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E.G.S. PILLAY ENGINEERING COLLEGE(Autonomous)Approved by AICTE, New Delhi Affiliated to Anna University, Chennai Accredited by NAACwith “A” Grade Accredited by NBA (CSE, EEE, MECH)NAGAPATTINAM – 611 002DEPARTMENT OF MECHANICAL ENGINEERINGIV SEMESTER1702ME402 - MEASUREMENTS AND METROLOGY LABORATORYLAB MANUALPrepared & Compiled byDr. J.Jeevamalar, M.E., Ph.D.Laboratory in Charge
Department of Mechanical EngineeringE.G.S. PILLAY ENGINEERING COLLEGE(Autonomous)Approved by AICTE, New Delhi Affiliated to Anna University, Chennai Accredited by NAACwith “A” Grade Accredited by NBA (CSE, EEE, MECH)NAGAPATTINAM – 611 002DEPARTMENT OF MECHANICAL ENGINEERING1702ME402 - MEASUREMENTS AND METROLOGY LABORATORYName: Reg. No.: Branch: Year & Sec.: @EGS PILLAY ENGINNERING COLLEGEPage 2
INDEXEX.NO.1DATENAME OF THE 15Completed Date:Average Mark:@DEPT. OF MECH. ENGG., EGSPECStaff-in-chargePage 3
LIST OF EXPERIMENTSEX.NO.123NAME OF THE EXPERIMENTIntroduction to Metrology and MeasurementsComparing the accuracy of Vernier Caliper, Vernier Height Gauge,Vernier Depth Gauge and Micrometer to check the various dimensions ofa given specimenChecking the dimensional limits of components using MechanicalComparatorPAGENO.57114Measurement of taper angle of a specimen using Sinebar135Measurement of thread specifications by Floating Carriage Micrometer1567Measurement of gear tooth specifications by using Gear Tooth VernierCaliperMeasurement of gear tooth specifications by using Tool Marker‟sMicroscope17198Measurement of Thread Parameters using Profile Projector229Measurement of Surface Roughness using Surface Roughness Tester2510Measurement of Force using Force measuring setup2711Measurement of Straightness using Autocollimator2912Measurement of Temperature using Thermocouple3113Measurement of Torque using Torque Measuring Setup3314Measurement of Distance using LVDT3515Measurement of bore diameter using Telescopic Gauge3716Viva questions@DEPT. OF MECH. ENGG., EGSPEC39-57Page 4
EX. NO.: 1INTRODUCTION TO METROLOGYAND MEASUREMENTSDATE:AIM:To study about the basics of the metrology and measurements.FUNDAMENTALS:Metrology is a “Science of measurement‟. The most important parameter in metrology isthe length. Metrology is divided into Industrial Metrology and Medical Metrology underconsideration of its application and may be divided into metrology of length and Metrology oftime under consideration of its quantity.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 MeasurementCommercial transactionsPublic health and human safety ensuring.BASIC CONCEPTS OF MEASUREMENTS: Measurement is the outcome of an opinion formed by observers about some physicalquantity.Measurement is an essential part of the development of technology.Measurement is a complex of operations carried out by means of measuring instruments.ELEMENTS OF A MEASUREMENT:Measurand: It is a physical quantity or property (length, diameter, thickness, angle etc.).Reference: Reference is a physical quantity or property and comparisons are made by them.Comparator: Comparing measurand with some other reference.@DEPT. OF MECH. ENGG., EGSPECPage 5
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 the design.For evaluating the performance of a system.To ensure interchangeability with a view to promoting mass production.Check the limitations of description in actual situation.To establish the validity of design and for finding new data and new designs.RESULT:Thus the basics of the metrology and measurements are studied.@DEPT. OF MECH. ENGG., EGSPECPage 6
EX. NO.: 2COMPARING THE ACCURACY OF VERNIERDATE:CALIPER, VERNIER HEIGHT GAUGE, VERNIERDEPTH GAUGE AND MICROMETER TO CHECK THEVARIOUS DIMENSIONS OF A GIVEN SPECIMENAIM:To compare the accuracy of Vernier Caliper, Vernier Height Gauge, Vernier Depth Gaugeand Micrometer to check the various dimensions of a given specimen.APPARATUS REQUIRED: Vernier CaliperVernier Height GaugeVernier Depth GaugeMicrometerSpecimen1. DESCRIPTION OF VERNIER CALIPER:Vernier caliper has two scales namely the main scale and Vernier scale which moves alongthe main scale. Verniers are used to measure both internal and also external dimensions. Thecaliper is placed on the object to be measured and the fine adjustment screw is rotated until thejaws fit tightly against the workpiece. The readings from the main scale and Vernier scale aretaken. The main principle of Vernier is that the two scales of different sizes are used to measurethe dimension in high accuracy. The least count of Vernier caliper is 0.02mm.2. DESCRIPTION OF VERNIER HEIGHT GAUGE:This is also a Vernier caliper but attached with a special block and other attachments. Thewhole assembly is made in such s way to measure height of parts to be measured. A removalclamp is attached between measuring jaw and Vernier. Both upper and lower end of measuringjaws are parallel to the base of Vernier height gauge. A scribbling attachment is fitted to markscribe lines on the parts where it is required. Sometimes the measuring jaws of the Vernier arereplaced by a dial gauge according to the type of measurement is needed. Least count of Vernierheight gauge is 0.02mm.3. DESCRIPTION OF VERNIER DEPTH GAUGE:A Vernier depth gauge is one type of Vernier caliper. The graduated scale is directly slidethrough the base but the Vernier scale remains stationary. This instrument is mainly used formeasuring the depth of holes, recesses and distance from a plane. The range trueness andsquareness of Vernier depth gauges should be correct. Otherwise the rest of the depth gauges willbe inclined. The base and anvil should be firmly rested on the surface of the part to be measured.If it is not so the base may be lifted above the surface of the part. Sometimes the base may beaffected by a trifle affected when the applied force increases. The least count of Vernier depthgauge is 0.02mm.@DEPT. OF MECH. ENGG., EGSPECPage 7
4. DESCRIPTION OF MICROMETER:The micrometer is a linear measuring instrument. The micrometer has an accurate screwconsisting of 10 to 20 threads per cm. This screw rotates inside a fixed nut. The end of the screwacts as one measuring tip and fixed anvil acts as other measuring tip. Threads are cut for certainlength on screw and it is left to free remaining portion called sleeve. The spindle moves towardsthe fixed anvil or away from it by rotating the thimble. The spindle is placed inside the barrel insuch a way to freely to slide over the barrel. The barrel is firmly fixed with the frame. 20divisions per cm are made in the barrel. This is the lead screw for one complete revolution. Onecomplete rotation of barrel is produced 0.5 mm movement of an anvil and the least count ofmicrometer is 0.01mmPROCEDURE FOR VERNIER CALIPER, HEIGHT GAUGE AND DEPTH GAUGE:1.2.3.4.5.6.Check the zero reading for error.Place the workpiece to be measured in between the measuring face.Adjust the sliding jaw until there is no further movement of sliding bar.Note the main scale, Vernier reading for the calculation of workpiece dimension.Tabulate the readings.Then the dimension of workpiece is calculated and average value is taken.PROCEDURE FOR MICROMETER:1.2.3.4.5.6.Check the zero position for error.Place the specimen to be measured.Adjust the spindle by rotating the ratchet unit at began to slip.Note the reading on the main scale and the thimble scale.By calculating the division on both scales the reading was tabulated.Thus the thickness of the workpiece was measured.DIAGRAM:(i)Vernier Caliper@DEPT. OF MECH. ENGG., EGSPEC(ii) Vernier Height GaugePage 8
(iii) Vernier Depth Gauge(iv) MicrometerTABULATION:TrialNo.Type oftheinstrument1Vernier Caliper2Vernier HeightGauge3Vernier DepthGauge4MicrometerMain ScaleVernier / ThimbleReading (MSR)Scale Reading(mm)(VSR/TSR) (mm)@DEPT. OF MECH. ENGG., EGSPECMeasured Value ofAveragethe SpecimenValue (mm) MSR VSR (mm)Page 9
RESULT:i.Length of the Specimen: -----------------------------ii.Height of the Specimen: -----------------------------iii.Depth of the Specimen: -----------------------------iv.Thickness of the Specimen: -----------------------------Thus the accuracy of Vernier Caliper, Vernier Height Gauge, Vernier Depth Gauge andMicrometer is compared for a given specimen.OUTCOME:Students will be able to select proper linear measuring instruments and know requirementof calibration, errors in measurement can perform accurate measurements.APPLICATIONS:1. Quality Department@DEPT. OF MECH. ENGG., EGSPECPage 10
EX. NO.: 3CHECKING THE DIMENSIONAL LIMITS OFCOMPONENTS USING MECHANICALCOMPARATORDATE:AIM:To check the dimensional limits of the given workpiece with a standard specimen usingmechanical comparator.APPARATUS REQUIRED: Mechanical ComparatorStandard specimenDESCRIPTION:The mechanical comparator is a one of the type of comparator used to only check thespecimen. There are graduations in the dial gauge and there is a counter dial in the gauge. Thereis a plunger, by this sensitive plunger the pointer in the dial gauge points out the reading. Byusing the slip gauge the values of the specimen was verified. The least count of mechanicalcomparator is 0.01mm.PROCEDURE:1.2.3.4.Measure the height of the specimen using a vernier height gauge.Take a standard specimen and get the value in the comparator.Check for the deviation from standard value using the dial gauge.Check all the test pieces, note down the variations, and mention if it is „Accepted‟ (or) „Rejected‟.DIAGRAM:@DEPT. OF MECH. ENGG., EGSPECPage 11
TABULATION:Height of the Standard Specimen :Tolerance:TrailNo.Dial gauge readingDivisionsActual Reading(mm)Deviation(mm)SampleAccept/ Reject(mm)12345RESULT:The dimensional limits of the given workpiece are checked with a standard specimen usingmechanical comparator.OUTCOME:Students will be able to check the variation in tolerance during the inspection process of amachined part.APPLICATIONS:1. Alignments checking in Lathe, Drilling and Milling machines.@DEPT. OF MECH. ENGG., EGSPECPage 12
EX. NO.: 4MEASUREMENT OF TAPER ANGLE OF ASPECIMEN USING SINEBARDATE:AIM:To measure the taper angle of given specimen using Sinebar.APPARATUS REQUIRED: Sine barSlip gaugeSurface plateDESCRIPTION:Sine bars are always used along with slip gauge as the device for the anglemeasurement. Generally sine bars are made from high carbon, high chromium and corrosionresistant steel. These materials are highly hardened, ground and establish. In sine bars twocylinders of equal diameter are attached at the ends parallel to each other. The distance betweentwo cylinders is 100mm, 200mm, or 300mm. There are some relief holes was made in the sinebar mainly to reduce the weight also to facilitate handling.FORMULA:Sin h1-h2/LHere, h is the required slip gauge combination in mm and L is the spacing between the rollers inmm.PROCEDURE:1. Clean the surface plate and Place the set-up on the surface plate2. Note down the length of the sine bar3. Note down the dimensions of the slip gauges available4. For the given angle, calculate the height of the slip gauge required5. Bring all the selected slip gauges together, so that the combination gives the height h6. Place the sine bar with the contact roller on top of the combination of slip gauges on the surfaceplate, as shown in Fig.7. Measure the built-up angle to ascertain accuracy, if angle/gap gauges are availableDIAGRAM:@DEPT. OF MECH. ENGG., EGSPECPage 13
TABULATION:Trail No.Height of Slip Gaugeat left side (h1) (mm)Height of Slip Gaugeat right side (h2) (mm)Angle ( )(h1-h2)/l(degree)12345RESULT:The taper angle of the given specimen using sinebar is ---------------degrees.OUTCOME:Student will become familiar with sinebar that is available for angular measurements.APPLICATIONS:1. To measure unknown angle of the specimen2. To locate the tool for known angle@DEPT. OF MECH. ENGG., EGSPECPage 14
EX. NO.: 5MEASUREMENT OF THREAD SPECIFICATIONSBY FLOATING CARRIAGE MICROMETERDATE:AIM :To measure the major, minor and effective diameters of given thread component by usingFloating Carriage Micrometer.APPARATUS REQUIRED: Floating Carriage MicrometerStandard wiresSpecimen screwSpecimenDESCRIPTION:Floating carriage micrometer is also a micrometer used to measure the major diameter,minor diameter and the effective diameter of a threaded surface. This micrometer having a mainscale, thimble scale and an anvil and also a pressure gauge is attached to measure the applyingpressure. The least count of the floating carriage micrometer is 0.002mm.PROCEDURE:1. First the indicator of the pressure gauge is set to zero by using initial adjustment then thespecimen is placed between two centre‟s, the standard dimensions in the correspondingvalues are noted.2. Then the thread plug gauge is placed in the two centers for measuring the effective, majorand minor diameter.3. Simultaneously the thread work piece is first measured by placing between the twocenters.4. By placing the prism plug gauge, the readings are noted. By using the formula, we cancalculate the Rw of the work piece.DIAGRAM:@DEPT. OF MECH. ENGG., EGSPECPage 15
FORMULA:1. Major diameterMax D (Rs – Rw)Min D - (Rs – Rw)2. Minor diameterMax D (Rs – Rw)Max D - (Rs – Rw)3. Effective diameterMax D (Rs – P) - RwMax D (Rs – P) - RwTABULATION:ParameterDiameter(mm)Std. Reading‘Rs’(mm)Work PieceReading inorDiameterEffectiveDiameterRESULT:1. Major diameter of the specimen -----------------------2. Minor diameter of the specimen -----------------------3. Effective diameter of the specimen -----------------------Thus the minor, major and effective diameters of specimen are measured by using FloatingCarriage Micrometer.OUTCOME:Students will be able to determine the various parameters of thread using Floating CarriageMicrometer.APPLICATIONS:Gauge dimensions such as outside diameter, pitch diameter, and root diameter are measuredwith the help of this instrument.@DEPT. OF MECH. ENGG., EGSPECPage 16
EX. NO.: 6MEASUREMENT OF GEAR TOOTHSPECIFICATIONS BY USING GEAR TOOTHVERNIER CALIPERDATE:AIM:To measure the thickness and depth of the gear using Gear Tooth Vernier.APPARATUS REQUIRED: Gear tooth VernierSpecimen - spur gearDESCRIPTION:Gear tooth Vernier is also a type of Vernier used to measure the depth between the gearsand thickness of the tooth in a same operation. This gear tooth Vernier having separate main scaleand Vernier scale for the measurement of thickness and depth. The lower main scale and slidingVernier scale in horizontal direction is used to measure the thickness of the teeth. The main scaleand Vernier scale in vertical direction is used to measure the depth between teeth.PROCEDURE:1. Calculate chordal thickness W and chordal addendum d using the following formula:Chordal thickness (W) N m sin (90/N)Depth (d) N m/2 [1 2/n cos 90/N]where N is the number of teeth and m is the module.2. Determine the error in the chord with a gear tooth vernier caliper.3. Determine the error in the instrument in the vertical and horizontal vernier jaws coinciding withmainframe4. Note down the error5. Adjust the vertical vernier jaw for the chordal addendum d and place the tongue over the space ofthe gear tooth (i.e., d error value)6. Measure the gear tooth thickness w in a manner similar to the measurement by a conventionalcaliperDIAGRAM:@DEPT. OF MECH. ENGG., EGSPECPage 17
TABULATIONGear Tooth NumberMain Scale Reading(mm)Vernier ScaleReading (mm)Measured Value(mm)GEAR TOOTH DEPTH:123GEAR TOOTH THICKNESS:123RESULT:i. Gear tooth thickness --------------------------------ii. Gear tooth width ---------------------------------Thus the thickness and depth of the gear using Gear Tooth Vernier is measured.OUTCOME:Students will be able to select proper measuring instrument for measuring gear tooththickness.APPLICATIONS:Measuring hobs, form and thread tools.@DEPT. OF MECH. ENGG., EGSPECPage 18
EX. NO.: 7MEASUREMENT OF GEAR TOOTHSPECIFICATIONS BY USING TOOL MARKER’SDATE:MICROSCOPEAIM:To measure the major diameter, minor diameter, and pitch of the given screw thread using atool marker‟s microscope.APPARATUS REQUIRED: Tool maker‟s microscopeSteel scaleSpecimen screwDESCRIPTION:A large tool maker‟s microscope, shown in Fig., essentially consists of a cast base, themain lighting unit, the upright with carrying arm, and the sighting microscope. The rigid cast baserests on three foot screws by means of which the equipment can be leveled with reference to thebuild-in box level. The base carries the coordinate measuring table, consisting of two measuringslides, one along the X and the other along the Y direction, and a rotary circular table providedwith a glass plate. The slides run on precision balls in hardened guide ways warranting reliabletravel. Two micrometer screws, each of them measuring a specified range given by the equipmentmanufacturer, permit the measuring table to be displaced in the directions X and Y. The range ofmovement of the carriage can be widened up to 150 mm in the X direction and up to 50 mm in theY direction with the use of gauge blocks.PROCEDURE:The steps to be adopted for the experimental procedure are as follows:1. Clamp the given screw thread on the table keeping the axis approximately horizontal2. Move the microscope in the X and Y directions to the vicinity of the screw thread profile3. Adjust the optical head for focusing the screw thread profile at the cross-wires.(i). Measurement of Major or Outer DiameterThe major or outer diameter can be measured in the following way:1. Coincide the horizontal cross-wire to the crest (outermost point) of the screw thread profile. Notedown the reading (IR)2. Move the optical head along the Y-axis and coincide the horizontal cross-wire with the outermostpoint on the other side of the profile. Note down the reading (FR)3. The difference between initial reading and final reading gives the major diameter.(ii). Measurement of Inner or Minor DiameterThe inner or minor diameter can be measured in the following way:1. Coincide the horizontal cross-wire with the root of the screw thread profile. Note down thereading (IR)2. Move the optical head along the Y-axis and coincide the horizontal cross with the root of thescrew thread on the other side3. The difference between final reading and initial reading gives the inner or minor diameter@DEPT. OF MECH. ENGG., EGSPECPage 19
(iii). Measurement of PitchThe steps involved in pitch measurement are as follows:1. Coincide the vertical cross-wire approximately with the line of symmetry passing through thescrew thread, apex, or notch. Note down the reading (IR)2. Move the optical head along the X-axis and coincide the cross-wire with the adjacent screwthread. Note down the reading (FR).3. The difference between initial reading and final reading gives the pitch of the screw thread. Theexperimental results are documented in Table.DIAGRAM:@DEPT. OF MECH. ENGG., EGSPECPage 20
TABULATION:ParameterTrial No.FinalInitialReading (IR) Reading (FR)Difference(IR-FR)Average (mm)1OuterDiameter (D)21Inner Diameter(d)21Pitch (p)2
1702ME402 - MEASUREMENTS AND METROLOGY LABORATORY LAB MANUAL Prepared & Compiled by Dr. J.Jeevamalar, M.E., Ph.D. Laboratory in Charge @EGS PILLAY ENGINNERING COLLEGE Page 2 . Metrology is a “Science of measurement‟. The most important parameter in metrology is
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