Metrology And Measurement Laboratory Manual
JSS MAHAVIDYAPEETHAJSS SCIENCE & TECHNOLOGY UNIVERSITY(JSSS&TU)FORMERLY SRI JAYACHAMARAJENDRA COLLEGE OF ENGINEERINGMYSURU-570006DEPARTMENT OF MECHANICAL ENGINEERINGMetrology and Measurement Laboratory ManualIV Semester B.E. Mechanical EngineeringUSN :Name:Roll No: Sem SecCourse NameJSSMAHAVIDYAPEETHACourse CodeJSSSTU, MYSURUDepartment of Mechanical Engineering
DEPARTMENT OF MECHANICAL ENGINEERINGVISION OF THE DEPARTMENTDepartment of mechanical engineering is committed to prepare graduates, post graduates andresearch scholars by providing them the best outcome based teaching-learning experience andscholarship enriched with professional ethics.MISSION OF THE DEPARTMENTM-1: Prepare globally acceptable graduates, post graduates and research scholars for theirlifelong learning in Mechanical Engineering, Maintenance Engineering and EngineeringManagement.M-2: Develop futuristic perspective in Research towards Science, Mechanical EngineeringMaintenance Engineering and Engineering Management.M-3: Establish collaborations with Industrial and Research organizations to form strategic andmeaningful partnerships.PROGRAM SPECIFIC OUTCOMES (PSOs)PSO1Apply modern tools and skills in design and manufacturing to solve real worldproblems.PSO2Apply managerial concepts and principles of management and drive global economicgrowth.PSO3Apply thermal, fluid and materials fundamental knowledge and solve problemconcerning environmental issues.PROGRAM EDUCATIONAL OBJECTIVES (PEOS)PEO1: To apply industrial manufacturing design system tools and necessary skills in the fieldof mechanical engineering in solving problems of the society.PEO2: To apply principles of management and managerial concepts to enhance globaleconomic growth.PEO3: To apply thermal, fluid and materials engineering concepts in solving problemsconcerning environmental pollution and fossil fuel depletion and work towardsalternatives.
PROGRAM OUTCOMES (POS)PO1Engineering knowledge: Apply the knowledge of mathematics, science, engineeringfundamentals, and an engineering specialization to the solution of complexengineering problems.PO2Problem analysis: Identify, formulate, review research literature, and analyzecomplex engineering problems reaching substantiated conclusions using firstprinciples of mathematics, natural sciences, and engineering sciences.PO3Design/development of solutions: Design solutions for complex engineeringproblems and design system components or processes that meet the specified needswith appropriate consideration for the public health and safety, and the cultural,societal, and environmental considerations.PO4Conduct investigations of complex problems: Use research-based knowledge andresearch methods including design of experiments, analysis and interpretation ofdata, and synthesis of the information to provide valid conclusions.PO5Modern tool usage: Create, select, and apply appropriate techniques, resources, andmodern engineering and IT tools including prediction and modeling to complexengineering activities with an understanding of the limitations.PO6The engineer and society: Apply reasoning informed by the contextual knowledgeto assess societal, health, safety, legal and cultural issues and the consequentresponsibilities relevant to the professional engineering practice.PO7Environment and sustainability: Understand the impact of the professionalengineering solutions in societal and environmental contexts, and demonstrate theknowledge of, and need for sustainable development.PO8Ethics: Apply ethical principles and commit to professional ethics andresponsibilities and norms of the engineering practice.PO9Individual and team work: Function effectively as an individual, and as a memberor leader in diverse teams, and in multidisciplinary settings.PO10Communication: Communicate effectively on complex engineering activities withthe engineering community and with society at large, such as, being able tocomprehend and write effective reports and design documentation, make effectivepresentations, and give and receive clear instructions.PO11Project management and finance: Demonstrate knowledge and understanding ofthe engineering and management principles and apply these to one’s own work, as amember and leader in a team, to manage projects and in multidisciplinaryenvironments.PO12Life-long learning: Recognize the need for, and have the preparation and ability toengage in independent and life-long learning in the broadest context of technologicalchange.
METROLOGY AND MEASUREMENTS LABORATORYSubject Code: ME46LNo. of Practical Hours / Week: 03Total No. of Practical Hours: 39No. of CreditsCIE Marks: 0 – 0 - 1.5: 50COURSE OBJECTIVES:1. To provide students with the necessary skills for calibration and testing of different gauges andinstruments.2. To provide students with the necessary skills to collect data, perform analysis and interpret resultsto draw valid conclusions through standard test procedures using various metrology instruments.COURSE CONTENTPART-AMECHANICAL MEASUREMENTS1. Calibration of Pressure Gauge2. Calibration of Thermocouple3. Calibration of LVDT4. Calibration of Load cell5. Determination of modulus of elasticity of a mild steel specimen using strain gauges.PART-BMETROLOGY1. Measurements using Optical Projector / Toolmaker Microscope.2. Measurement of angle using Sine Center / Sine bar / bevel protractor3. Measurement of alignment using Autocollimator / Roller set4. Measurement of cutting tool forces usinga) Lathe tool Dynamometerb) Drill tool Dynamometer.5. Measurement of Screw threads Parameters using two wire or Three-wire methods.6. Measurements of Surface roughness, Using Tally Surf/Mechanical Comparator7. Measurement of gear tooth profile using gear tooth vernier /Gear tooth micrometer8. Calibration of Micrometer using slip gauges9. Measurement using Optical Flats
COURSE OUTCOMES:Upon completion of this course, students should be able to:CO1Demonstrate the necessary skills for calibration and testing of different gauges and instruments.CO2Demonstrate the necessary skills to collect data, perform analysis and interpret results to drawvalid conclusions through standard test procedures using various metrology instruments.
ContentsExptPageTitle of the ExperimentNo.No.PART-AINTRODUCTION11Calibration of Pressure Gauge062Calibration of Thermocouple093Calibration of LVDT144Calibration of Load cell175Determination of modulus of elasticity of a mild steel specimenusing strain gauges. (Bending tor (Profile Projector)Measurement of thread parametersusingOptical24using Toolmaker278MicroscopeMeasurement of angle using Sine bar9Measurement of alignment using Autocollimator / Roller oolDynamometer, Measurement of torque & thrust force using39Drill tool Dynamometer.11121315Measurement of Screw thread parameters using two wireor Three-wire method (Floating Carriage Micrometer)Measurement of thickness by using ComparatorsMeasurement of gear tooth profile using gear toothvernier/Gear tooth micrometerCalibration of Micrometer using slip gaugesViva-Voce Questions4348515560
INTRODUCTIONIn science and engineering, objects of interest have to be characterized bymeasurement and testing. Measurement is the process of experimentallyobtaining quantity values that can reasonably be attributed to a property of abody or substance. Metrology is the science of measurement. Metrology is also a fine avenue for discussing accuracy, error, andcalibration.Testing is the technical procedure consisting of the determination ofcharacteristics of a given object or process, in accordance with a specifiedmethodIn metrology (the science of measurement), a standard is an object, system, orexperiment that bears a defined relationship to a unit of measurement of aphysical quantity.Metrology is mainly concerned with the following aspects Unit of measurement and their standards. Errors of measurement. Changing the units in the form of standards. Ensuring the uniformity of measurements. New methods of measurement developing. Analyzing these new methods and their accuracy. Establishing uncertainty of measurement. Gauges designing, manufacturing and testing. Researching the causes of measuring errors. Industrial Inspection.1
FUNCTIONS OF METROLOGY To ensure conservation of national standards. Guarantee their accuracy by comparison with international standards. To organize training in this field. Take part in the work of other National Organization. To impart proper accuracy to the secondary standards. Carry out Scientific and Technical work in the field of measurement. Regulate, supervise and control the manufacturer. Giving advice to repair of measuring instruments. To inspect and to detect guilty of measurement.APPLICATIONS OF METROLOGY Industrial Measurement Commercial transactions Public health and human safety ensuringNEED OF INSPECTIONTo determine the fitness of new made materials, products or component partand to compare the materials, products to the established standard. It issummarized as To conforming the materials or products to the standard. To avoid faulty product coming out. To maintain the good relationship between customer andmanufacturer. To meet the interchangeability of manufacturer. To maintain the good quality. To take decision on the defective parts. To purchase good quality raw materials. To reduce the scrap2
NEED FOR MEASUREMENT To determine the true dimensions of a part. To increase our knowledge and understanding of the world. Needed for ensuring public health and human safety. To convert physical parameters into meaningful numbers. To test if the elements that constitute the system function as per thedesign. For evaluating the performance of a system. For studying some basic laws of nature. To ensure interchangeability with a view to promoting mass production. To evaluate the response of the system to a particular point. Check the limitations of theory in actual situation. To establish the validity of design and for finding new data and newdesigns.METHODS OF MEASUREMENT1. Direct comparison with Primary or Secondary Standard.2. Indirect comparison with a standard through calibration system.3. Comparative method.4. Coincidence method5. Fundamental method.6. Contact method.7. Transposition method.8. Complementary method.9. Deflection method.1) Direct method :The value to be measured is directly obtained. Examples:Vernier calipers, Scales.2) Indirect method:The value of quantity to be measured is obtained bymeasuring other quantities. Diameter measurement by using three wires.3) Comparative method: In this method, the quantity to be measured iscompared with other known value. Example: Comparators.3
4) Coincidence method: The value of the quantity to be measured&determined is coincide with certain lines and signals.5) Fundamental method: Measuring a quantity directly in related with thedefinition of that quantity6) Contact method: The sensor or measuring tip of the instrument touchesthe area (or) diameter (or)surface to be measured. Example: Vernier caliper.7) Transposition method: In this method, the quantity to be measured isfirst balanced by a known value and then it is balanced by other new knownvalue. Example: Determination of mass by balancing methods.8) Complementary method: The value of quantity to be measured iscombined with known value of the same quantity. Example: Volumedetermination by liquid displacement.9) Deflection method: The value to be measured is directly indicated by adeflection of pointer. Example: Pressure measurementAccuracy and ErrorYou may have heard the expression ―close enough for engineering.‖ It is areference to accuracy— how good is the measurement (dimensional orotherwise)? More specifically, accuracy isa reference to the relative magnitudeof the error in one or more measurements— how close is my measurement tothe true value? Typically, one device (or technique, for that matter) is said tobe more accurate than another because it gives measurements that havesmaller errors.Error in a measurement is classified into two types: Bias errors and Precision errors.A measurement is accurate if both the precision error and bias error arelow.Figure 1 shows the relationship graphically. Precision error refers to therepeatability of a measurement: a group of measurements with a low precisionerror is always close to the same average value. However, this average valuemay not be the correct (i.e. true) value because of bias error. Bias error movesthe average value away from the true value in a systematic (i.e. constant) way.On the other hand, a group of measurements with the correct average value,4
but showing a great deal of scatter has a low bias error and a large precisionerror. So, precision error is a consequence of repeatability and bias error is aconsequence of constant offset errors.Fig1. Relationship of Accuracy, Precision Error and Bias ErrorCalibrationA good measurement procedure is one which attempts to minimize theseerrors. An important part of this procedure is calibration— the procedure ofverifying the accuracy of the measurement device itself by measuringknown quantities and comparing the output of the measurementinstrument to the expected values.These “known quantities” are called standards. The primary standard isthe internationally accepted definition of the quantity of interest, such asmass and length1, and is maintained at a facility in France. A mirrorstandard is typically maintained in a national facility such NIST in the UnitedStates. Secondary standards are copies of the primary standard that aremore accessible than the primary standard. These copies are rated, and canbe certified as accurate to a certain level against the primary standard. Forexample, for verifying my electronic balance, I can purchase either ASTMClass 1 calibration masses, accurate to within 0.00025% of their rated mass,or NIST Class F masses, accurate to within 0.01%. Other than accuracy, thedifference is a factor of ten in cost.Note: Please note that this stated accuracy is an assessment of howclosely these standards represent the true value relative to the primarystandard.5
EXPERIMENT NO.1CALIBRATION OF PRESSURE GAUGEAim: To calibrate the given pressure and calculate the errorTheory: Many techniques have been developed for the measurement ofpressure and vacuum. Instruments used to measure pressure are calledpressure gauges or vacuum gauges.A dead weight tester consists of a pumping piston with a screw thatpressurizes the oil present in the cylinder which connects pressure gauge andprimary piston. It works by loading the primary piston (C/s area, A) with theamount of weight W, that corresponds to the desired calibration pressure (P W/A).When the screw is turned, the fluid pressure increases both in the primarypiston and gauge.This pressure increase is indicated in the pressure gauge; simultaneously theprimary piston raises the dead weight to the reference mark. The indicatedgauge pressure is recorded and calibrated with the actual pressure acting onthe primary piston with the dead weights.6
Procedure:1. The given pressure gauge is fixed in the proper position.2. The barrel is filled with the oil.3. The weight of the plunger and the diameter of the stem measured and thearea of the cross section calculated.4. The pressure is applied to the oil by turning the hand wheel, this is donetill the certain pressure is built and the plunger is raised upto the referencemark.5. A known weight is placed on the platform of the plunger.6. The reading of the pressure gauge is noted and experiment is repeated byplacing different weights on the plunger.7. Actual pressure is calculated and the pressure indicated by the pressuregauge is compared.8. Calibration curves are drawn (graph of Actual pressure v/s Indicatedpressure are plotted).Tabular ColumnSL.NOWeight on theTotal weightplunger(Wt ofplunger wtplaced onthe n pressureAPIPDP% oferrorWKgNKgNN/m2Kg/cm2N/m2N/m27
Observation:1. Weight of the plunger, W . gms2. Diameter of the plunger, d .mmCalculation:1. Area of cross section, A πd2/4 m22. Actual pressure, AP total weight / cross section area W/A N/m23. Difference in pressure, DP AP – IP N/m24. Percentage error DP 100/APConclusion:8
EXPERIMENT NO.2CALIBRATION OF THERMOCOUPLEAim: To study about different Thermocouples and their calibration.Theory:Thermocouples, devices used to measure temperature, are composed of twodissimilar metals that produce a small voltage when joined together—one endof a thermocouple joins each metal.The thermocouple is the most common type of temperature sensor, primarilybecause it is inexpensive and easy to use. Infact, it is used in many placesfamiliar to you: in the home, it is used to control the temperature of thefurnace, water heater, and the kitchen oven; in the automobile, it is used tomonitor coolant and oil temperature, and even to control the air conditioner.It is not the most accurate technique available to measure temperature–typical thermocouples is accurate to around 0.5 C–but for many applicationsthis accuracy is acceptable.Thomas Johann Seebeck (1770-1831) discovered that a circuit comprised ofdissimilar metals produces a voltage(andcurrent)when the two dissimilarjunctions are exposed to different temperatures. This phenomenon ,called theSeebeck Effect,is depicted in Figure below. The voltage produced isproportional to the temperature difference between the junctions. The voltageproduced is small, on the order of millivolts, so it is not very suitable forproducing power1.But the device can easily be calibrated to measure temperature.9
Laws of ThermocouplesThe two laws governing the functioning of thermocouples are:i)Law of Intermediate Metals: It states that the insertion of an intermediatemetal into a thermocouple circuit will not affect the net emf, provided the twojunctions introducedby the third metal are at identical temperatures.Application of this law is as shown in Fig. In Fig.(a),as shown in Fig. In Fig.(a),if the third metal C is introduced and the new junctions R and S are held attemperature T3, the net emf of the circuit will remainunchanged. Thispermits the insertion of a measuring device or circuit without affecting thetemperature measurement of the thermocouple circuit Circuitsillustratingthe Law of Intermediate Metals In the Fig.(b) The third metal is introduced ateither a measuring or reference junction. Also junctions P1 and P2aremaintained at the same temperature TP the net emf of the circuit will not bealtered. This permits the use of joining metals, such as solder used infabricating the thermocouples. In addition, the thermocouple may beembedded directly into the surface or interior of a conductor without affectingthe thermocouple's functioning.i)Law of Intermediate Temperatures:It states that―If a simple thermocouple circuit develops an emf, e1when itsjunctions are at temperatures T1 and T2,and an emf e2, when its junctionsareat temperature T2 and T3.Andthesamecircuitwilldevelopanemfe3 e1 e2,when its junctions are at temperatures T1 and T3. This is10
illustrated schematically in the above Fig. This law permits thethermocouple calibration for a given temperature be used with any otherreference temperature through the use of a suitable correction. Also, theextension wires having the same thermo-electric characteristics as those ofthe thermocouple wires can be introduced in the circuit without affectingthe net emf of the thermocouple.Classification of Thermocouples: 3 Types1.2.3.4.Nickel alloy thermocouples Type E (chromel – constantan) Type J (iron – constantan) 3.1.3 Type K (chromel – alumel) 3.1.4 Type M (Ni/Mo 82%/18% – Ni/Co 99.2%/0.8%, by weight) 3.1.5 Type N (Nicrosil – Nisil) 3.1.6 Type T (copper – const
Metrology and Measurement Laboratory Manual IV Semester B.E. Mechanical Engineering JSS MAHAVIDYAPEETHA JSSSTU, MYSURU . METROLOGY AND MEASUREMENTS LABORATORY . To inspect and to detect guilty of measurement. APPLICATIONS OF METROLOGY Industrial Measurement
A Laboratory Manual for Mechanical Measurements& Metrology (2141901) 4th Semester Mechanical Engineering DARSHAN INSTITUTE OF ENGINNERING AND . Metrology is a science of measurement. Metrology may be divided depending upon the quantity under consideration into: metrology of length, metrology of time etc. Depending upon the field of .
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