Faculty Orientation Programme-2017

 SAE, Mechanical Department, Kondhwa, Pune

Metrology & Quality Control
T.E Mechanical
UNIT-II
Comparators, Thread and Gear Metrology, Surface
Roughness Measurement.

Mechanical Engineering Department.

Smt.Kashibai Navale College Of Engineering,Vadgaon
Pune-411041.
 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.
Characteristics of Comparators:-
1.The instrument must be of robust design and construction The
scale must be linear and must have straight line characteristic.
2. Indicator should be constant in its return to zero.
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.
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
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
Johansson Mikrokator
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.
Zeiss Ultra Optimeter
Electrical comparator(LVDT)
Pneumatic Comparator
Measurement of Thread form
Elements of Threads
Errors In Threads
 There are at least five important elements which require
consideration:
 Major diameter
 Minor diameter
 Effective diameter
 Pitch and angle of the thread form
 Errors on the major and minor diameters will cause
interference with the mating thread
 Errors on the effective diameter will also result in weakening of
the assembly.
 Pitch and angle errors are also not desirable as they cause
progressive tightening and interference on assembly
Drunken Thread Error

Thread drunkenness is a particular case of a periodic pitch error

recurring at intervals of one pitch.
Pitch Errors in Screw Threads
 Irregular Errors in Threads
 These arise from disturbances in the machining set-up,
variations in the cutting properties of material etc
 Erratic Pitch. This is the irregular error in pitch and varies
irregularly in magnitude over different lengths of thread.
 Progressive Error. When the pitch of a screw is uniform, but is
shorter or longer than its nominal value, it is said to have
progressive error.
 Periodic Error. If the errors vary in magnitude and recur at
regular intervals, when measured from thread to thread along
the screw are referred to as periodic errors.
Best Size Wire
Measurement of Minor, Major and Effective
diameter (Three Wire Method),
Floating Carriage Micrometer
(Numerical).
Measurement of Major, Minor and Effective
diameter using FCM
Screw Thread Micrometer
It has various type and size of interchangeable spindle and
anvils are used for measuring the pitch diameter of external
threads.
The pitch diameter of internal threads are measured by inside
thread micrometers having various type and dimensions for
different applications
Pitch Measuring Machine
Numericals
1.For M24x3 mm external thread, Calculate best size wire
diameter(Db) .
Solution:- For metric thread thread angle = 600
Pitch=3 mm
Db=P/2 SecƟ/2
=3/2 Sec60/2
= 1.732 mm
2.A metric screw thread of pitch 1.25 mm is inspected by 3-wire
method. Distance over the wire is 25.08 mm.Determine
effective diameter.
Solution:- Pitch =1.25 mm,angle of thread = 600
Db=P/2 SecƟ/2
=1.25/2 Sec60/2
= 0.722 mm.
M=E+2h+2r or M=E+2h+d--------A
Where M=Dimension Over the wire=25.08mm
H=d/2cosecƟ/2-P/4cotƟ/2
= 0.722/2cosec60/2-1.25/4cot60/2
=0.18 mm.
From A,
E=M-2h-d
=25.08- 2x0.18-0.722
= 23.998 mm
3. A master cylinder of 30 mm diameter(D) is used for
measuring effective diameter of thread having pitch of 3.5
mm(p).The diameter of best size wire(db) used is 2.00
mm.The micrometer reading over master cylinder and
wire, screw thread and gauge are 13.3768(R1) mm and
12.2428 mm(R2).Calculate effective diameter of thread.
Solution:- T= D - (R1 - R2)
=30- (13.3768 -12.2428)
=28.8661 mm
P=0.866 p - db
=0.866x3.5 – 2
=1.031 mm
E=T +P
= 28.8661 +1.031
=28.897 mm
Gear Terminology:
 Base circle : It is the circle of gear from which the involute profile is derived.
 Pitch circle diameter (PCD):The diameter of a circle which will produce the same
motion as the toothed gearwheel
 Pitch circlet is the imaginary circle of gear that rolls without slipping over the circle of
its mating gear.
 Addendum circle: The circle coincides with the crests (or) tops of teeth.
 Dedendum circle (or) Root circle: This circle coincides with the roots (or) bottom on
teeth..
 Pressure angle (a):It is the angle making by the line of action with the common
tangent to the pit circles of mating gears.
 Module(m):It is the ratio of pitch circle diameter to the total number of teeth.
 Circular pitch It is the distance along the pitch circle between corresponding points
of adjacent teeth
 Addendum: Radial distance between tip circle and pitch circle.
 Dedendum: Radial distance between itch circle and root circle,
 Clearance (C): A mount of distance made by the tip of one gear with the root of
mating gear
 Blank diameter: The diameter of the blank from which gear is out. Blank diameter =
PCD + 2m
Errors in Spur Gear form
 1. Profile error: - The maximum distance of any point on the tooth profile form
to the design profile.
 2. Pitch error: - Difference between actual and design pitch
3. Cyclic error: - Error occurs in each revolution of gear
 4. Run out: - Total range of reading of a fixed indicator with the contact points
applied to a surface rotated, without axial movement, about a fixed axis.
5. Eccentricity: - Half the radial run out
6. Wobble: - Run out measured parallel to. the axis of rotation at a specified
distance from the axis
7. Radial run out: - Run out measured along a perpendicular to the axis of
rotation.
8. Axial run out: - Run out measured parallel to the axis of rotation at a speed.
9. Periodic error: -Error occurring at regular intervals.
Gear Tooth Vernier
Measurement of Chordal Tooth Thickness
using Gear Tooth Vernier
Measurement of Chordal addendum using Gear
Tooth Vernier
Numerical-Assignment
1.Calculate the settings for Gear tooth vernier for
inspecting a spur gear having 40 teeth and 3 module.
Solution:
W=NmSin90/N
=40 x3 Sin90/40
=120 x Sin2.15
= 4.5mm
h= 3.042 mm
Measurement of Gear by constant chord method
Base Tangent Method of Gear Measurement
Numerical
Calculate the setting of David brown tangent comparator to
measure the distance over 4 teeth of a spur gear of 30 teeth with
module of 2.5 mm and pressure angle of 200 .

Solution:- N=30teeth, m=2.5 mm, Ø=200

Space(S)=1-T

= 1-4=3

Span (w) = N m ( tan Ø – Ø + Π/2N + ΠS/N)

=30 x 2.5(tan200 - 200 + Π/2x30 + Πx3/30)

=19.50 mm
Base pitch measurement of gear
Gear Rolling Tester.
Parkinson Gear Tester

.
Profile Projector
It is used for inspecting and comparing very small and
complex parts
It is also known as an optical comparator, or even called
a shadowgraph, a profile projector is an optical
instrument that can be used for measuring. It is a useful
item in a small parts machine shop or production line
for the quality control inspection team. The projector
magnifies the profile of the specimen, and displays this
on the built-in projection screen. On this screen there is
typically a grid that can be rotated 360 degrees so the X-
Y axis of the screen can be aligned with a straight edge
of the machined part to examine or measure.
Tool Maker’s Microscope
Introduction to Surface texture
Surface texture characteristics
Roughness: The irregularities in the surface texture which
result from the inherent action of the production process.
These are deemed to include traverse feed marks and the
irregularities within them.
Waviness: is component of surface texture upon which
roughness is superimposed. Waviness may result from such
factors as machine or work deflections, vibrations, chatter,
heat treatment or warping strains.
Profile: The shape of a specified section through the surface
Surface Texture
Spacing: The average distance between the more prominent
irregularities on the profile.
Lay: The direction of the predominant surface pattern,
ordinarily determined by the production method.
The surface geometrical irregularities could be
classified into four categories:-
First Order. This includes the irregularities arising out of inaccuracies in
the machine tool itself e.g. lack of straightness of guide ways on which
tool post is moving. This includes the surface irregularities arising due to
deformation of work under the action of cutting forces and the weight of
the material itself.

Second Order. Some irregularities are caused due to vibrations of any

kind such as chatter marks and are included in second order.

Third Order. Even if the machine were prefect and completely free of

vibrations, some irregularities are caused by machining itself due to
characteristic of the process. This also Includes the feed marks of the
cutting tool. (Contd.)
Fourth Order: These irregularities from rupture of material during
separation of chip.

Further these irregularities of four orders can be grouped under two

groups :

First group includes irregularities of considerable wave-length of a

periodic character resulting from mechanical disturbances in the
generating set-up. These errors are also referred to as Waviness or
Secondary Texture.

Second group includes irregularities of small wavelength caused by the

direct action of the cutting element on the material or by some other
disturbance such as friction, wear, or corrosion. Errors in this group are
referred to as Roughness or Primary Texture.
Surface Roughness Parameters
Ra-Average surface roughness
CLA-Center Line Average Method
RMS Value of Surface Roughness
Taylor-Hobson Talysurf
Tomlinson Surface meter
THANK YOU