DEPARTMENT OF MECHANICAL ENGINEERING
ME6513 – METROLOGY AND MEASUREMENTS LABORATORY
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V SEMESTER - R 2013
LABORATORY MANUAL
Name : _________________________
Register No. : _________________________
Section : _________________________
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DHANALAKSHMI
VISION
College of Engineering is committed to provide highly disciplined, conscientious and enterprising professionals conforming to global standards through value based quality education and training.
MISSION
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- To provide competent technical manpower capable of meeting requirements of the industry
- To contribute to the promotion of Academic Excellence in pursuit of Technical Education at different levels
- To train the students to sell his brawn and brain to the highest bidder but to never put a price tag on heart and soul
DEPARTMENT OF MECHANICAL ENGINEERING
VISION
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Rendering the services to the global needs of engineering industries by educating students to become professionally sound mechanical engineers of excellent caliber.
MISSION
To produce mechanical engineering technocrats with a perfect knowledge intellectual and hands on experience and to inculcate the spirit of moral values and ethics to serve the society
PROGRAMME EDUCATIONAL OBJECTIVES (PEOS)
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- Fundamentals
To impart students with fundamental knowledge in mathematics and basic sciences that will mould them to be successful professionals
- Core competence
To provide students with sound knowledge in engineering and experimental skills to identify complex software problems in industry and to develop a practical solution for them
- Breadth
To provide relevant training and experience to bridge the gap between theory and practice which enable them to find solutions for the real time problems in industry and organization and to design products requiring interdisciplinary skills
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- Professional skills
To bestow students with adequate training and provide opportunities to work as team that will build up their communication skills, individual, leadership and supportive qualities and to enable them to adapt and to work in ever changing technologies
- Life-long learning
To develop the ability of students to establish themselves as professionals in mechanical engineering and to create awareness about the need for lifelong learning and pursuing advanced degrees
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PROGRAMME OUTCOMES (POS)
On completion of the B.E. (Mechanical) degree, the graduate will be able
- To apply the basic knowledge of mathematics, science and engineering
- To design and conduct experiments as well as to analyze and interpret data and apply the same in the career or entrepreneurship
- To design and develop innovative and creative software applications
- To understand a complex real world problem and develop an efficient practical solution
- To create, select and apply appropriate techniques, resources, modern engineering and IT tools
- To understand the role as a professional and give the best to the society
- To develop a system that will meet expected needs within realistic constraints such as economical environmental, social, political, ethical, safety and sustainability
- To communicate effectively and make others understand exactly what they are trying to tell in both verbal and written forms
- To work in a team as a team member or a leader and make unique contributions and work with coordination
- To engage in lifelong learning and exhibit their technical skills
- To develop and manage projects in multidisciplinary environments
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?6513 – METROLOGY AND MEASUREMENTS LABORATORY
COURSE OBJECTIVES
To familiar with different measurement equipment's and use of this industry for quality inspection
List of Experiments
- Tool Maker's Microscope
- Comparator
- Sine Bar
- Gear Tooth Vernier Caliper
- Floating gauge Micrometer
- Coordinate Measuring Machine
- Surface Finish Measuring Equipment
- Vernier Height Gauge
- Bore diameter measurement using telescope gauge
- Bore diameter measurement using micrometer
- Force Measurement
- Torque Measurement
- Temperature measurement
- Autocollimator
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COURSE OUTCOMES
- Ability to handle different measurement tools and perform measurements in quality impulsion
- Learnt the usage of precision measuring instruments and practiced to take measurements
- Learnt and practiced to build the required dimensions using slip gauge
- Able to measure the various dimensions of the given specimen using the tool maker's microscope
- Able to find the accuracy and standard error of the given dial gauge
- Able to measure taper angle of the given specimen using Sine bar method and compare
- Learnt to determine the thickness of tooth of the given gear specimen using Gear tooth vernier
- Able to measure the effective diameter of a screw thread using floating carriage micrometer by two wire method
- Learnt to study the construction and operation of coordinate measuring machine
- Learnt to determine the diameter of bore by using telescopic gauge and dial bore indicator
- Able to measure the surface roughness using Talysurf instrument
- Studied the characteristic between applied load and the output volt
- Learnt the characteristics of developing torque and respective sensor output voltage
- Studied the characteristics of thermocouple without compensation
- Able to check the straightness & flatness of the given component by using Autocollimator
- Learnt to measure the displacement using LVDT and to calibrate it with the millimeter scale reading
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?6513 – METROLOGY AND MEASUREMENTS LABORATORY
CONTENTS
| Sl. No. | Name of the Experiments | Page No. |
|---|---|---|
| CYCLE - 1 EXPERIMENTS | ||
| 1 | Precision measuring instruments used in metrology lab – A Study | 7 |
| 2 | To build up the slip gauge for given dimension – A Study | 16 |
| 3 | Thread parameters measurement using Tool Makers Microscope | 20 |
| 4 | Calibration of dial gauge | 23 |
| 5 | Determination of taper angle by sine bar method | 26 |
| 6 | Determination of gear tooth thickness using gear tooth vernier | 29 |
| 7 | Measurement of thread parameters using floating carriage micrometer | 32 |
| CYCLE - 2 EXPERIMENTS | ||
| 8 | Measurement of various dimensions using Coordinate Measuring Machine | 35 |
| 9 | Measurement of surface roughness | 39 |
| 10 | Measurement of bores using dial bore indicator and telescopic gauge | 42 |
| 11 | Force measurement using load cell | 46 |
| 12 | Torque measurement using strain gauge | 49 |
| 13 | Temperature measurement using thermocouple | 53 |
| 14 | Measurement of alignment using autocollimator | 56 |
| ADDITIONAL EXPERIMENT BEYOND THE SYLLABUS | ||
| 15 | Thread parameters measurement using profile projector | 60 |
| 16 | Displacement measurement – linear variable differential transducer (LVDT) | 62 |
| PROJECT WORK | 65 | |
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Expt.No.01 PRECISION MEASURING INSTRUMENT USED IN METROLOGY LAB – A STUDY
Aim:
To study the following instruments and their usage for measuring dimensions of given specimen
- Vernier caliper
- Micrometer
- Vernier height gauge
- Depth micrometer
- Universal bevel protractor
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Apparatus required:
Surface plate, specimen and above instruments
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Vernier caliper:
The principle of vernier caliper is to use the minor difference between the sizes two scales or divisions for measurement. The difference between them can be utilized to enhance the accuracy of measurement. The vernier caliper essentially consists of two steel rules, sliding along each other.
Parts:
Different parts of the vernier caliper are
- Beam - It has main scale.
- Fixed jaw
- Sliding or Moving jaw – It has vernier scale and sliding jaw locking screw.
- Fine adjustment clamp – It has fine adjustment clamp locking screw and fine adjustment screw knife edges for internal measurement.
- Stem or depth bar for depth measurement
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Least count:
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Least count = 1 MSD – 1 VSD
1 MSD = 1 mm
50 VSD = 49 mm
1 VSD = 0.98 mm
Least count = 1 -0.98 = 0.02 mm
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Measurement:
Given Vernier caliper can be used for external, internal depth, slot and step measurement.
Measurement principle:
When both jaws contact each other scale shows the zero reading. The finer adjustment of movable jaw can be done by the fine adjustment screw. First the whole movable jaw assembly is adjusted so that the two measuring tips just touch the part to be measured. Then the fine adjustment clamp locking screw is tightened. Final adjustment depending upon the sense of correct feel is made by the adjusting screw. After final adjustment has been made sliding jaw locking screw is also tightened and the reading is noted.
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All the parts of the Vernier caliper are made of good quality steel and measuring faces are hardened.
Types of vernier:
Vernier caliper, electronic vernier caliper, vernier depth caliper
Tabulation:
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| Main scale reading (MSR) (mm) | Vernier scale coincidence (VSC) | Vernier scale reading (VSR) (mm) | Total reading (MSR + VSR) (mm) |
|---|---|---|---|
| OD | |||
| ID | |||
| Depth |
Vernier height gauge:
Vernier height gauge is a sort of vernier caliper equipped with a special instrument suitable for height measurement. It is always kept on the surface plate and the use of the surfaces plates as datum surfaces is very essential.
Least count:
Least Count = 1 MSD - 1 VSD
1 MSD = 1 mm
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50 VSD = 49 mm
1 VSD = 0.98 mm
Least Count (LC) = 1 – 0.98 = 0.02 mm
Parts:
- Base
- Beam - It has main scale.
- Slider - It has a vernier scale and slider locking screw.
- Scriber
- Fine adjustment clamp – It has fine adjustment clamp locking screw and fine adjustment screw.
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Material:
All the parts of vernier are made of good quality steel and the measuring faces hardened.
Types of vernier gauge:
- Analog vernier height gauge
- Digital vernier height gauge
- Electronic vernier height gauge
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Tabulation:
| SI.No. | Main scale reading (MSR)(mm) | Vernier scale coincidence (VSC) | Vernier scale reading (VSR)(mm) | Total reading (MSR + VSR)(mm) |
|---|---|---|---|---|
| 1. | ||||
| 2. | ||||
| 3. |
Outside micrometer:
The micrometer essentially consists of an accurate screw having about 10 or 20 threads per cm. The end of the screw forms one measuring tip and other measuring tip is constituted by a stationary anvil in the base of the frame. The screw is threaded for certain length and is plain afterwards. The plain portion is called spindle and its end is the measuring surface. The spindle is advanced or retracted by turning a thimble connected to a spindle. The spindle is a slide fit over the barrel and barrel is the fixed part attached with the frame. The barrel & thimble are graduated. The pitch of the screw threads is 0.5 mm.
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Least count:
Least Count (LC) = Pitch / No. of divisions on the head scale
= 0.5/50 =0.01 mm
Parts:
- Frame
- Anvil
- Spindle
- Spindle lock
- Barrel or outside sleeve
- Thimble - It has head scale. Thimble is divided into 50 divisions
- Ratchet stop – Barrel is graduated into steps of 0.5 mm.
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The least count of the given micrometer is 0.01 mm.
Measurement:
It can be used for any external measurement.
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Types of micrometer:
- Outside micrometer,
- Inside micrometer,
- Depth micrometer,
- Stick micrometer,
- Screw thread micrometer,
- V – anvil micrometer,
- Blade type micrometer,
- Dial micrometer,
- Bench micrometer,
- Tape screw operated internal micrometer,
- Groove micrometer,
- Digital micrometer,
- Differential screw micrometer,
- Adjustable range outside micrometer.
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Ratchet stop mechanism:
The object of the ratchet stop is to ensure that same level of torque is applied on the spindle while measuring and the sense of the feel of operator is eliminated and consistent readings are obtained. By providing this arrangement, the ratchet stop is made slip off when the torque applied to rotate the spindle exceeds the set torque. Thus this provision ensures the application of same amount of torque during the measurement.
Tabulation:
| SI.No. | Pitch Scale Reading (PSR) (mm) | Head Scale Coincidence (HSC) | Head scale reading (HSR x LC) (mm) | Total Reading (PSR + HSR) (mm) |
|---|---|---|---|---|
| 1. | ||||
| 2. |
Depth micrometer:
Depth micrometer is a sort of micrometer which is mainly used for measuring depth of holes, so it is named as depth micrometer.
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Parts:
- Shoulder
- Spindle
- Spindle lock
- Barrel or outside sleeve – It has pitch scale.
- Thimble - It has head scale. Thimble is divided into 50 divisions.
- Ratchet stop – Barrel is graduated into steps of 0.5 mm.
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The least count of the given micrometer is 0.01 mm.
Least count:
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Least Count = Pitch / No. of divisions on the head scale = 0.50/50
= 0.01 mm
Measurements:
It can be used for measuring the depth of holes, slots and recessed areas. The pitch of the screw thread is 0.5 mm. The least count is 0.01 mm. Shoulder acts as a reference surface and is held firmly and perpendicular to the centre line of the hole. For large range of measurement extension rods are used. In the barrel the scale is calibrated. The accuracy again depends upon the sense of touch.
Procedure:
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First, calculate the least count of the instrument. Check the zero error. Measure the specimen note down the main scale reading or the head scale reading. Note down the vernier or head scale coincidence with main or pitch scale divisions.
Tabulation:
| Sl.No. | Pitch Scale Reading (PSR) (mm) | Head Scale Coincidence (HSC) | Head scale reading (HSR x LC) (mm) | Total Reading (PSR + HSR) (mm) |
|---|---|---|---|---|
| 1. | ||||
| 2. |
Universal bevel protractor:
Description:
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Bevel protractor is an instrument for measuring the angle between the two faces of a specimen. It consists of a base plate on which a circular scale is engraved. It is graduated in degrees. An adjustment plate is attached to a circular plate containing the vernier scale. The adjustable blade can be locked in any position. The circular plate has 360 division divided into four parts of 90 degrees each. The adjustable parts have 24 divisions of to the right and left sides of zero reading. These scales are used according to the position of the specimen with respect to movable scale.
Procedure:
- Place the specimen whose taper is to be measured between the adjustable plate and movable blade with one of its face parallel to the base.
- Lock the adjustable plate in position and note down the main scale reading depending upon the direction of rotation of adjustable plate in clockwise or anticlockwise.
- Note the VSC to the right of zero.
- Multiply the VSC with the least count and add to MSR to obtain the actual reading.
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Least count:
Least Count = 2 MSD – 1 VSD
1 MSD = 1° 24 VSD = 46° => 1 VSD = 23/12
LC = 2 – 23/12 = 1/12° = 5' (five minutes)
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Tabulation:
| Sl.No. | Main scale reading (MSR) (deg) | Vernier scale coincidence (VSC) | Vernier scale reading (VSR) (deg) | Total reading (MSR + VSR) (deg) |
|---|---|---|---|---|
| 1. | ||||
| 2. |
The angle of scriber of the vernier height gauge =
Result:
Thus the various precision measuring instruments used in metrology lab are studied and the specimen dimensions are recorded.
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Outcome:
Student will become familiar with the different instruments that are available for linear, angular, roundness and roughness measurements they will be able to select and use the appropriate measuring instrument according to a specific requirement (in terms of accuracy, etc).
Application:
- Quality Department
Viva-voce
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- Define - Metrology
- Define - Inspection
- What are the needs of inspection in industries?
- What are the various methods involving the measurement?
- Define - Precision
- Define - Accuracy
- Define - Calibration
- Define - Repeatability
- Define - Magnification
- Define - Error
- Define - Systematic Error
- Define - Random Error
- Define - Parallax Error
- Define - Environmental Error
- Define - Cosine Error
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Expt.No.02 BUILD UP THE SLIP GAUGE FOR GIVEN DIMENSION – A STUDY
Aim:
To build up the slip gauge for given dimension
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Apparatus required:
- Slip gauges set
- Surface plate
- Soft cloth
Diagram:
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Description:
Slip gauge are universally accepted standard of length in industry. They are the working standard for linear dimension. These were invented by a Swedish Engineer, C.E. Johansson. They are used
- For direct precise measurement where the accuracy of the workpiece demand it.
- For use with high- magnification comparators to establish the size of the gauge blocks in general use.
- Gauge blocks are also used for many other purposes such as checking the accuracy of measuring instrument or setting up a comparator to a specific dimension, enabling a batch of component to be quickly and accurately checked or indeed in any situation where there is need to refer to standard of known length these blocks are rectangular.
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Most gauge blocks are produced from high grade steel, hardened and established by a heat treatment process to give a high degree of dimensional stability. Gauge blocks are also manufactured from tungsten carbide which is an extremely hard and wear resistant material. The measuring faces have a lapped finish. The faces are perfectly flat and parallel to one another with a high degree of accuracy. Each block has an extremely high dimensional accuracy at 20°C.
These slip gauge are available in variety of selected sets both in inch units and metric units. Letter 'E' is used for inch units and ‘M' is used for metric standard number of pieces in a set following the letter E or M. For example EBI refers to a set whose blocks are in metric units and are 83 in number. Each block dimensions is printed on anyone of its face itself the size of any required standard being made up by combining the appropriate number of these different size blocks.
If two gauges are slid and twisted together under pressure they will firmly join together. This process, known as wringing, is very useful because it enables several gauge blocks to be assembled together to produce a required size. In fact the success of precision measurement by slip gauges depends on the phenomenon of wringing.
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First the gauge is oscillated slightly with very light pressure over other gauge so as to detect pressure at any foreign particles between the surfaces. One gauge is placed perpendicular to other using standard gauging pressure and rotary motion is applied until the blocks are lined up.
Procedure:
- Build the given dimension by wringing minimum number of slip gauges.
- Note the given dimension and choose the minimum possible slip gauge available in the set so as to accommodate the last decimal value. The minimum slip gauge value dimension available i.e., 1.12 mm must be chosen followed by 1.5 mm thick gauge block.
- Follow the above steps to build up the slip gauge of any dimension.
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Precautions:
- Slip gauges should be handled very carefully placed gently and should never be dropped.
- Whenever a slip gauge is being removed from the set, its dimensions are noted and must be replaced into the set at its appropriate place only.
- Correct procedure must be followed in wringing and also in removing the gauge blocks.
- They should be cleaned well before use and petroleum jelly is applied after use.
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Tabulation:
| Range (mm) | Increment (mm) | No. of pieces |
|---|---|---|
Total = Pieces
Total length of slip gauge = mm
| Given diameter | Slip gauges used | Obtained dimensions |
|---|---|---|
Result:
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Slip gauge set is studied and the given dimensions are building up by wringing minimum number of slip gauges.
Outcome:
Students will be able to select proper measuring instrument and know requirement of calibration, errors in measurement etc. They can perform accurate measurements.
Application:
- Quality Department
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Viva-voce
- Why C.I. is preferred material for surface plates and tables?
- Why V - blocks are generally manufactured in pairs?
- Why micrometer is required to be tested for accuracy?
- Define - Linear Measurement
- List the linear measuring instrument according to their accuracy.
- Define Least Count
- What are the uses of vernier depth gauge?
- What are the uses of feeler gauges?
- What are the uses of straight edge?
- What are the uses of angle plate?
- What are the uses of V - block?
- What are the uses of combination square?
- What precautions should be taken while using slip gauges?
- What is wringing?
- Why the slip gauges are termed as “End standard"?
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Expt.No.03 THREAD PARAMETERS MEASUREMENT USING TOOL MAKERS MICROSCOPE
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Aim:
To study the tool makers microscope and in the process measure the various dimensions of the given specimen
Apparatus required:
- Tool makers microscope
- Specimen
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Diagram:
Description:
The tool maker's microscope is designed for measurement of parts of complex forms; for example, profile of a tool having external threads. It can also be used for measuring centre to centre distance of the holes in any plane as well as the coordinates of the outline of a complex template gauge, using the coordinates measuring system.
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Basically it consists of an optical head which can be adjusted vertically along the ways of supporting column. The optical head can be clamped at any position by a screw. On the work table (which as a circular base in which there are graduations) the part to be inspected is placed. The table has a compound slide by means of which the part can be measured. For giving these two movements, there are two micrometer screws having thimble scales and verniers. At the back of the base light source is arranged that provides horizontal beam of light, reflected from a mirror by 90 degrees upwards towards the table. The beam of light passes through the transparent glass plate on which flat plates can be checked are placed. Observations are made through the eyepiece of the optical head.
Procedure:
- Place the given specimen on the work table and switch on all the three light sources and
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