Metrology Lab Manuals

DELHI SKILL AND ENTREPRENEURSHIP UNIVERSITY OKHLA-II CAMPUS
(Formerly Known as Delhi Institute of Tool Engineering)

Program: B.Tech.(Mechanical Engineering)(Affiliated to GGSIPU)
Subject Name- Metrology (Code: ETME-312)
Experiment No.-1
Aim: Study and working of simple measuring instrument like vernier caliper, micrometer and
tachometer.
Instruments used: Vernier caliper, micrometer and tachometer
Theory:
Vernier Calliper :
Vernier Calipers is the most commonly used instrument for measuring outer and inner diameters. It
works on the principle of Vernier Scale which is some fixed units of length (Ex: 49mm) divided into 1
less or 1 more parts of the unit(Ex:49mm are divided into 50 parts).
The exact measurement with upto 0.02mm accuracy can be determined by the coinciding line between
Main Scale and Vernier Scale.
Total Reading = M.S.R + L.C X V.C

Where:
M.S.R – Main Scale Reading
L.C – Least Count
V.C – Vernier Coincidence
Fig.1.1
Vernier Principle
Vernier principle is used in vernier caliper which are designed both for internal and external
measurements. Callipers are also available of the type where in arrangement there provided internal,
external and depth measurements. The unit consists of a rectangular steel bar with graduates main
scale made integral with the fix jaw and sliding jaw carries the vernier scale, slides along the main
scale and can be fixed at any position by the locking screws.
Generally when the two jaws touches each other, the zero of the vernier scale consides with zero of
the main scale. If it not so, here is zero error which must be accounted for.
Fig.1.2
Procedure:
1. The Least Count is to be determined.

L.C = (Minimum Main Scale Reading) / (No. of Vernier Scale Divisions)
2. The workpiece is placed between the jaws of Vernier Calipers correctly.
3. The reading on Main scale which is just behind the first Vernier Scale Division is noted as Main
Scale Reading.
4. The Division on Vernier Scale which coincides with the line on Main Scale is noted down as
Vernier Coincidence.
5. The Diameter can be calculated using the given Formula.
Fig.1.3
Observation:
S. No. Main Scale Vernier Zero error Vernier Total

Reading Scale Scale Dimension
(in mm) coincidence Reading (in mm)
(in mm)
1 10 51 0.0 1.02 11.02
2 10 51 0.0 1.02 11.02
3 10 52 0.0 1.04 11.04
4 10 50 0.0 1.00 11.00
Micrometer:
Vernier calipers can measure accurately up to 1/10 of a mm. For greater accuracy which is essential
in the measurement of small sizes such as the diameter of a wire, thickness of a metal plate etc. we
use a micrometer screw guage. Micrometer screws are designed according to the screw and the nut
principle where calibrated screw thread and a circular scale division are are scale division.
Fig.1.4
The semicircular frame carries affixed anvil at one extremity and a cylindrical barrel at the other
end. A fine accurately cut screw of uniform pitch is machined on a spindle. The spindle passes
through the barrel and its left hand side constitutes the movable anvil. A sleeve fits on the screw and
carries on its inner is edge (called thimble) a thimble or circular scale division divided into desired
number of divisions. The spindle with its screw and the thimble are in one piece and sleeve forms
the nut. The thimble scale serves to measure the friction of its circular rotation. The number of
complete rotations is read on the main (or pitch) scale which is graduated in mm on the nut parallel
to axis of the screw.
The least count or the screw refers to the distance through which the screw moves forward or
backward when the head (thimble) is rotated through one division on the thimble (circular) scale.
Least count = Pitch of the screw/ No. of divisions on the circular scale
If the pitch of the screw is 0.5 mm, and the circular scale has 50 division mark on it , then .
Least Count = 0.5/50= 0.01mm= 0.001cm
Procedure:
1. The least count is to be determined.
2. The w/p is placed between the two anvils after the instruments are adjusted for zero error.
3. Work piece is held strongly without applying under pressure on the instrument.
4. The value of the main scale is noted down. The main scale division just coincides with the index line.
This is called the main scale division which just procedures edge of the main scale is noted down.
This is called thimble scale reading (T.S.R).
Fig. 1.5
Diameter of workpiece is given by:
D = Main Scale Reading + L.C * (Thimble Scale Coincidence ± error)

Observation:
S. No. Main Scale Vernier Zero error Vernier Total
Reading Scale Scale Dimension
(in mm) coincidence Reading (in mm)
(in mm)
1 9.5 24 0.0 0.024 9.524
2 9.5 23 0.0 0.023 9.523
3 9.5 24 0.0 0.024 9.524
4 9.5 21 0.0 0.021 9.021
Tachometer:
Angular measurements are made with a device called Tachometer. It is an instrument used to
measure angular velocity as of shaft, either by registering the number of rotation during the period
of connector by indicating directly the number of rotation per minute. It is an instrument which
either continuously indicate the value of rotary speed, or continuously displays a reading of average
speed over rapidly operated short interval of time.
Fig.1.6
Tachometer Classification:-
Tachometer may be classified in to two categories
1. Electrical tachometer
2. Mechanical tachometer
Electrical tachometer:
An electrical tachometer depends for its indication upon an electrical signal generated in proportion
to the rotation speed of the shaft. Depending on the type of transducer, electrical tachometers have
been constructed in a variety of different designs.
Mechanical tachometer:
This tachometers employ only mechanical parts and mechanical movement for the measurement of
speed.
Experiment No.-2
Aim: Measurement of angle using Sine bar & Slip gauges.
Apparatus: Sine Bar, Slip Gauges, Granite Surface Plate and dial gauge with stand.
Theory: The sine principle uses the ratio of the length of two sides of a right angle in deriving a
given angle. Sine bar is based upon laws of trigonometry. To set a given angle one roller of the bar
is placed on the surface plate and the combination of slip gauges is inserted under the second roller
as shown in the figure.
It is a simple instrument which can be easily used for setting and measuring angles. Fairly high
accuracy can be expected when measuring smaller angles that is less than 450 .
h2
h1
Taper Angle, θ = Sin-1(h2-h1)/l
Where, h2 = Max. Height

h1 = Min. Height
l = size of Sine Bar
Procedure:
The work piece is placed over a surface plate and the Sine Bar made to rest against the inclined
surface of the taper piece. Make two piles of slip gauge set, then finding h1 and h2.
Precautions:
(1) Dust and air particles must be removed from slips gauge.
(2) Wringing is must before making piles.
Observations:
(1) Length of sine bar = 200 mm
(2) Height of one end h1 = 25 mm
(3) Height of other end h2 = 78.6mm
Calculations:
Sin θ = (h2-h1)/l
θ = Sin-1((h2-h1)/l = 15.5
Result:
Taper angle of a given piece is 15.5
Experiment No.-3
Aim: To study the limit gauges.
Apparatus: Plug gauge, snap gauge, ring gauge and taper gauge
Theory:
Gauges are inspection tools of rigid design, without a scale, which serve to check the dimension of
manufactured parts. Limit Gauges are also called “go” and “no go” gauges. These are made to the
limit sizes of the work to be measured. One of the sides or ends of the gauge is made to correspond
to maximum and the other end to the minimum permissible size. The function of limit gauges is to
determine whether the actual dimensions of the work are within or outside
the specified limits. A limit gauge may be either double end or progressive. A double end gauge has
the “go” member at one end and “no go” member at the other end. The “go” member must pass into
or over an acceptable piece but the “no go” member should not.
The progressive gauge has “no go” members next to each other and is applied to a workpiece with
one movement. Some gauges are fixed for only one set of limits and are said to be solid gauges.
Others are adjustable for various ranges.
A snap gage is a form of Go/no go gauge. It is a limit gage with permanently or temporarily fixed
measurement aperture(s) (gaps) which is used to quickly verify whether an outside dimension of a
part matches a preset dimension or falls within predefined tolerances. The surfaces which define the
edges of the aperture are the anvils, which may be made of separate pieces of hard material such as
tungsten carbide for wear resistance.
Plug gauges 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.
The taper plug gage is an internal gage in the shape of the frustum of a cone. It is used to measure
internal tapers. It has wide application in design engineering, mechanical engineering and water
flow engineering.
A ring gauge, or ring gage, is a cylindrical ring of a thermally stable material, often steel, whose
inside diameter is finished to gauge tolerance and is used for checking the external diameter of a
cylindrical object.Ring gauges are used for comparative gauging as well as for checking,
calibrating, or setting of gauges or other standards. Individual ring gauges or ring gauge sets are
made to variety of tolerance grades in metric and English dimensions for master, setting, or
working applications.
Fig.3.1
Fig.3.2 Fig.3.3
Fig.3.4
Procedure:
While checking each of these two gauges are offered in turn to the work. A part is considered to be
good if the GO gauge passes through or over the work and NO GO gauge fails to pass under the
action of its own weight. This indicates that the actual dimension of the part is within the specified
tolerance. If both gauges fail to pass, it indicates that the hole is undersize or shaft is oversized. If
both gauges pass, it indicates that the hole is oversize and shaft is indersize.
Precaution:
1. As a gauge has a sharp portion to satisfy requirements for its function, concern about
avoiding injury.
2. Be sure to check that the gauge and handle are not loose before use.
3. Before using a gauge, check the gauge for any rust, flaw, burr, etc.
4. When using a limit gauge, check that GO gauge passes and then check that NOT GO gauge
stops.
5. Check that dust and cuttings accumulated on the product have been thoroughly removed,
and then inspect the product with a gauge.
6. Do not hit the gauge by strong force.
Experiment No.-4
Aim: Study and angular measurement using bevel protector.
Apparatus: Bevel Protractor, V-Block
Theory: It is probably the simplest instrument for measuring the 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 containing Vernier scale. The adjustable blade is capable of rotating
freely about the center of main scale engraved on the body of the instrument & can be locked in any
position an acute angle attachment is provided at the top for the purpose of measuring acute angle
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 – 360. The vernier scale has 24 divisions
coinciding with 23 main scale divisions. Thus the least count of the instrument is 5’. This
instrument is most commonly used in workshop for angular measurement till more precision is
required.
Fig.4.1
The Vernier principle can be applied for increasing the accuracy of angular measurements. In the
Vernier Protractor the main scale is fixed to degrees and 23 degrees of the main scale are divided on
the Vernier scale into 12 equal divisions. The difference between the width of one division on the
Vernier scale and two divisions on the main scale is 1/120
Therefore each division on the Vernier is shorted by 12 tab two divisions on the main scale.
Least count of Vernier Bevel Protractor = Value of 1 division of the main scale (Circular scale) /
Total No. of division on Vernier scale
=20 - 230/ 12 =1/120=360’/12=5’
Procedure:
Take the V-Block between the fixed blade and sliding blade on the Vernier Bevel Protractor and the
read total angle.
Observation:
S.No. Main Scale Reading Vernier Scale Reading ×L.C. Total Reading = M.S.
+V.S.
1
2
3
Results: Angle of the V-Block is= 45
Precaution:
1. Take precise measurement.
2. Excess pressure must not be applied on the object for taking the reading.
Experiment No.5
Aim: To adjust spark plug gap using feeler gauge.
Apparatus: Feeler gauge, spark plug
Theory:
Feeler gauges are used to measure the width of the gap between two parallel flat faces e.g. in
gauging of the clearance between the piston and cylinder. A feeler gauge consists of a narrow strip
of sheet steel made to a given thickness. The complete set consists of a number of gauging blades of
different thickness assemble together. Their working depend entirely on the sense of feel the feeler
blade should neither before between the surface nor should it slide freely, rather the correct blade
will give a characteristic gauge fit type of feel. If necessary, two blades may be joined together for
nothing any dimension.
Fig.5.1
Feeler gauge generally comprise of a series of gauging blade of different grades and thickness, from
0.03 to 1 mm assembled in protective sheath. The blades are made of heat treated bright polished
tool steel. Generally the blades are available in over all length of 100 mm. These are 12 mm wide at
heel and are tapered for the outer part of their length so that the width at the tip is approximately
6mm. These are hinged in the sheath on a screw and nut of such a design that the blades are
removable. The nut is in the form of bush, passing through both sides of the sheet and form a hinge
upon which the blades may be rotated. The sheath is so design as to fully protect the blades when
not in use.
Each blade is legibly and permanently marked with the nominal thickness and grade. These are
available in two grades depending upon the accuracy. The various blades should be assembled in
such a way that each thin blade is given the maximum protection by being inter-leaved between two
thicker blades. The maximum variation in the thickness of blades should not exceed .04 mm for
blades up to and including 0.3 mm thick.
Procedure:
The gap between the center and side electrodes of a spark plug must be an exact distance;
otherwise, your plugs don’t fire efficiently. Adjusting the distance between the two electrodes is
called gapping your spark plugs. A feeler gauge is needed to gap the spark plugs properly.
The following steps explain how to gap spark plugs:
Fig.5.2
1. During regapping a used plug, it is assured that it’s clean (gently scrub it with a wire brush).
If plug is new, it should be clean and new-looking, with the tip of the side electrode centered
over the center electrode.
2. Select the proper number on your feeler gauge, and run the gauge between the electrodes. If
the gauge doesn’t go through, or if it goes through too easily without touching the
electrodes, you need to adjust the distance between the electrodes.
3. If the wire didn’t go through, the gap is too narrow. Hook the part of the feeler gauge that’s
used for bending electrodes under the side electrode and tug very gently to widen the gap. A
feeler gauge is shown here. If the gauge goes through too easily without touching the
electrodes, the gap is wide. Press the side electrode very gently against a clean, mar-proof
surface until it’s slightly bent down toward the center electrode.
4. Run the gauge through the gap again.
Experiment No.6
Aim: To study the Dial indicator and its constructional details.
Theory: Dial indicators are instruments used for making & checking linear measurements. Dial
indicators are small indicating devices containing a graduated scale & these depend upon gear &
pinion or liver magnification system. These are generally used as comparators. Some dial indicator
know as dial micrometer or thickness gauges however, used for actual (direct) measurement
(without comparison). When dial indicator is used as essential part in the measurement purposes, it
is referred to as dial gauge.
A good Dial Indicator should exhibits some important aspects, which are listed below:
[I] The instrument should be capable of giving a trouble free measurement over a long period of
time without attention.
[II] No oscillation should be present in the pointer, when reading are being taken.
[III] There should be some precision to avoid damage to the instrument due to larger movements of
the plunger than the specified amount on scale.
[IV] Instruments is likely to be used in such a way that plunger may move sharply in either
direction
[V] The relative movements of the pointer and scale should be such as to suggest the direction of
the movement of the measuring plunger.
Fig.6.1
Working:
There is a plunger, which is a perfect sliding fit in its bearings. This carries a rack, which accurately
meshes with a pinion A . A pin attached to it , which is located in a slot in a rack guide G, prevents
the rotation of plunger abuts its own axis .In order to keep the plunger in an extended position a
light spring S is employed . A small movement of contact point causes the two term the pinion A
with which it is meshed. A longer gear B is attached to the same spindle As pinion A . The B is
further meshed with a pinion C, which thus magnifies the movement of pinion A . Attached to the
second pinion C is another gear D, which meshes with a third pinion E mounted on the same
spindle as the indicator pointer.
Fig.6.2
The over all magnification is thus
(Td/Te)*(Tb/Tc)
Where Tb,Tc etc , represent the no. of the teeth of gears B&C respectively.
This magnification is further enlarged at the of the pointer by a amount depend upon its length,
Parts:
(i) Contact point:-
In order to make the dial indicator more versatile in its use, the arrangement is provided to change
the contact point. The measuring plunger is tapped out and corresponding threads are provided at
end of contact point. They are generally made of hardened steel and blackened to avoid the rusting
(ii) Tolerance Pointers:-
For rapid checking of parts, tolerance Description of Various Parts .Once pointers can be attached
to the dial face. By these any tolerance can be clearly indicated on the dial gauge.
(iii) Special Stems:-

Where deep recesses are to be inspected, long stem indicators are available.
(iv) Shock Proof Cushion Movement:-
Some dial indicators are designed to with stand sudden shock due to rough usages at the same time
it reads correctly. In such indicators, before impact reaches indicator movement, it is cushioned by
specially loaded attachment on the plunger.
(v) Lever Attachment:-
They are very useful and facilitate the work of machine setting. The awkward corners and recesses
can be easily gauged by this attachment.
Experiment No.7
Aim: Use of dial indicator to check a shape run.
Apparatus: Dial Gauge, Slip Gauge, Dial Gauge Indicator
Procedure For Slip Gauges:
1. The slip gauges are cleaned by using cloth
2. The thickness of the given MS plate is determined to the nearest 0.1mm size by using
micrometer.
3. The slip gauges are selected to built up required dimension.
4. Required combination of slip gauges is built up by wringing.
5. The jaws and the built up gauges are held in the holder.
6. The given MS plate is placed between the flat surfaces of the measuring jaws and the thickness of
the plate is measured.
Observation:
Slip gauge
For linear measurement least count = (0.2/200)=0.001 mm/div
For standard dimension
For specimen
Main scale reading =MSR = -------
Circular scale reading =CSR= ---------
Total reading (TR) = MSR + (CSR * LC)
Total Height of specimen = -----------
Result:
• The thickness of the given MS plate is measured by using slip gauges.
• The thickness of the given MS plate is _______________ mm.
Procedure for Dial Guage:

1. The slip gauges are built up to the given weight of the component.
2. Dial gauge with stand is placed on the surface plate.
3. The built up gauge is placed under the plunger.
4. The indicator is set to zero.
5. The built up gauge is removed.
6. The given machined component is placed under the plunger.
7. The variation in the height of the component is noted from the reading of the dial.
Calculation of Dial Gauge:

Slip Gauge Reading ----Dial Gauge Reading
= 50+ ...... = 0.2 + .......
= 51.001 mm = 0.2 + ......
= 51.003 mm = 0.2 + .......
Difference for the both should be equal
Result:
• The height of the machined component is checked with standard
dimensioned Component (slip gauges) using dial gauge.
• The variation in height is ________________ mm
.
Experiment No.8
Aim: Study and understanding of limit, fits and tolerances.
Theory:
Nominal size- The nominal size of the dimension or part is the size by which it is refer to as a
matter of convenience.
Basic size- It is got to be ascribed for the sake of convenience and is the size of a part in relation to
which are limits of variation are determine. Often basic size and nominal size of a part of dimension
are used with the same sense. When used for fits between shaft and holes, same basic size is
specified for both shaft and hole.
Zero line –this is the line which represents the basic size so that the deviation from the basic size is
zero Fig1.1 illustrates the concepts of basic size and zero line.
Actual Size – This is the measured size.
Limits-These are two extreme permissible sizes for any dimension (high & low).
Fig.8.1
Tolerances-Tolerances on a dimension are the difference between the high and low limits of size. It
is got to be allowed in order to cover reasonable imperfection in workmanship and the inevitable in
accuracy of manufacturing process, and various with different grades of work .it can be unilateral
and bilateral.
Allowances –An international difference between the whole dimension and shaft dimension for any
type of fit is called the allowance .Maximum allowance is obtained by subtracting the minimum
shaft size from the largest whole size and the minimum allowance is the difference is the largest
shaft and the smallest hole size .
Thus allowance is positive for clearance fit and negative for interference fit.
Fits- When two parts are to be assemble, the relation resulting from the difference between there
sizes before assembling is called the fit .Depending upon the actual limit of hole or shaft , the fit
may be clearance fit, or tolerance fit, or interference fit.
Tolerance is considered on one side only. Actually it is reprehensive of total tolerance. It is done for
sake of clarity and simplification. In schematic representation of tolerances, no regard is given to
show shaft and holes fully, but only there magnitude and relative position with respect to basic size
are highlighted.
(a) Clereance Fit- In this type of fit, largest permitted shaft diameter is smaller than the
diameter of the smallest hole, so that the shaft can rotate or slide though with difference
degrees of freedom according to the purpose of the mating member.
Fig.8.2
(b) Interference Fit – In this type of, the min. Permitted diameter of the shaft is larger than the
max. Allowable diameter of the hole. In this case shaft and whole members are intended to
be attached permanently and used as a solid component but according to the application of
this combination, this type of fit can be varied. Thus, if in use one of the two members is
subjected to were, it should be possible to derive or force the two members apart for
replacement purposes. Examples of this type of fit are bearing bushes which are in an
interference fit in their housing e.g. A small end in the connecting rod of an engine.
(c) Transition Fit: - In a fit of this type the diameter if the largest allowable hole is greater than
that of the smallest shaft, but the smallest hole is smaller than the largest shaft, so that small
positive or negative clearance between the shaft and whole members are employable.
Location fits e.g. Spigot in mating holes, coupling rings and recesses are the example of
transition fit.
Fig.8.3
Deviation: - It is defined as the algebraic difference between a size (Actual, maximum etc) and the
corresponding basic size.
A. Upper Deviation: - it is the algebraic difference between the maximum limit of size (of
either hole or shaft) and the corresponding basic size. It is designated by letters ES for hole
and es for shaft. It is a positive quantity when the maximum limit of size is greater than the
basic size and a negative quantity when the maximum limit of size is less than the basic size.
B. Lower Devaition: - it is the algebraic difference between the maximum limit of size and the
corresponding basic size. It is a positive quantity when the minimum limit of size is greater
than the basic size and a negative quantity when the minimum limit of size is less than the
basic size it is designated by EI for whole and ei for shaft.
C. Fundamental Deviation: - It is that one of the two deviations which is conventionally
chosen to define the position of the tolerance zone in relation to the zero. This may be upper
or lower deviation which is closes to the zero line. It fixes the position of zero line.
Minimum Clearence: - In a clearance fit, it refers to the difference between the minimum size of
hole and maximum size of shaft.
Maximum Clearence: - In the case of clearance or transition fit, it refers to the difference between
the maximum of hole and minimum size of shaft.
Minimum Interference: - It is a difference between the maximum size of hole and the minimum
size of shaft in and interference fit prior to assembly.
Maximum Interfernce:-In interference or transition fit it is the difference between the minimum
size of hole and the maximum size of the shaft prior to assembly.
Allowance: - The difference the maximum shaft size and minimum hole is known as allowance. In
a clearance fit this is the minimum clearance and positive allowance. In an interference fit, it is the
maximum interference and is negative allowance.
Basic shaft is a shaft whose upper deviation is zeros e.g. Shaft ‘h’.
Basic hole is one whose lower deviation is zero, eg.hole ‘H’
Experiment No.9
Aim: To measure angle with help of profile projector.
Apparatus: Profile Projector
Theory: This machine is used to measure and check the dimensions. It greatly simplifies the use of
an optical comparator to perform precise, repeatable measurements. The profile projector is
capable to measure points, lines, circles and other geometric shapes. All the dimension should be
done from a given datum point, which is known as Absolute Origin.
Procedure: In this process, the first line and the second line are indefinite, and the included angle
they make should not be more than 180º and rotated anticlockwise from first line to the second line.
The angle can be measured by targeting points on two lines (legs) that develop an angle. Generally,
accuracy of the overall angle measurement is increased as more Points are targeted.
1. Press key to measure an angle α as in figure.
L2
α
L1
2. Move the stage to place the cross hair over the first point of the first line and press “Enter”
key. The location of point will be targeted.
3. Continue the process until all the points have been targeted and entered for the first line of
the angle. When all the points have been entered, press “Finish” key. The LCD displays
“Second Line” and now target and enter points on second line. After entering all points press
“Finish” key.
4. The message displays information about the angle.
Observation:
S. No. Angle Measured
1 45
2 30
3 45

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DELHI SKILL AND ENTREPRENEURSHIP UNIVERSITY OKHLA-II CAMPUS

(Formerly Known as Delhi Institute of Tool Engineering)

Total Reading = M.S.R + L.C X V.C

1. The Least Count is to be determined.

S. No. Main Scale Vernier Zero error Vernier Total

D = Main Scale Reading + L.C * (Thimble Scale Coincidence ± error)

Taper Angle, θ = Sin-1(h2-h1)/l

Where, h2 = Max. Height

Aim: Study and angular measurement using bevel protector.

Apparatus: Bevel Protractor, V-Block

Results: Angle of the V-Block is= 45

Apparatus: Feeler gauge, spark plug

(iii) Special Stems:-

Procedure for Dial Guage:

Calculation of Dial Gauge:

Actual Size – This is the measured size.

Apparatus: Profile Projector

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