Unit No:-II

Comparators, Thread and Gear Metrology,

Surface Roughness Measurement (08 hrs)
 
Comparators: Mechanical, Pneumatic, Optical, Electrical (LVDT).
Measurement of Thread form: Thread form errors,
Measurement of Minor, Major and Effective diameter (Three
Wire Method), Flank angle and Pitch, Floating Carriage
Micrometer (Numerical).
Gear Metrology: Errors in Spur Gear form, Gear tooth Vernier,
Constant chord, Base tangent (Numerical), Gear Rolling Tester.
Profile Projector, Tool maker’s microscope and their
applications
Surface Roughness Measurement: Introduction to Surface
texture, Parameters for measuring surface roughness, Surface
roughness measuring instrument: TalySurf
 Comparators
A comparator works on relative measurements, i.e. to say, it gives
only dimensional differences in relation to a basic dimension. So a
comparator compares the unknown dimensions of a part with
some standard or master setting which represents the basic size,
and dimensional variations from the master setting are amplified
and measured.
(1)    Mechanical comparators.
(2)    Optical comparators.
(3)    Electrical comparators.
(4)    Pneumatic comparators.

Comparator gives the difference between the actual and

standard dimensions of the work piece.
Characteristics of Comparators:-
1.The instrument must be of robust design and construction.
2. High Magnification.
3.Instrument, though very sensitive, must withstand a reasonable
ill usage without permanent harm.
4. Instrument must have the maximum versatility, i.e., its design
must be such that it can be used for a wide range of operations.
5.Measuring pressure should be low and constant.
6.Hard contact point, with long life.
7. Free from backlash and wear
8. Reliable while in use.
9 Less cost, easily available, light weight.
Uses of Comparators
(1)    In mass production, where components are to be checked at
a very fast rate.
(2)    As laboratory standards from which working or inspection,
gauges are set and correlated.
(3)    For inspecting newly purchased gauges.
(4)    Attached with some machines, comparators can be used as
working gauges to prevent work spoilage and to maintain
required tolerances at all stages of manufacturing.
(5)   In selective assembly of parts, where parts are graded in three
groups depending upon their tolerance.
 Elements of Comparators
 (i) A Sensing Device (Usually a Plunger): A sensing device is
faithfully senses the input signals. The input singles may be
change in length, diameter or a displacement.
 (ii) A Magnification System (Amplifying System): This system is
used to magnify the signals to a suitable magnitude. A
comparator of 3000 magnification will magnify the plunger
movement of 0.05 mm to 150mm. The magnification system
used may be mechanical, optical, pneumatic, hydraulic, electro-
mechanical or electronic.
 (iii) A Display System: A display system shows the deviation of
size with some magnification. Usually a scale and pointer is
used in a dial for display the variation of size
Types of Mechanical Comparator

1.Dial Indicator
2.Sigma Comparator
3.Johanson Mikrokator
Dial Indicator
Applications of Dial Indicator:
1.Use to determine the geometrical
errors such as roundness, taper,
circularity , etc.
2.To determine the positional errors of
surfaces.
3.It is used in the alignment testing of
the lathe machine, drilling machine,
milling machine etc.
Magnification of Dial gauge
Diameter of Dial=50 mm.
Length of Pointer(L)=25 mm
No. of division on Dial=100
Scale (OR) Least Count=0.01 mm
Magnification= 50 x Π =157 times
100 x 0.01
Magnification =G1/P2 xG2/P3 x ΠD/L
= 100/20 x100/20 x 50xΠ/25
= 157 times
Sigma Comparator
If, l = distance from hinge pivot to the knife edge.
L = Length of Y Arm
R = Driving drum radius.
d = Length of the pointer.

Then total magnification=

= Ist stage magnification * IInd stage magnification
=L / l * d / R
Johansson Mikrokator
The mechanical movement is used for the
magnification purpose. Magnification is given by-

Thus, with the help of principle of button spinning

the magnification can be carried out and the
readings can be displayed on the scale.
Optical Comparator

 Mechanical amplification= l2/l1

 and Optical amplification =l4/l3  * 2.
 It is multiplied by 2, because if mirror is tilted by an angle δθ , then image will be
tilted by 2 * δθ .Thus overall magnification of this system=2*l2/l1 * l4/l3.
In Mechanical Optical Comparator,
small variation in the plunger
movement is magnified, first by
mechanical system using a pivoted
lever and then by optical system.
The important factor is the mirror used is of
front reflection type only.
The back reflection type mirror will give 2
reflected images, hence the exact reflected
image can not be identified.
The second important factor is when the mirror
is tilted by an angle 10 degree, then the image
will be tilted by an angle 20 degree.
Mechanical amplification= l2/l1
and Optical amplification =l4/l3  * 2.
It is multiplied by 2, because if mirror is tilted by an angle δθ ,
then image will be tilted by 2 * δθ .
Thus overall magnification of this system=2*l2/l1 * l4/l3.
Electrical comparator(LVDT)
The LVDT consists of 3 coils such as P, S1 and S2.
The primary coil connected to the mains A.C. supply,
A magnetic flux is generated by this coil is cut by the
soft iron core and hence voltage is induced in two
sec windings.
The LVDT consists of 3 coils such as P, S1 and S2.
The primary coil connected to the mains A.C. supply,
A magnetic flux is generated by this coil is cut by the
soft iron core and hence voltage is induced in two
sec windings.

The secondary coils are connected together in series

but opposite to each other.

When core is at centre position the voltage induced

in each secondary coil will be identical and 180 degree
out of phase so net o/p will be zero.
Pneumatic Comparator
 Solex Pneumatic Comparator

it works on the principle of pressure difference generated by the

air flow.
Any variation in the dimension changes the value of h.
Change in dimension of 0.002mm changes the value of h from 3 to
20mm. Moderate and const press is required for high sensitivity.
Level Beam Comparator