Metrology Manual - Final

KLE Society's
KLE Technological University

SCHOOL OF MECHANICAL ENGINEERING
LABORATORY MANUAL
Metrology and Quality Engineering Lab
2017-18
V Sem Bachelor of Engineering
(School of Mechanical Engineering)
KLE Society's
Curriculum Content
Course Code: 15EMEP301 Course Title: Metrology and Quality Engineering

Lab
L-T-P: 0-0-1 Credits: 1 Contact Hrs: 2
ISA Marks: 80 ESA Marks: 20 Total Marks: 100
Exam Duration: 2 hrs
Expt. Brief description about the experiment No. of

No. Lab.
Slots
01 Introduction to the Laboratory-Standards of measurement for Linear and 01

02 Analysis of performance characteristics of measuring instruments using 01
Hypothesis testing.
03 Analysis of Repeatability and Reproducibility using gauge R& R test. 01
04 Measurement of Angular dimensions 01
05 Measurement of Screw thread parameter(Profile Projector, 3-Wire Method 01
06 Measurement of Gear parameter(Gear tooth thickness) 01

07 Machine Tool Alignment Test (Lathe, Drilling, Milling). 01
08 Measurement of Dimensions and GD&T parameters of given components 01
using CMM (Coordinate Measuring Machine).
09 Extraction of 2-Dimensions of the given part using 3D scanner using 01
reverse engineering concept
10 Testing the goodness of fit for the given quality characteristics by Chi 01
Square test Construction and Analysis of control charts for defectives.
11 Construction of control chart for variables and defectives and analysis of 01
process capability for the different components manufacturing
12 Open ended experiment- Error analysis/ Gauge Design. 01
Reference books:
1. Hume K.J.& Sharp G.H, ”Practical metrology”, ELBS &Macdonald .
2. Montogomery D. C., Introduction to statistical Quality control, John wiley and sons.
3. Juran J.M. & F.M. Gryna, Quality Planning & Analysis, TMH.
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GENERAL INSTRUCTIONS:
Instruction to the students:
All students are,
 Required to be present in the laboratory in time.
 Informed to note down the tabular column, specifications of the

machines/Instruments, observations and calculations from lab manual before the
commencement of each lab.
 Informed to follow the procedure, which is given in the laboratory manual to

conduct respective experiment.
 Informed to come with the write- up and results of the previous experiment
without fail for conducting the next experiment.
 Informed to conduct each experiment in presence of staff member or lab instructor.
 Informed to take the instruments to conduct each experiment and must

return them on completion of that experiment without fail. If students are
unable to return the tools in good conditions, a suitable penalty will be imposed
on them.
Safety Precautions:
a) Contact the instructors before starting an instruments or the experiment
b) Do not start a machine of which the operation is not known which leads to accidents as
well as damage to the instrument.
c) Keep your eyes protected from the rays emitting from the lamp
source. d) Handle Instruments properly and carefully.
e) Avoid loose clothing and long unbuttoned sleeves while working on a
machine.
Dress code:
Student should wear sky blue pant and apron during his laboratory session.
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Experiment no. 1
1. Introduction to the Laboratory-Standards of measurement for Linear and angular dimensions.
Study of Slip gauges:
Slip gauges are rectangular blocks of steel having a cross-section of about 30 mm x 10

mm. These are first hardened to resist wear and carefully stabilized so that they are
independent of any subsequent variation in size or shape. After being hardened, blocks are
carefully finished on the measuring faces to such a fine degree of finish, flatness and
accuracy that the two faces, when perfectly clean, can be wrong together. This is
accomplished by pressing the faces in contact and then imparting a small twisting motion
whilst maintaining a contact pressure. The contact pressure is just sufficient in order to hold
the two slip gauges in contact. The phenomenon of wringing occurs due to molecular
adhesion between a liquid film and the mating surface. When two gauges are wrong together,
the overall dimension of a pile made up of two or more slips is exactly the sum of the
constituent gauges. It is the property of wringing units together for building up combinations
that the success of system depends, since by combining gauges selected from a suitably
arranged combination, almost any dimension may be built up.
The slip gauges may be used as reference standards for (transmitting, transferring
the dimensions of the unit of length from the primary standard to gauge blocks of lower
accuracy and for the verification and graduation of measuring apparatus and length measures
for the regulation and adjustment of indicating measuring apparatus.
These are classified according to their guaranteed accuracy as:
 AA for master slip gauges
 A for reference purpose
 B for working slips
As for grades or classes of slip gauges these can be in five grades as
below. Grade 2: For workshop grade
1: For good class room tool
0: For inspection
00: For work of highest precision only
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Calibration
grade:
This is a special grade with the actual sizes of slip calibrated on a special chart supplied with
the set. Except for this grade, all slip gauge sets are manufactured to within specified limits; the
closer the units, costlier the gauges.
Rectangular shaped slip gauges are most widely used ones as they are less costly to
manufacturer and adopt themselves better to application where space is restricted. The
accuracy of slip gauges can be affected by dimensional instability in the material, wear in
usage or handling. These can be taken care by periodic calibration.
Wringing:
It is defined as the property of measuring faces of a gauge block of adhering by sliding
or pressing the gauges against each other or the reference faces of datum surfaces without the
use of extraneous means.
It is believed that this phenomenon of wringing is due to molecular adhesion between a

liquid film and mating surfaces of flat gauges. The success of precision measurement by slip
gauges depends upon the phenomenon of wringing. It has been found that the gap between two
wring flat plates is of the order of 0.00635 m.
Procedure for conducting the experiment:
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Slip Gauge Box –1 (M83)
Sl. No. Range Increment No. of slips
Total Number of slip gauges
Slip Gauge Box –2(M125)
Sl. Range Increment No. of slips

No.
1
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Slip Gauge Box –2(M112)
Sl.
Range Increment No. of slips
No.
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KLE Society's
Experiment no.1
Title of the experiment: - Calibration of Vernier and Micrometer
Learning Objectives:
The students should be able to:
1. Ensure that an instrument is working properly and hence will be suitable for its
intended monitoring purpose.
2. Compares the actual value with indicated value.
Aim of the experiment: -To calibrate the given Vernier Calliper for progressive error.
Apparatus: - Vernier Calliper, slip gauge set.
Theoretical background the experiment: -
The principle of Vernier is that when two scales or divisions slightly different in size
are used, the difference between them can be utilized to enhance the accuracy of
measurement. The Vernier Calliper essentially consists of two steel rules and these can slide
along each other. The details are shown in fig. below
Fig.1 Vernier Calliper

1. Outside jaws: used to measure external diameter or width of an object
2. Inside jaws: used to measure internal diameter of an object
3. Depth probe: used to measure depths of an object or a hole
4. Main scale: gives measurements of up to one decimal place (in cm).
5. Main scale: gives measurements in fraction(in inch)
6. Vernier gives measurements up to two decimal places(in cm)
7. Vernier gives measurements in fraction(in inch)
Procedure to carry out the experiment: -
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.
Table of Observation:-
1. Range of given Vernier Calliper ---------------- mm
2. Least count of Vernier Calliper -------------------mm
3. Given range for calibration ----------------------------------mm
4. Specification of slip gauge box = ----------------------
Sl. No. Vernier Calliper reading Slip gauge reading (B) Error (A-B) in mm
(A) in mm in mm
(Actual Value) (True Value) (AV-TV)
Space for calculation:
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Graph
Plot the graph: Error v/s Indicating reading
Results: -
1. The graph thus drawn is called as calibration chart of the Vernier Calliper.
2. This calibration chart can be used for the micrometer to measure the dimensions
accurately.
Calibration of Micrometer
1. Ensure that an instrument is working properly and hence will be suitable for
its intended monitoring purpose.
2. Compares the actual value with indicated value.
Aim of the experiment: -To calibrate the given micrometer screw gauge for
progressive error and periodic error.
Apparatus: - Micrometer screw gauge, slip gauge set, micrometer stand.
The calibration of any measuring system is very important to get meaningful results
comparing the known indicated value of the instrument with the available standards. . In this
case we are using slip gauges as the standard. These are rectangular end standards. Because
of their wringing property, any dimension can be build up by combination of gauges.
Micrometer screw gauge is consists of an accurate screw having 10 or 20 thread per cm and
revolves in a fixed nut. A stationery anvil in the box constitutes the end of the screw forms on
measuring tip and other tip. The screw is threaded for certain length and plain afterwards.
The plain portion is called sleeve and its end is the measuring surface. The spindle the plain is
called sleeve and its end is the measuring surface .The spindle is advanced or retracted by
turning a thimble connected to the spindle. A lock nut is provided for locking a dimension by
preventing motion of the spindle. Ratchet stop consists of an overriding clutch held by a weak
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spring. When the spindle is brought into contact with work at correct measuring pressure, the
clutch starts slipping and no further movement of the spindle takes place by the rotation of
the ratchet
Fig.2.1 Micrometer screw gauge
1. Range of given micrometer screw gauge ---------------- mm
2. Least count of micrometer screw gauge -------------------mm
4. Specification of slip gauge box = ----------------------
For progressive error:
Sl. No. micrometer reading Slip gauge reading Error (A-B) in

(A) (B) mm
in mm in mm
(Actual Value) (True Value) (AV-TV)
1
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Graph
Plot the graph: Error v/s Indicating reading
Results: -
1. The graph thus drawn is called as calibration chart of the micrometer.
2. This calibration chart can be used for the micrometer to measure the dimensions
accurately.
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Experiment no:2
Title of the experiment: Analysis of performance characteristics of measuring instruments using

Hypothesis testing.
1. Compare responses from two samples and differentiate between the means of the
same.
2. Carry out the hypothesis testing depending upon the sample size.
3. Test this on Minitab-16 software package.
Aim of the experiment: Design and conduct an experiment to compare the calibration
performances of two measuring instruments and analyse the data collected by using
Hypothesis testing and determine the following situations (using sample size n≤30),
 Is there a significant difference between the means of the population of measurements

from which the two samples were selected? Use α=0.05
 Find the p-value for the test.
 Draw the box-plots and analyse the data.
 Perform the above test using Minitab-16 software package.
Apparatus: Component (or sample), Instrument (Vernier Calliper or Micrometer screw

gauge)
Theoretical background the experiment:
Hypothesis testing:
A procedure, based on sample evidence and probability theory, used to determine whether the
hypothesis is a reasonable statement and should not be rejected, or is unreasonable and
should be rejected.If the population standard deviation, σ, is known and either the data is
normally distributed or the sample size n > 30, we use the normal distribution (z-statistic).
When the population standard deviation, σ, is unknown and either the data is normally
distributed or the sample size is lesser than 30 (n < 30), we use the t-distribution (t-statistic).
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Introduction to the z and t-tests

Z-test and t-test are basically the same; they compare between two means to suggest whether
both samples come from the same population. There are however variations on the theme for
the t-test. If you have a sample and wish to compare it with a known mean (e.g. national
average) the single sample t-test is available. If both of your samples are not independent of
each other and have some factor in common, i.e. geographical location or before/after
treatment, the paired sample t-test can be applied. There are also two variations on the two
sample t-test, the first uses samples that do not have equal variances and the second uses
samples whose variances are equal.
Data types that can be analysed with z-tests
 Data points should be independent from each other.
 Z-test is preferable when n is greater than 30.
 The distributions should be normal if n is low, if however n>30 the distribution of the
data does not have to be normal.
 The variances of the samples should be the same (F-test).
 All individuals must be selected at random from the population.
 All individuals must have equal chance of being selected.
 Sample sizes should be as equal as possible but some differences are allowed.
Data types that can be analysed with t-tests

 Data sets should be independent from each other except in the case of the paired-
sample t-test where n<30 the t-tests should be used.
 The distributions should be normal for the equal and unequal variance t-test (K-S test
or Shapiro-Wilke).
 The variances of the samples should be the same (F-test) for the equal variance t-test.
 All individuals must be selected at random from the population.
 All individuals must have equal chance of being selected.
 Sample sizes should be as equal as possible but some differences are allowed.
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Limitations of the tests

If you do not find a significant difference in your data, you cannot say that the samples are
the same.
H0:- There is no significant difference between the performances of two instruments

H1:- There is significant difference between the performances of two instruments
Procedure to carry out the experiment:
1. Range of given Vernier Calliper (1 & 2) ---------------- mm
2. Least count of Vernier Calliper(1& 2) -------------------mm
4. Specification of slip gauge box = ---------------------
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Tabular column
Sl. No. Inspector Verniar Calliper Verniar Calliper 2 (Y2)
1(Y1)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Results:
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Experiment no:3
Title of the experiment: Analysis of Repeatability and Reproducibility using gauge R& R test
The specific objectives of the current initiative in the metrology laboratory are
Achieve higher order of learning.
Determine whether the measurement systems is adequate or not
Predict how the precision of a measurement system affects the variability of a measurement using a
crossed gage R&R study.
Theoretical background the experiment:-“MEASURE FOR MEASURE” is a word which tells

about the need for a reliable measurement system, which is used in decision making in a
manufacturing industry. Despite the quality being a major concern for manufacturing organizations,
experts in manufacturing industries, express their anxiety about the measurement reliability, which
is used in decision making.The quality of the data measured is vital for appropriate understanding,
monitoring or improving a process. If the data are contaminated with errors, it could lead to wrong
decisions. The ability to make the right decisions depends on the availability of a measurement
process, selecting the right measurement process and operating the measurement process in the
correct manner. When the data quality is low, the benefits of a measurement system are also low;
likewise when the data quality is high, the benefit is high too
The measurement systems analysis (MSA) assesses the adequacy of a measurement system for a
given application. In measuring the output from a process, there are two sources of variation,
namely, part-to-part variation and measurement system variation. Before you collect data from the
process in order to analyze and control the process, use measurement system analysis (MSA) to
confirm that the measurement system measures consistently and accurately, and adequately.
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Measurement System Variations
Repeatability: - The variation due to the measuring device, or the variation observed
when the same operator measures the same part repeatedly with the same device.
Reproducibility: - The variation due to the measuring system, or the variation observed
when different operators measure the same part using the same device.
If the operator gets the same measurement during the repeated trials, the Gage is said to
have high repeatability. Poor repeatability could be due to the device being inaccurate,
the instructions being faulty, the operator not following the instructions, or a number of
other factors. Fig. shows the schematic of repeatability.
.
If several different operators get the same result when measuring the same object, the
measurement device is said to have high reproducibility. This does not mean the device
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is accurate, but simply that the same result is produced over time. Fig. shows the
schematic of reproducibility
Fig. Reproducablity
Gage R&R:-
The purpose of Gage R&R study is to determine the amount of variability in the
collected data that is due to the measurement system, isolate the sources of variability
in the measurement system, assess whether the measurement system is suitable for
broader application and quantify the variability in the measurement process attributed
by the operators, parts and operators-part interaction.
Analysis of Variance (ANOVA)
ANOVA is a statistical technique that estimates the amount of variability induced in
measurements of the measurement system itself, and compares it to the total variability
observed in order to determine the viability of the measurement system. The ANOVA
technique tests the hypotheses of mean biases of the experiment and also provides the
estimates of the variance components attributed to gage and operator.
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Automotive Industry Action Group (Aiag Msa Gage R&R % Guidelines)

Measurement systems whose purpose is to analyze a process, a general thumb rule for acceptability
of measurement system is as follows:
Table. AIAG MSA Gage R&R % Guidelines
% Gage
Decision Comments
R&R
Generally Recommended, especially
considered to be an useful when trying to sort or
Under 10 acceptable classify parts or when
measurement tightened process control is
system. required.
May be acceptable A decision should be based
for some upon, for example, the
applications. importance of the application
measurement, cost of
10 to 30
measurement devices, and the
cost of rework or repair.
Should be approved the
customer.
Considered to be Every effort should be made
Over 30 unacceptable to improve the measurement
system.
Procedure for Gauge R&R study
Experimental Data sheet
Metrology and quality engineering lab

Operator Roll No. Name of Student
1 A X
2 B Y
3 C Z
Gage name: Date of study:
Tolerancegiven: Reported By:
Experimental plan for gage R&R study
Run
Part Operator Diameter measured (mm)
Order
1 3 1
2 1 1
3 2 1
4 2 2
5 1 2
6 3 2
7 1 3
8 2 3
9 3 3
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10 2 1
11 1 1
12 3 1
13 2 2
14 3 2
15 1 2
16 2 3
17 3 3
18 1 3
19 2 1
20 3 1
21 1 1
22 1 2
23 2 2
24 3 2
25 2 3
26 3 3
27 1 3
Analysis of Experimental data
Result:-
Experiment no:4 Angular measurement
Title of the experiment: MEASUREMENT OF ANGLE USING SINE BAR
Learning
Objectives:
The students should be able

to:
1. Explain the principal and working of Sine bar.

2. Explains the procedure for determining unknown angles
Aims of the experiment: -

To measure the taper angle of a given component using sine bar.
Apparatus: Specimen, sine bar, dial gauge, slips gauge, vernier caliper etc.
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The sine bar is a simple and moderately accurate device, which is used to measure angles in
conjunction with gauge blocks. The sine bar consists of a hardened tapped steel bar and two
rollers of equal diameter. The rollers and the steel surface are accurately polished, so that the
measurements are accurate.
The principle behind the sine bar is based on the simple trigonometric relation for a
right-angled triangle formed. In use, the sine bar is mounted on two rollers at the ends as
shown. The center distance between the two steel rollers is taken as the length of the
hypotenuse of the right-angled triangle formed in measuring the angle. The sine bars are used
in measuring angles and they are available usually with center distance of 100 mm -250 mm.
A sine bar is always specified by its roller center distance.
The use of surface plate is essential to ensure perfect base and alignment of the work
and the gauge blocks. Sine bars used when the use of bevel protractor is not convenient or
desirable.
For greater accuracy, requirement of a sine bar are,
I) The two rollers must have equal diameter and should be true cylinders.
II) The axes of the two rollers must be exactly parallel.
III) Center distance between the rollers must be precise.
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However, some drawbacks of the sine bar are;
a) It cannot be used as primary angle measuring device because of inherent error possibilities.
b) Results are reliable only up to 15 degrees.
c) Temperature variations are very critical.
d) Long gauges stocks are not nearly as accurate as shorter gauge blocks.
PRINCIPLE OF SINE-BAR
The sine bar is designed basically for the precise setting out of angles and is generally used in
conjunction with slip gauges and surface plate. The principle of operation of the sine bar
relies upon the application of trigonometry.In the right angled triangle ABC as shown in the
figure, the ratio of the length BC to that of hypotenuse AB is referred to as the sine of the
angle θ.
where, Sinө= AB/BC

Accuracy requirements of the Sine Bar
1. The axes of the rollers must be parallel to each other and the centre distance L,
must be precisely known.
1. The top surface of the sine bar must be flat and parallel to a plane connecting
the axes of the rollers.
2. The axes of two rollers must be parallel to each other.
3. The rollers must be of identical diameters and round to within a close tolerance
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1) Least count of Vernier = ---------------mm
2) Least count of dial indicator = ---------------mm
3) Larger diameter of the component = D = ----------mm
4) Smaller diameter of the component = d =-----------mm
5) Length of the component = l = ----------mm
6) Length over the roller = L1 =----------mm
7) Diameter of the rollers = d1 =----------mm
8) Length between the centres of the rollers =L= (L1-d1) = ----------mm
9) Approx. Taper angle of the component (θ) =----------degrees
10) Initial height of the slip gauge for sine bar (H) = L Sin2θ = ----------mm
Tabular column:-
Sl.No Slip gauge height (mm) Dial Indicator Reading(mm) Difference(mm)
Left Right
Slip gauge height for zero difference = h = mm
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Formula required:
i) H= L x Sin2 θ =……………………..in mm Where H= Final height of slip gauge where

difference reading is nearer to zero.
ii) 2θ = Sin-1 (H/L) =…………… in Degrees
Results: -
The taper angle of the given job is found to be degrees.
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Experiment No :05
Title of the experiment: Measurement of Screw thread and Gear parameters, surface
roughness
Screw thread Parameter Measurement

The students should be able to
1. Describes the. Principle and working of profile

projector
2.Operates profile projector
3. Explain the procedure for measuring profile parameters using profile

projector.
I. To determine/measure various screw thread terminologies/parameters using profile
projector. Major diameter.

i. Minor diameter.
ii. Pitch.
iii. Depth
iv. Angle of thread
Apparatus: Profile projector, screw thread micrometer, screw, V-block.
Theoretical background the experiment: -Profile projectors are versatile and highly
sophisticated and are designed as per international standard. This comprehensive range
covers all conceivable applications. It is used for rapid inspection and measurements (linear
and angular) of small to medium size components such as water parts, gears, tools, and so on.
It has best quality high resolution optics provide accurate, bright clear and sharp images. The
special front and back surface coated mirror are highly polished ad lobbied distortion and
reproduction. Three element condenser system and high intensity HALOGEN LAMPS
provide brilliant images even in daylight condition. Commitment to quality ensures the
highest levels of precision, quality reliability and performance.
TECHNICAL SPECIFICATION:
1. PROJECT SCREEN: Fully usable fine grain ground screen and rotatable screen has
cross hair line and detachable clops to hold comparator charts.
2. MAGNIFICATION LENS: 10X lens for general purpose, 20X lens for clear
observation for higher precision works. All projection lens screw mount type to project
the work piece image on the screen at direct magnification, brightness adjustable for
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each magnification by condenser on turret, Magnification, accuracy: Counter:t 0.1%

and surface: 0.15%.
3. WORK STAGE: Medium duty 200 X 200 mm standard micrometer heads 0 – 25

least count 0.1mm, life ling smooth movement assured by the incorporation of hard
steel rolling both in longitudinal and transverse slide for accurate measurements.
4. CONTOUR ILLUMINTOR: Equipped with helical type condenser, built in cooling

for quick to match the respective objective so as to ensure bright and sharp image on
the screen provided with 24V – 150 / 250 W HALOGEN LAMP with solid stage light
control transformer.
5. SURFACE ILLUMINATOR: Specially designed surface illumination system for
shadow less light on the optical axis for the inspection of deep cavities. Provided with
12V 100W HALOGEN LAMP with solid stage light control transformer.
Basically a profile projector consists of illuminating system with a light source, tungsten arc
lamp. The glowing element in the lamp is a small cylinder of tungsten which is heated to
incandescence by electron bombarding. It is enclosed in a ventilated lamp house. The lamp
from light lamp passes to a system of lenses called a chromatic condenser; with single lens
condensers the screen image consists of various colors. The parallel beam of light from the
condenser is then transmitted to the illuminating mirror, which sends the beam vertically
upward through the glass stage plate in the worktable, past the object. The projection system
consists of the projector lens, roof prism, and a pair of image reflections and screen. The
magnification of the projector can be adjusted by changing the projecting lens assembly. The
measuring system consists of X and Y tables each with micrometer for linear measurement
and a protractor scale on the screen for angular measurement. The important application of
profile projector are tracing profiles, measure terminology of screw threads, gears etc.
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Table of observations
Sl. No. Screw thread Micrometer reading in mm Actual Reading

parameters Initial Final in mm
(intail-Final)
1 Major Diameter
2 Minor Diameter
3 Pitch
4 Depth
Calculations:
Least count of micrometer = Value of 1 MSD / No. of divisions on thimble scale =
Least count of the circular scale =
1. Major Diameter measurement:
R1 =
R2 =
Major Diameter = (R1 - R2) =
2. Minor Diameter measurement:
Minor Diameter = (R3- R4) =
3. Depth of cut: Major Diameter –Minor diameter
4. Pitch measurement:
Pitch Measurement= (R5-R6)

=
5. Angle Measurement:
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Pitch
Tan θ= Depth / Pitch/2
Thread angle = (90- θ) * 2 Depth
4.9 RESULT:
1. Major diameter = mm
2. Minor diameter = mm
3. Pitch = mm
4. Angle =
Measurement of effective diameter using 3 wire
Learning bjectives:

to:
1. Explains the different terminologies of screw thread.
2. Describes the procedure for determining effective diameter using 2-wire and 3-wire
method.
To determine the effective diameter of given screw thread by three-wire method.
Apparatus: Screw thread specimen, Pitch gauge, Micrometer, Three-wire set, Surface plate.

A screw thread is a continuous helical shape formed around a cylinder by cutting continuous
helical grooves. It can also be formed by cutting a helical groove on the inner surface
of a hollow cylinder.The different forms of screw threads used are ISO-V threads, square
thread, knuckle thread, Whitworth thread, metric thread etc.
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Screw thread terminology is as follows:

1) External thread: The thread formed on the outside, of the work piece is called external
thread.
2) Crest of the thread: It is the permanent part of the thread whether external or
Internal.
3) Root of thread: It is the bottom of the groove between the two flanks of the thread whether
external or internal.
4) Major diameter: It is the diameter of the inner cylinder. It is often referred to as the
outside diameter.
5) Flank angle: It is the angle between the individual flank and perpendicular to axis of the
thread, which passes through the vertex of the fundamental triangle.
6) Pitch: It is the distance between two consecutive crests of a thread on the same side of
the axis.
7) Minor diameter: It is the diameter of minor cylinder. It is also referred to as root
diameter.
8) Effectivediameter: In case of straight thread this is the diameter of the pitch cylinder. If the
pitch cylinder is imagined as to be generated by a straight line parallel to axis of the
screw, that straight line is referred to as the pitch line.
1) Least Count of micrometer = mm
2) Thread angle of given thread  = degrees
3) Pitch of the given screw thread P = mm
4) Best size wire diameter Ds = P/2 sec (/2) = mm
5) Wire chosen from the wire box / ser Ds = mm
6) Measurement over the wire = R1 =
mm, R2 =
mm,
R3 = mm
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Mean = R1+R2+R3/ 3 = mm
7) Effective diameter of screw thread,

E = R- d (1 + cosec  / 2) + p / 2 cot /2 = mm
Space for calculations:
6.8Results: -
Theeffective diameter of the given screw thread is found to be mm
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Experiment No: 06 Gear tooth Parameter Measurement
Title of the experiment: -Measurement of gear tooth thickness using gear tooth vernier
Learning
Objectives:

to:
1. Understands the different terminologies of Gear.
2. Explains the procedure for measuring gear tooth

thickness.
Aim of the experiment:
To measure gear tooth thickness of a given spur gear using gear tooth
Vernier.
Apparatus:
Gear specimen, Verniercaliper, Gear tooth
Vernier.
Gears are the running wheels of the engineering industries. No mechanical system can be
made without a suitable gearing arrangement. The gears are mainly used for transmission of
power and motion. Obtain trouble free and noise free gears, both the driver and driven gears
should be of accurate geometry. Gears are difficult to manufacture accurately because of their
complex tooth shape. Thus, there are many errors introduced into the finished gears during
manufacturing stage itself.
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No
me
ncl
atu
re
of
a
Ge
ar:
Fig. gear tooth

profile
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In the following section, many of the terms used are explained.

Base circle: It is the circle from witch involve from is generated only base circle of a gear is fixed
and
unalterable.
Pitch circle: It is an imaginary circle most useful in many calculations

Module: It is defined as the length of the pitch circle diameter per tooth .It is generally
expressed in mm.
Diameter Pitch: It is the number of teeth per inch of Pitch Circle Diameter.
Addendum: It is the radial distance from the pitch circle to the tip of the tooth. Its value is
equal to one module.
Dedendum: This is the radial distance from the pitch circle to the bottom of the tooth space.
Tooth thickness: There is distance measured along the pitch circle from its intercept with one
flank to its intercept with the other flank of the same tooth.
Faceofthetooth: It is that part of the tooth, which is above the pitch surface.A gear tooth
Vernier can very conveniently measure the gear tooth thickness. Since the gear tooth thickness
varies from the tip to the base circle of the tooth, the device should be capable of measuring
the tooth thickness at a specified position on the tooth. The thickness is generally measured at
pitch circle and is thus referred to us as Pitch line thickness. The gear tooth Vernier has two
scales, one is set for width of the tooth and the other is set for the depth at which the width
occurs.
Fig. Gear tooth vernier
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1. L.C of horizontal scale of gear tooth vernier = mm
2. L.C of vertical scale of gear tooth vernier = mm
3. Number of teeth on gear, N =
4. Outer diameter of the gear = Do = mm
5. Pitch circle diameter = d = N x Do / N + 2 = mm
6. Module, m= d/N =
7. Initial height h = m + N m/2 1 - COS (90/N)
8. Gear tooth thickness =
Space for calculations:
Result: -
The Gear tooth thickness of the given screw thread is found to be mm.
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Experiment No:07
Title of the experiment: - Machine Tool Alignment Test (Lathe, Drilling,)
Test the quality of the slide ways and the locating surfaces
Test the accuracy of the main spindle and its alignment with respect to other parts of the
machine tool.
Apparatus:- Lathe , Dial indicator, spirit level
The surface components produced by machining processes are mostly by generation. As a result, the
quality of surface produced depends upon the accuracy of the various movements of the machine
tool concerned. It therefore becomes important to know the capability of the machine tool by
evaluating the accuracy of the various mechanisms that are directly responsible for generating the
surface. For this purpose a large variety of tests have been designed.
MEASURING INSTRUMENTS USED FOR TESTING:

The accuracy of the machine tools employed should be higher than the accuracy of the components
that it produces. Similarly the quality of the measuring equipment used for machine tool testing
should be commensurate with the quality expected from such testing. A few commonly used
equipments are
Dial Indicators Test mandrels Straight edges Spirit levels
LATHE MACHINE
Tests that can be conducted on Lathe machine:
1. Quality of slide ways: To test the quality of the slide ways it is necessary to mount the dial
indicator on a good datum surface. Then the plunger is moved along the longitudinal direction of the
slide ways which provides an indication of the undulations present on the surface of the slide ways.
2. Accuracy of the spindle:
These tests are related to the true running of the spindle and the centre located in the spindle along
with the alignment, parallelism and perpendicularity of the spindle with the other axes of the
concerned machine tool.
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True running of the centre: The live centre may be loaded into the lathe spindle and a dial indicator
mounted as shown in fig. This test is required only for machines where the work piece is held
between centres. The readings of the dial indicator are taken while rotating the spindle through full
rotation.
True running of the spindle: the taper shank of the test mandrel of about 300 mm length is mounted
into the spindle as shown in fig. The plunger of the dial indicator rests on the cylindrical surface of
the mandrel. The spindle is rotated slowly and the readings of the dial indicator are noted. The
deviation should normally be less than 0.01mm. The test is to be repeated with the dial indicator
positioned close to the spindle bore as well as at the extreme end of the test mandrel.
Parallelism and perpendicularity: Parallelism and perpendicularity between two axes or two surfaces
is normally measured in two planes, horizontal and vertical. For this purpose the test mandrel is
mounted in the spindle as shown in fig. with dial indicator mounted on the saddle or carriage. The
plunger of the dial indicator touches the mandrel surface as shown in fig. the saddle is moved for a
specified distance and the dial reading noted. The test is repeated in the horizontal direction as well.
Parallelism between the outside diameter of the tail stock sleeve and the slide ways as shown in fig.
Parallelism between the line of centres and the slide ways shown in fig
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RADIAL DRILLING MACHINE:

Tests that can be conducted on Drilling Machine are:
1. True running of the spindle.
2. Perpendicularity between the spindle and the base plate.
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3. Perpendicularity between the feed movement and the base plate.
Experiment no:-08
Title of the experiment: - Measurement of Dimensions and GD&T parameters of given

components using CMM (Coordinate Measuring Machine).
1. Measure the dimensions of the given component using CMM.
2. Compare the dimensions of the part between conventional machine and CMM.
Apparatus:- CMM, Component , Vernier caliper.
Theoretical background the experiment: Geometric dimensioning and tolerancing is an

international language used on drawings to accurately describe a part. The language consists of a
well-defined set of symbols, rules, definitions, and conventions that can be used to describe the size,
form, orientation, and location tolerances of part features.
Geometric tolerancing is an exact language that enables designers to “say what they mean” on a
drawing, thus improving product designs. Production uses the language to interpret the design
intent, and inspection looks to the language to determine set up. By providing uniformity in drawing
specifications and interpretation, GD&T reduces controversy, guesswork, and assumptions
throughout the manufacturing and inspection process.
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Tabular Column:-
Sl.no Geometric Conventional CMM (Measured GD &T

parameter Measurement Value value) Value
1
2
3
4
5
6
7
8
9
10
Result:-
Conclusion:-
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Experiment no: - 09
Title of the experiment: - Extraction of 2-Dimensions of the given part using 3D scanner using reverse
engineering concept
Scanning and Capturing of high resolution 3D coordinates of a given component by using Array
Imager for various industrial applications
Apparatus:
Faro Cobalt Array Imager, Rotary table, test chart, Component etc.
OVERVIEW OF ARRAY IMAGER:
The FARO® Cobalt Array Imager is a metrology-grade non-contact scanner which captures millions
of high resolution 3D coordinate measurements in seconds. The Cobalt Array Imager is equipped
with dedicated on-board processors – an industry first. The smart sensor allows unique multi-image
array configurations which expand the scan area to deliver rapid, automated and comprehensive
inspection; dramatically improving cycle time. The actionable data is then displayed as simple
go/no-go result or an easy-to-read dimensional deviation colour map. The Cobalt Array Imager is
designed for the factory floor so it can be used anywhere inspection is needed, thereby aligning to
lean manufacturing principles of eliminating unnecessary movements and time. Cobalt delivers fast
and consistent measurements for dimensional inspection and reverse engineering applications on
parts, assemblies, and tooling. Cobalt’s versatility supports a variety of deployment options
including tripod, rotary table, robot, industrial inspection cells and multiple imager arrays. Cobalt,
which is available in two resolution models, both offering interchangeable fields of view, combines
speed, accuracy, flexibility and portability making it an ideal solution for your demanding metrology
needs. At an affordable price point providing unparalleled value, the Cobalt is a simple-to-use
solution ideal for maximizing productivity and automating workflows for near-line and in-line
inspection applications, anywhere in the factory.
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Typical Size and weight: 440 x 210 x 80mm, 5kg
APPLICATIONS:
Industries such as automotive, aerospace and machining, metalworking & assembly rely on the
FARO Cobalt Array Imager for tasks such as:
Tool Inspection, Sheet Metal Inspection, Automated Quality Control & Assembly Verification,
Mould and Die Inspection, Casting & Machined Part Inspection, Composite Tooling, Reverse
Engineering, CAD-Based Inspection, Dimensional Analysis, In-Process Inspection and so on.
ARRAY IMAGER FEATURES:
The FARO Cobalt Array Imager is a metrology-grade, non-contact scanner which utilizes blue light
technology and on-board processing to capture millions of high resolution 3D coordinate
measurements in seconds. It delivers fast and consistent measurements for dimensional inspection
and reverse engineering applications. Compact and lightweight, the Cobalt Array Imager is easy to
use across multiple applications. The combination of flexibility, portability, speed and accuracy
makes Cobalt Array Imager an ideal solution for a demanding metrology needs.
1. Multiple Imager Arrays
Expand the field of view and increase data

capturing speed by flexibly deploying multiple
Cobalt units. With Multiple Imager Arrays, two or
more Cobalt units can be used to simultaneously
gather data on an object that is being inspected.
Benefits:
Increases the effective field of view which, in turn,
reduces inspection time and increases productivity.
A multiple imager array of Cobalt sensors is often
more flexible and affordable than purchasing a
larger field of view system.
2. On-Board Processing:
On-board processing enables the Cobalt system to calculate accurate point cloud data before the
data is sent to the PC. Dedicated processing on the Cobalt ensures consistent calculation speed,
regardless of other tasks that the PC may be performing. Integration into manufacturing processes is
simplified and enables the control of multiple units from a single PC.
Benefit:
Integration is simplified, and inspection times become more predictable and more reliable,
ultimately enabling more efficient throughput. Implementing the simultaneous use of multiple units
further reduces cycle time.
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3. Blue Light Technology:
Enhances ability to measure dark and reflective surfaces in variable lighting conditions
The Cobalt system uses blue LED and digital
projection to achieve a high-intensity, structured light
pattern. Blue light provides an excellent contrast, even
on dark and shiny surfaces. Filters on the camera
reject ambient light outside of the blue spectrum,
enabling operation independent of lighting conditions.
The LED provides a high-intensity light which
reduces exposure time, while the digital projector can
cycle through several image projections in seconds.
Benefit:
Simplified capture of dark and shiny surfaces.
4. High Resolution:
For inspections where precision is critical for capturing fine details, features, and edges
High resolution refers to the point spacing of the
resulting point cloud, which is a function of the
resolution of the camera and the field of view. Choose
between the 5MP Cobalt or the 2MP Cobalt. The 5MP
version improves the resolution and the ability to
capture features on edges and surfaces. Cobalt offers 5
and 2 megapixel cameras and multiple fields of view.
The narrow fields of view have a higher resolution
than the wider fields of view.
Benefit:
Fine details are easily scanned with the system. The interchangeable field of view allows Cobalt to
be tailored to the customer's need.
5. High Dynamic Range:
Easily handles complex parts with dark surfaces, light surfaces, different colors, textures and
reflectivity. The High Dynamic Range (HDR) feature provides the ability to measure both dark and
light surfaces at the same time, by collecting data with multiple exposures. Automatic-exposure
selects the optimal settings to achieve coverage on selected areas. The user can define any number
of areas to get full coverage of a surface.
Benefit:
Accurately capture light and dark surfaces and/or multi-colour objects in a single scan.
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6. Automatic Exposure:
Automatic exposure selects the optimal exposure, ensuring the best possible data at all times. These
optimal exposures can then be saved and entered into an inspection program to skip subsequent
auto-exposure steps and further accelerate the process.
Benefit:
Ensures the best possible data set and records exposures for repeated measurements. There is no
need for the user or the Cobalt system to continuously recalculate exposures. Throughput is
increased and inspection time is reduced.
7. Stereo Cameras:
Ensure high accuracy and stability and enable self-monitoring: Stereo Cameras deliver the highest
accuracy and also monitor the system itself. This ensures the system is working within specification
and is scanning with a high consistency during each measurement process.
Benefit:
Reliable and stable measurement results are automatically assured during the inspection process.
8. Enhanced Stereo Mode:
Maximizes coverage area in each scan and shortens inspection time

With Enhanced Stereo Mode, the left and
right cameras optimally combine all the
data to get the most out of each
measurement, maximizing coverage area
in each scan, and reducing line-of-sight
issues typical of other imaging systems.
In short, what one camera may not see
(due to line of sight issues) the other
camera is able to capture.
Benefit:
The number of images required during inspection is reduced and overall inspection time is
shortened.
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Experiment no:-10
Title of the experiment: GOODNESS OF FIT TEST OF UNIFORM DISTRIBUTION
Aim: To test whether we can fit a uniform distribution for the observed data.
Apparatus: One Die
Theory: The uniform distribution is a discrete probability distribution. If the random variable X
assumes the values X1, X2,…..Xk, with equal probabilities then the discrete uniform distribution with
parameter k is given by
f(X:k)= 1/k for X=X1,X2,…..Xk
The graph representation of the uniform distribution by means of a histogram turns out to be a set of
rectangles with equal heights as shown in the graph. The mean and variance of the uniform
distribution f(X:k) are
Mean=µ=∑Xi/k and Variance=σ=∑(Xi-µ)2/k
Procedure:
1. Through the Dice for about N times.
2. Tabulate the no of times each face occurs for N trials which give the observed frequency.
3. Calculate the estimated frequency taking the probability of occurrence of each face as 1/6
using Ei= (1/6) x N.
4. Calculate the Chi-square value using
5. Refer to the Chi-square table for 0.05 level of significance and (N-1) degrees of freedom for
XT2.
6. Compare both the values of Chi-square XT2 and Xc2 to draw the conclusion.
Tabular column1:
No of trials, N=
X Tally marks Observed
frequency(Oi)
1
2
3
4
5
6
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Tabular column2:
X P(X) Estimated Observed
frequency frequency(Oi)
Ei= P(X)*N
1
2
3
4
5
6
∑Xc2=
Specimen calculations:
For Xi=
1. No. of trials, N=
2. P(Xi)=
3. Estimated frequency Ei= P(Xi)*N
4. Observed frequency(Oi)=
5. Chi-square value, Xc2=
6. The sum of Chi-square value= Xci2=∑ Xci2
7. The value of Chi-square for 0.05 level of significance and (6-1) degrees of freedom from
Chi-square table= XT2=
Conclusion:
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Experiment no:-11
Title of the experiment: Construction of control chart for variables, attributes and Analysis of
process capability for the different components manufacturing
Aim: To determine process capability of Lathe used in turning shaft to diameter of sample of
consecutive pieces for 10 days.
Apparatus: Samples, Vernier caliper.
Theory: A control chart is a graphical representation of the collected information. The information
may pertain to measured quality characteristics of samples. It detects the variation in processing and
warns if there is any departure from specified tolerance limits. With help of control chart it is
possible to find out the natural capability of production process. A control chart is important
statistical device used for the study and control of the respective process.
Procedure:-
1. Calculate the Average X for each subgroup
X = X1+X2+X3+X4+ X5 / 5
2. Calculate Range R for each subgroup
R = [Highest Value - Lowest Value]
3. Calculate 3-Sigma control limit for X and R chart
UCLx = X +A2 R UCLR =D4 R
CCLx = X CCL R = R
LCLx = X -A2 R LCL R = D3 R
4. Interpret the chart whether all points fall within the control limits or not.
R
5. Find the process capability 6σ =
d2
6. State whether the process is capable or not to meet the specification.
7. If process is not capable find the percentage of products likely to fall below the lower
specification Limit.
Day x R
X1 X2 X3 X4 X5 X6
1
2
3
4
5
6
7
8
9
10
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Calculations:
X
R
1. X = N R= N
2. 3-Sigma control limit for X and R chart
UCLx = X +A2 R UCLR =D4 R
CCLx = X CCL R = R
LCLx = X -A2 R LCL R = D3 R
R
3. Process capability (6σ) = d 2
Conclusion:
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Conclusion:-
] Page 54

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KLE Society's

KLE Technological University

Metrology and Quality Engineering Lab

Course Code: 15EMEP301 Course Title: Metrology and Quality Engineering

Expt. Brief description about the experiment No. of

01 Introduction to the Laboratory-Standards of measurement for Linear and 01

06 Measurement of Gear parameter(Gear tooth thickness) 01

Instruction to the students:

All students are,

 Required to be present in the laboratory in time.

 Informed to note down the tabular column, specifications of the

 Informed to follow the procedure, which is given in the laboratory manual to

 Informed to conduct each experiment in presence of staff member or lab instructor.

 Informed to take the instruments to conduct each experiment and must

a) Contact the instructors before starting an instruments or the experiment

source. d) Handle Instruments properly and carefully.

e) Avoid loose clothing and long unbuttoned sleeves while working on a

1. Introduction to the Laboratory-Standards of measurement for Linear and angular dimensions.

Study of Slip gauges:

Slip gauges are rectangular blocks of steel having a cross-section of about 30 mm x 10

These are classified according to their guaranteed accuracy as:

 AA for master slip gauges

 A for reference purpose

 B for working slips

As for grades or classes of slip gauges these can be in five grades as

below. Grade 2: For workshop grade

1: For good class room tool

00: For work of highest precision only

It is believed that this phenomenon of wringing is due to molecular adhesion between a

Procedure for conducting the experiment:

Slip Gauge Box –1 (M83)

Sl. No. Range Increment No. of slips

Total Number of slip gauges

Slip Gauge Box –2(M125)

Sl. Range Increment No. of slips

Total Number of slip gauges

Slip Gauge Box –2(M112)

Total Number of slip gauges

Title of the experiment: - Calibration of Vernier and Micrometer

The students should be able to:

Apparatus: - Vernier Calliper, slip gauge set.

Theoretical background the experiment: -

Fig.1 Vernier Calliper

Procedure to carry out the experiment: -

1. Range of given Vernier Calliper ---------------- mm

2. Least count of Vernier Calliper -------------------mm

3. Given range for calibration ----------------------------------mm

4. Specification of slip gauge box = ----------------------

Space for calculation:

Plot the graph: Error v/s Indicating reading

The students should be able to:

Apparatus: - Micrometer screw gauge, slip gauge set, micrometer stand.

Theoretical background the experiment: -

Fig.2.1 Micrometer screw gauge

Procedure to carry out the experiment: -

1. Range of given micrometer screw gauge ---------------- mm

2. Least count of micrometer screw gauge -------------------mm

3. Given range for calibration ----------------------------------mm