourdon tube is simple in
give
for high
construction. 4. They can be modified to give electrical outputs. 5. They are safe even
pressure measurement. Limitations of bourdon tube pressure gauge: 1. They respond slowly

to changes in pressure. 2. They are subjected to hysteresis. 3. They are sensitive to shocks and

vibrations. 4. Amplification is a must as the displacementof the free end of the bourdon tube
. is low. 5. 1t cannot be used for precision measurement. Calibration: Calibration is the name of
the term applied to checking the accuracy or the working condition of the concerned device.
So, the calibration of Bourdon Pressure Gauge refers to the checking of its accuracy or
reliability in taking a reading. The apparatus used for this purpose is called the Dead-Weight
Gauge Tester. Dead weight Tester: The dead weight apparatus consists of a chamber
tester

which is filled with oil free impurities and a piston - cylinder combination is fitted above the
chamber as shown in diagram. The top portion of the piston is attached with a platform to
carry weights.
A plunger with a handle has been provided to vary the pressure of oil in the

chamber. The pressure gauge to be tested is fitted at an appropriateplate. The dead weight
tester is basically a pressure producing and pressure measuring device. It is used to calibrate
pressure gauges. Calibration of pressure gauge means introducing an accurately known
sample of pressure to the gauge under test and then observing the response of the gauge.
 Dead weight Tester

Test
gauge weights Handle
platform
Limit

Vave stops cylinder

Piston

plunger

Oll

Fig: Dead weight Tester

Procedure:The following procedure is adopted for calibrating pressure gauge:

1. The valve of the closed.

apparatus is

2. A known weight is placed

on the platform.

to the other side of the piston until

3. Now by operating
is
the plunger, fluid pressure applied
combination.When this happens, the
enough developed to lift the piston-weight
force is
floats freely within the cylinder between limit stops.
piston weight combination
the pressure force of fluid is balanced against the
4. In this condition of equilibrium,

force of the weights pulls the friction drag.

gravitational

Therefore, PA =Mg+F

Hence: P= Mg +F/A
where, P =pressure M =Mass; Kg g=Acceleration due to gravity; m/
F Friction drag; N A
=Equivalent area of piston -cylinder combination;m?
weights placed on the platform is calculated.
Thus the pressure P which is caused due to the

5. After calculating P, the plunger is released.

6. Now the pressure gauge to be calibrated is fitted atan appropriateplace on the dead weight
tester. The same known weight which was used to calculate P is placed on the platform. Due
 the fluid. Now the
to the
weight, the piston moves downwards and exerts a pressure P on
valve in the apparatusis opened so that the fluid pressure P is transmitted to the gauge, which
should
makes the gauge indicate a pressure This pressure value shown by the gauge
value.
other than p
be equal to the known indicates some other value
input pressure P. If the gauge
is calibrated.
the is so that it reads a value equal to p. Thus the gauge
gauge adjusted

on a
Conclusion:Hence the working of Bourdon Pressure Gauge and checking of calibration

is
deadweight pressure gauge completed
ExperimentNo:09 Date:

Study of Co-ordinate Measuring

Machines(CMM).

Aim: To study Co-ordinate Measuring Machine

Apparatus: Co-ordinate Measuring Machine

Theory:

Coordinate measuring machines (CMM) represent one of the most accurate and
flexible measuring instruments used in the metrology field. These are the main

reasons why they have become widespread throughout manufacturing

companies. Therefore, with this kind of measuring device, it is possible to carry
measurements with a high degree of precision for manufactured parts of
practically any type of shape and size.

Coordinate Measuring Machine(CMM)Parts

C D

A: Moving bridge C:Stage

D:
B:Trigger probe Controller

Equipment description:

As was mentioned above, the coordinate measuring machine used in the

present study was of the moving bridge type. Fig. 1 shows a picture of the CMM,
where it can be observed that this type of CMM has a stationarytable, made of
8ranite, which supports the part to be measured.

Fig. 1. Moving bridge coordinate measuring machine used in the present study.

Some of the advantages that this CMM configurationpresents are as follows:

higher natural frequencies (if it is compared to cantilever configuration), small to

medium measuring range and relatively small measuring uncertainties (Hocken

and Pereira (2012)).On the other hand, due to the yawing effect, which is
caused when the two CMM columns move at different speed values, the bridge
can twist, thus affecting both the CMM accuracy and precision.

The CMM used in this precision study, which belongs to the Public Universityof
Navarre, is a DEA Global Image Clima. It has an articulated probe head of type
PH10MQ and the measuring software is PC-DMISTM 3.7. As was mentioned
above, the standard uncertaintyofthe CMM is given by: uCMM =(1.7+
3L/1000) um, where L is the length being evaluated, and its measuring volume is

as follows:850 mm (X) x 1460 mm (Y) x 780 mm (2). The two contact probes

whose performances are to be compared in this present study are TP-200 and
SP-25, which can be observed in Figs. 2 (a) and 2 (b), respectively.
 (a)

Fig 2. Renishaw®contact probes utilized in the present precision study: (a)TP-200, (b) SP-25.

TP-200 is touch-triggerprobe manufactured by Renishaw which uses

a precision

strain gauge technology, thus giving a higher accuracy than kinematic touch-

trigger probes. The stylus module is mounted

on the probe via a highly

repeatability magnetic kinematic joint, providing rapid stylus changing capability

and overtravelprotection. With respectto the length of the stylus employed,

this was 20 mm and the tip was a ruby ball with a diameter of 3 mm (see

Renishaw's TP200 specifications).

Fig. 3.Machined part to be measured with both contact probes: TP-200 and SP-25

T
Measuremcnt Laboratory

The ladder to be measured consists of parallel planes with different height

values (70mm,45 mm, 25 mm and 10 mm) from the horizontal plane,
which islocated on the granite table of the coordinate measuring machine.

Fig. 4 shows the dimensions of the part in the shape of the straight ladder. The
measuring process of the part will be made at five distinct locations.
10

140
Fig. 4. Sizc dimcnsions (in mm)of the straight ladder.

Conclusion:

After having measured this part with the two previously-mentioned

contactprobes, the mean and the expanded uncertainty(following

the recommendations set out in the GUM) values of these
measurements werecalculated.

AISSMS College of Engineering Pune Page 41