IIITDM Kurnool Department of Mechanical Engineering

MEC220P–Quality Inspection and Product Validation

)
Practice
LABORATORY MANUAL
(For B.Tech II Year II Semester)
(2019 – 2020)

DEPARTMENT OF MECHANICAL ENGINEERING

INDIAN INSTITUTE OF INFORMATIONTECHNOLOGY

DESIGN AND MANUFACTURING, KURNOOL
Jagannathagattu, Dinnedevarapadu, Kurnool-518007,
Andhra Pradesh, India
(An Institute of National Importance under MHRD, Govt. of India)

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

LIST OF EXPERIMENTS
S. No. Name of the Experiment Page No.
1. Study of Linear Measuring Instrument: Vernier Caliper 1

2. Study of Linear Measuring Instrument: Micro Meter 4

3. Study of Linear Measuring Instrument: Vernier Height Gauge 7

4. Measurement of Taper Angle Using – Slip Gauges And Sine Bar 9

5. Calibration of Dial Gauge 12

6. Measurement of Taper Angle Using Rollers – Slip Gauges and Rollers

14

7. Measurement of Bores Using Dial Bore Gauge And Telescopic 17

Gauge
8. Temperature Measurement Using Pyrometer During Turning 21
Operation
9. Measurement of Taper Angle Using Bevel 25
Protractor
10. Surface Roughness Measurement Using Surface Roughness 27
Tester
11.

12.

13.

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)
GENERAL INSTRUCTIONS AND SAFETY RULES
 Students must attend the lab classes with ID cards and in the prescribed uniform.
 Boys-shirts tucked in and wearing closed leather shoes. Girls‟ students with cut shoes, overcoat,
and plait incite the coat. Girls‟ students should not wear loose garments.
 Students must check if the components, instruments and machinery are in working condition
before setting up the experiment.
 Power supply to the experimental set up/ equipment/ machine must be switched on only after the
faculty checks and gives approval for doing the experiment. Students must start doing the
experiments only after getting permissions from the faculty.
 Any damage to any of the equipment/instrument/machine caused due to carelessness, the cost
will be fully recovered from the individual (or) group of students.
 Students may contact the lab in charge immediately for any unexpected incidents and emergency.
 The apparatus used for the experiments must be cleaned and returned to the technicians, safely
without any damage.
 Make sure, while leaving the lab after the stipulated time, that all the power connections are
switched off.
 When you work with furnaces for heat treatment procedures or other thermally activated
equipment you should use special gloves to protect your hands.
 Never carry out unauthorized experiments. Come to the laboratory prepared. If you are unsure
about what to do, please ask the instructor.
 Except the scientific calculator, any other electronic devices are not permitted to use inside
theLaboratory.
 ………………………………………….
………………………………………………..
………………………… Lab in-charge can be changing the General Instruction according
to the Lab.

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Experiment No. 1
)
Study of Linear Measuring Instrument: Vernier Caliper
AIM: To get acquainted with Vernier caliper
APPARATUS: Vernier Caliper
THEORY
The Vernier Caliper consists of two scales one is fixed and the other is movable. The fixed scale
called main scale is calibrated on L-Shaped frame and carries a fixed jaw. The movable scale
called Vernier Scale slides over the main scale and carries a movable jaw. The movable jaw carries
measuring tip. When the two jaws are closed the zero of the Vernier Scale coincides with the zero
of the main scale. For precise setting of the movable jaw an adjustment screw is provided. Also an
arrangement is provided to lock the sliding scale on the fixed mainscale. The thumb screw is used
to precisely adjust the jaws of the caliper. It helps the user to get a tight grip on the material they
are measuring. Final locking screw is used to lock the lower jaw.
Vernier Calipers are employed for both internal and external measurements. It is generally used
by closing the jaws on to the work surface and taking the readings from the main as well as the
Vernier scale. To obtain the reading the number of divisions on the main scale is first read off. The
Vernier scale is then examined to determine which of its division coincide or most coincident with
a division on the mainscale.

Fig. 1 Vernier Caliper

PROCEDURE:

1. Verify the number of divisions available on the Vernier. Also observe, how many number of
divisions of main scale divisions are equal to number of divisions on the Vernier.

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

Least count or LC of the Vernier = 1 M.S.D. – 1 V.S.D.

)
Where, M.S.D= Main Scale Division
V.S.D = Vernier Scale Division
L.C ofthe Vernier =

2. The two jaws of the Vernier calipers were cleaned and vernier was checked for zero error
by bringing the two jaws close at each other.
3. The given specimen, whose dimension to be measured, was cleaned.
4. A specimen was placed in between the two jaws of Vernier calipers and was adjusted.
5. Vernier calipers reading were noted down.
6. The measurement was repeated at different locations of the specimen and the readings were
tabulated.
7. The average value of measurements is calculated

Sample Calculation:

Let the number of divisions on the Vernier are 50 and let us say these 50 divisions are coinciding
with 49 divisions on the main scale. If each division on main scale is equal to 1 mm, then the L.C.
of the Vernier Calipers may be obtained asfollows:

L.C = 1 M.S.D. –1 V.S.D.

49M.S.D = 50 V.S.D

1VSD = M .S.D

L.C = 1 M.S.D.– M .S.D = M .S.D = 0.02 mm

PRECAUTIONS:

1. Before using the instrument clean it by cleaningcloth.

2. Readings must be observed without parallaxerror.
3. The line of measurement must coincide with line ofscale.
4. The measuring instrument must always be properly balanced in hand and held lightly in such
a way that only fingers handle the moving and adjusting screws.

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

Tabular Column
)
S.NO. M.S.R. V.S.R. Total Reading=

(M.S.R. + V.S.R. X L.C.)

3
Average:

RESULT:

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

Experiment No. 2
)
STUDY OF LINEAR MEASURING INSTRUMENT: MICRO
METER

AIM: To get acquainted with micro meter

APPARATUS: Micrometer

THEORY
Micrometers work on the principle of screw and nut. When a screw is turned through nut by one revolution,
it advances by one pitch distance. If the circumference of the screw is divided into number of equal parts
say ‘n’ its rotation through one division will cause the screw to advance through length. Thus the

minimum length that can be measured bysuch arrangement will be . By reducing the pitch of the
screw thread or by increasing the number of divisions on the circumference of the screw the length value of
one circumferential division can be reduced and accuracy of measurement can be increased considerably.

Fig. 1 Micrometer

The outside micrometer has U-Shaped or C shaped frame. It holds all the micrometer parts
together. The gap of the frame permits the maximum diameter or length of the job to be measured.
It is generally made of steel, cast steel, malleable C.I or light alloy. It is desirable that the frame of
the micrometer be provided with conveniently placed finger grips of heat insulating material.

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

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The micrometer has a fixed anvil protruding 3 mm from the left hand side of the frame. Another
anvil known as movable anvil is provided on the front
) of the spindle. The anvils are accurately
ground and lapped with its measuring faces flat and parallel to the spindle. The spindle engages
with nut and it runs freely and smoothly throughout the length of its travel. There should be no
backlash between the spindle screw and nut.

Lock nut: A lock nut is provided on the micrometer spindle to lock it when the micrometer is at its
correct reading, without altering the distance between the measuring faces.

Sleeve or Barrel: The Sleeve is accurately divided and clearly marked in 0.5 mm division along its
length which serves as a main scale. It is chrome plated and adjustable for zerosetting.

Thimble: The Thimble can be moved over the Sleeve. It has 50 equal to assure accurate
measurement and to prevent too much pressure being applied to the micrometer.

PROCEDURE:

1. First of all set the micrometer to zero reading. For this rotate the thimble until both anvils touch
each other. If the zero line on the thimble coincides with zero line on the Sleeve, error is zero.
Otherwise adjust the Sleeve to make the error zero.
2. Rotate the thimble by 5 revolutions and observe the main scalereading.

3. Determine the pitch of the screwas =

4. Finally determine the least count L.C =

5. The given specimen, whose dimension to be measured, was cleaned.

6. A specimen was placed in between the two anvil and spindle of micrometer and was adjusted.

7. The micrometer reading was noted down.

8. The measurement was repeated at different locations of the specimen and the readings were
tabulated.

9. The average value of measurements is calculated

PRECAUTIONS:

1. Before using the instrument clean it by cleaningcloth.

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

2. Readings must be observed without parallaxerror.

3. The line of measurement must coincide with line) ofscale.
4. The measuring instrument must always be properly balanced in hand and held lightly in such
a way that only fingers handle the moving and adjusting screws.
NOTE: By using the above instruments measure the external diameter and the height of the given work piece.
Use the followingtable.
Tabular column

S.NO. M.S.R. V.S.R. or P.S.R. Total Reading=

(M.S.R. + V.S.R. X L.C.)

RESULT:

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

Experiment No. 3
STUDY OF LINEAR MEASURING INSTRUMENT:
) VERNIER HEIGHT
GAUGE
AIM: To get acquainted with vernier height gauge

APPARATUS: Vernier Height gauge

THEORY
Vernier height gauge is used to measure vertical dimension from reference ground. Vernier Height Gauge
consists of a graduated scale or bar which is held in a vertical position by a finely ground fixed base.

Fig. 1 Vernier Height Gauge

A Vernier Height Gauge consists of
(i) Base:It’s a rectangular metallic part which is finely machined and horizontally jointed with other
structure as shown in picture. As name shows its acts like base to hold all other parts because these
all are mounted on it. It has lapped lower grounded surface for high accuracy
(ii) Main Scale:A long rectangular metallic bar mounted on base and its direction is perpendicular to
base shown in figure. Main scale is engraved on it in millimeters and inches.
(iii)Vernier scale: a sliding vernier head carrying the Vernier Scale is attached to the rectangular
metallic bar. It has a fine adjusting and a clampingscrew is to tighten the Vernier scale at
position during measurement.
(iv) Measuring Jaw (measuring Stylus): A measuring jaw with a scriber is attached to the front of
the sliding vernier.
(v) Fine adjustment screw: As name indicates it is used for fine adjustment during measurement
and allows Vernier scale to slide very little distances.
(vi) Fine adjustment clamp: When adjustment is completed, tightening of this clamp provides
provision to hold the Vernier height gauge measuring jaw at certain point in order to avoid
errors of reading.

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

The Vernier Height Gauge is designed for accurate measurements and marking of vertical
heights above a surface plate datum. It can also be used to measure differences in heights by
taking the Vernier scale readings at each height and) determining the difference by subtraction.
PROCEDURE:
1. Find out the L.C. of the Vernier height gauge similar to VernierCalipers.
2. The given Vernier height gauge was mounted on a leveled surface plate.
3. Before placing the height gauge, the surface plate should be degreased and free from dust.
4. The scriber was clamped to the measuring jaw of the height gauge.
5. Measuring jaw was moved down so that the scriber touches the surface plate and the scale is
adjusted to read ‘0’.
6. Measuring jaw was lifted and adjusted so that the scriber just touches on the top surface of the
slip gauge placed below it.
7. Observe the number of divisions on the Vernier and corresponding divisions on the mainscale.
8. The procedure was repeated at different locations of specimen and readings were tabulated
9. The average value is calculated.
PRECAUTIONS:
1. Before using the instrument clean it by cleaningcloth.
2. Readings must be observed without parallaxerror.
3. The line of measurement must coincide with line ofscale.
4. The measuring instrument must always be properly balanced in hand and held lightly in such a way
that only fingers handle the moving and adjusting screws.
NOTE: By using the above instruments measure the external diameter and the height of the given work piece.
Use the following table.

Tabular Column

S.NO. M.S.R. V.S.R. Total Reading= (M.S.R. + V.S.R. X L.C.)

RESULT:

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

Experiment No. 4
MEASUREMENT OF TAPER) ANGLE USING – SLIP
GAUGES AND SINE BAR

AIM: To determine the taper angle of the given specimen using slip gauges and Sine Bar and check
the angle using BevelProtractor.

APPARATUS: Sine Bar, slip gauge set.

Theory
Sine bar is a precision instrument used along with slip gauges for the measurement of:

(i) The angles veryaccurately

(ii) To locate the work to a given angle within very closelimits

It consists of a steel bar and two rollers. The sine bar is made of high carbon, high chromium
corrosion resistant steel. It contains two rollers which are very accurate and highly precise and truly
equal in Diameters. They are attached to the bar at each end. The axes of these rollers are parallel to
each other and also to the upper surface of the bar.

When the sinebar is placed on the truly flat surface, the top surface of the bar will be parallel to
the flat surface. The presence of relief holes in the steel bar is to handle the sine bar easily and also
reduces the overall weight. The normal distance between the two rollers usually available in 100mm,
200mm or 300mm.

Uses of sine bar are:

i) Sine-bar is used to set or locate the workpiece at a given angle.

ii) To check the measuring of unknown angles in the workpiece.

iii) Check the unknown angles on the heavier components.

Some specially designed Sine bars are used to mount the workpiece to do the conical shape machining
for the workpiece.

Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

Fig.1 Sinebar

Principle of Sine bar: The principle of operation of a sinebar is based on the laws of trigonometry. To set a
given angle, one roller of the bar is placed on the surface plate and the combination of slip gauges is inserted
under the second roller. If ‘h’ is the height of the combination of slip gauges and ‘L’ the distance between the
rollers centers. Then

Sin θ =

θ = Sin-1

Thus the angle to be measured or to be set is determined by indirect method as a function of sine, for
this reason, the device is called a ‘sinebar’.

PRECAUTIONS:

1. Slip blocks must be cleaned properly and wrungtogether.

2. Micrometer readings must be observed without parallaxerror.

3. The axes of the Setting rollers must be parallel to each other and parallel to the upper surface of
the Bar.
4. The distance between the two rollers must be known value. (Size of the sinebar is determined by
this distance only).

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5. The flatness of the upper surface of the bar should be truly flat. And it should be parallel to the
surface which is contacted to the two setting rollers.)
6. The two setting rollers must be equal in diameter and round within very close tolerances.

RESULT: Taper angle of the givenspecimen=

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IIITDM Kurnool Department of Mechanical Engineering

Experiment No. 5
CALIBRATION) OF DIAL GAUGE
AIM: To calibrate the given dial gauge with respect to a standard reference i.e. slip gauge set and
draw the calibration curve
TOOLS:
1. Dial gauge
2. Dial gauge stand
3. Slip gauge set
4. Surface plate
THEORY:
Measuring instruments in usage will acquire certain errors due to wear and tear. So every
instrument should be checked periodically to find out the errors and assess the accuracy. Comparing
the reading of the instrument with a standard reference does this. This type of inspection is known as
calibration. Depending on the type of instrument the standard reference is selected, against which the
error of the instrument is evaluated. Since the error cannot be eliminated from the instrument,
corresponding correction is applied to the measured reading of the instrument. Since the wear and
tear of the instrument is not uniform, the error in the measured value will be different at different
ranges of the instrument.

Fig.1 Dial Indicator

To apply correction for the various readings in the range of the instrument, a calibration curve
is to be drawn. Calibration curve is the curve drawn between the error and the instrument reading.
The error at any stage of the instrument can be either positive or negative. The correction to be
applied for a positive error is negative and vice – versa.

PROCEDURE:
1. The dial gauge was mounted securely on the stand.
2. The base of the stand was cleaned and free movement of the dial gauge plunger was ensured.
3. Slip gauges are degreased and an initial reading was set by selecting a suitable slip gauge so that
the plunger of the dial gauge just slide on the top surface.
4. Dial gauge reading with initial set up was adjusted to read zero
5. A small increment was given to the initial size of the slip gauge by combination of slip gauges
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and was placed under the dial gauge plunger by lifting it. The corresponding reading is noted
down.
6. The procedure was repeated for different sizes of )slip gauges within the range of the dial gauge
and readings were tabulated and corresponding errors were found.
7. A graph is plotted against dial gauge reading and error obtained

PRECAUTIONS:
1. The dial gauge should be clamped to the stand properly so that the plunger is vertical to the base.
2. The slip gauge set should be degreased properly.
3. The plunger of the dial gauge should be handled gently.
4. The dial gauge reading was set to zero after giving slight initial compression to the plunger.
5. Slip gauges should be increased in size with regular increments within the range of dial gauge.
6. Slip gauges should be wringing properly for various combinations.
Tabular Column

Dial gauge
Slip gauge reading Error Correction
S.No reading
Y mm E=X-Y C in mm
X mm

Graph

Result:

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Experiment No. 6
)
MEASUREMENT OF TAPER ANGLE USING
ROLLERS – SLIP GAUGES AND ROLLERS
AIM: To determine the taper angle of the given specimen using slip gauges and rollers and check
the angle using BevelProtractor.

APPARATUS:Two rollers of equal diameter, slip gauge set, micrometer.

THEORY:

Taperis defined as uniform reduction in dimension (may be width, height or diameter) over
specified length. For example, if the taper of any cylindrical specimen is specified as 1:10, it means
that for every 10 mm length there will be a reduction of diameter by 1 mm (from major to minor
dia.). Taper is employed on elements like cotter, keys and shanks of twist drill bits, end mills,
reamers adapters etc. Presence of taper enables self-locking of the element in the corresponding
mating part.

Slip Gauges: Slip gauges are rectangular blocks of alloy steel. Slip gauges are the universally
accepted ‘standard of length’ in industries. These are the simplest possible means of measuring
linear dimensions very accurately. These blocks are carefully finished on the measuring faces to a
fine degree of finish. Flatness and accuracy of the slip gauges is such that if any two slip gauges
when perfectly clean they can be joined by a sliding process called wringing, which causes their
ultra-flat surfaces to cling together. This is accomplished by pressing the faces into contact and then
imparting a small twisting motion whilst maintaining contact pressure. When two or more gauges
are wrung the total height of gauges is exactly the sum of the constituent gauges. By combining
gauges from a suitably arranged combination, almost any dimension may be builtup.

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Experimental Set Up:

)

Fig.1

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PROCEDURE:
)
1. Place the Taper specimen on the surface plate as shown in thefigure 1.
2. Pile up slip gauge combinations of equal heights H1 and place them on opposite sides of
taperspecimen.
3. Place two rollers of equal diameter on slip gaugecombinations.
4. Take measurement over the rollers with the help of micrometer (sayM1)
5. Take slip gauge combinations of another height H2 and repeat steps 3 and 4 let the measurement
over the rollers beM2
6. If θ is the included angle of taperspecimen. Taper angle
may be obtained asfollows:

Tan θ/2 =

7. To check the uniformity of taper H2 may be varied by two to three values and ‘θ’ may
becalculated.

Result: -

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IIITDM Kurnool Department of Mechanical Engineering

Experiment No. 7
Measurement of Bores Using) Dial Bore Indicator and
Telescopic Gauge
AIM:
To determine the diameter of bore by using telescopic gauge and checking the same by using dial bore
indicator.

APPARATUS REQUIRED:
Work piece, Vernier caliper, telescopic gauge and dial gauge indicator set with anvil.

THEORY:
BORE GAUGE:
A dial bore gauge is a comparative instrument similar to a telescoping gauge, but includes a digital or
analog readout. The dial bore gauge must be set to the nominal value of the bore, and it will measure
the variation and direction of the bore from nominal. There are multiple ways to set this gauges to the
nominal value. The most common method is using an outside micrometer that is set to the nominal
value. This is the quickest and least expensive way to set the dial bore gauge. This method is not the
most accurate because there can be high human error and variation in the micrometer is passed down
into the dial bore gauge.Dial bore gauges are typically used by machinists to measure the inner
diameter of bores in motor engines.

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Step 1: Place the bore gauge in a micrometer locked to the same diameter of the hole being measured.
Step 2: Rotate the indicator's dial until the pointer aligns with the "0" marking on the dial face.
)
Step 3: Insert the dial bore gauge in the bore, ensuring both anvils of the gauge touch the wall. Gently
rock the bore gauge back and forth while keeping the anvils along the same axis plane. The pointer
will swing either clockwise or counter-clockwise as the anvils settle into place square to the bore.
Step 4: Watch the dial face once the tool is squared. At some point the pointer will start to reverse
itself and head in the opposite direction. This could be on either side of the "0" marking on the
indicator. Record the measurement where the pointer reverses itself and remove the bore gauge from
the hole.
Step 5: Add or subtract the recorded value from the target number the indicator was calibrated to.

Example: -If the bore gauge's indicator was zeroed to 2 inches, and the pointer changed direction at
the .007-inch marking on the dial face, the final measurement of the hole is 2.007 inches.
Alternatively, if the pointer traveled counter-clockwise and changed direction .007 inches to the left of
the "0" on the indicator, the final measurement of the hole is 1.993 inches.

MEASUREMENT:
1. Select the extension rod and washer according to the bore diameter to be measured
2. Fix the suitable extension rod and washer with the bore gauge
3. Fix the dial gauge to the bore gauge in its position
4. Insert the bore gauge inside the bore to be measured and hold the gauge in parallel to the axis of the
bore. Ensure that the tips on either side of the bore gauge are in touch with inner wall of the bore
5. Note down the reading in the dial gauge and withdraw the bore gauge from the bore
6. Hold the measuring tips of bore gauge between the spindle and anvil of a micrometer and compress
the tips by rotating the thimble till the reading reaches the same one as noted earlier
7. Observe and record the micrometer reading as the bore diameter to be measured.

Practical observations:

SI.NO Micrometer Bore gauge Work piece Reading, Final reading

Reading, d (mm) Reading, R1(mm) R2(mm) d+(R1-R2) *0.01 (mm)

1
2

3
4
5

Average reading = ________ mm

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THEORY:
TELESCOPIC GAUGE:The telescopic gauge is used for measuring internal diameter of holes, slots
and grooves etc. Itconsists of a handle with two rods in) a tube at one end and a working screw at the
other end. Therods having spherical contacts can slide within a tube and are forced apart by an internal
spring.The locking screw can lock the rods at any desired position through a spring. While
takingmeasurements, the rods are pressed closer and inserted into the hole to be measured. The rods
then open out to touch the metal surface, of the hole on both sides. They are then locked inposition by
means of a locking screw. The telescopic gauge is then taken out from the hole. Thedimension across
the tips is measured by micrometer or Vernier caliper.

Fig: Telescopic Gauges

How to use: The following diagram shows the usage of Telescopic gauge to measure the bore.

MEASUREMENT:
1. Select the telescopic gauge according to the bore diameter to be measured.
2. Press the telescopic spindles in the telescopic gauge lock them by locking screw.

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3. Insert the telescopic gauge inside thee bore to be measured. Release the locking screw to expand the
telescopic spindles outwards inside the bore.
)
4. Hold the telescopic gauge in parallel to the axis of bore axis and ensure that the tips of telescopic
spindles are in touch with the inner wall of the bore.
5. Lock the telescopic spindles and withdraw it from the bore.
6. Measure the expanded length of the telescopic spindles using micrometer record them as the inner
diameter of the bore.

Practical observations:

Micrometer Reading
SI.NO Total reading
Main Scale Reading,MSR (mm) Thimble Scale coincidence MSR+(TSC*LC), mm
1
2
3
4
5

Average reading = ________ mm

RESULT
1. Internal diameter of the work piece by using telescopic gauge is ________mm
2. Diameter obtained by using dial gauge indicator is __________________mm

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Experiment No. 8
Temperature Measurement Using
) Pyrometer during
Turning Operation
AIM: To measure the temperature at different regions during turning process using pyrometer.

MATERIAL REQUIRED: Mild steel rod of 25 mm diameter and 150 mm long.

APPARATUS REQUIRED:
 Steel rule
 Scriber
 Chuck key
 HSS Single point cutting tool
 Pyrometer (Infrared Gun)

THEORY:
Lathe Machine Tool: -Lathe machine tool removes undesired material from a rotating work piece in
the formof chips with the help of a tool which is traversed across the work and can be feddeep in
work. The tool material should be harder than the work piece and thelater help securely and rigidly on
the machine. The tool may be given linearmotion in any direction. A lathe is used principally to
produce cylindricalsurfacesand plane surfaces, at right angles to the axis of rotation. It can also
producetapers and bellows etc.A lathe (shown in fig.) basically consists of a bed to provide support,
ahead stock, a cross side to traverse the tool, a tool post mounted on the crossslide. The spindle is
driven by a motor through a gear box to obtain a range ofspeeds. The carriage moves over the bed
guide ways parallel to the work pieceand the cross slide provides the transverse motion. A feed shaft
and lead screware also provided to power the carriage and for cutting the threads respectively.

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Heat generation during Machining: -It is known that during the transformation of work piece into
chips, because of energy transformation in the cutting zone, it releases significant quantities of heat.
During machining heat is generated at the cutting point) from three sources. Those sources and causes
of development of cutting temperature are as given below.

a. Primary shear zone: where the major part of the energy is converted into heat.
b. Secondary deformation zone:at the chip – tool interface where further heat is generated due
to rubbing or shear.
c. At the flank or Machine surface: due to rubbing between the tool and the finished surfaces.

The temperature developed is an important factor which has a dominant influence to the
mechanism of transformation of the work piece and cutting tool life. The development of temperature
influences the magnitude of the cutting force components, it also causes residual stresses in various
part of work piece.Therefore, in the machining process it is important to know accurately the
magnitude of the temperature that occurs in the cutting zone. There are two ways to determine the
temperature distribution in metal cutting; they are analytical method and experimental method. In
analytical method using a set of mathematical equations (models) which already existed or a newly
developed model is used to determine the temperature. Whereas the second method uses a set of
experimental set up to measure the temperature. Analytical method is inexpensive and simple but less
accurate and precise whereas the former one is more accurate and precise. The major concern areas in
the measuring the temperature are shear zone, tool-chip interface and the work tool interface.
Experimental methods for determination of cutting temperature the following are some of the methods
used for measuring temperature experimentally.

 Photo-cell technique.
 Pyrometer techniques.
 Tool work thermocouple technique.
 Indirect calorimetric technique.

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From above all pyrometer technique is simple and very much appropriate and most commonly used
method.
)
Pyrometer: -A pyrometer is a type of remote-sensing thermometer used to measure the temperature of
a surface. It is a device that from a distance determines the temperature of a surface from the amount
of the thermal radiation it emits. This process known as pyrometry and also called as radiometry.
There are different types of pyrometers like optical, radiation, digital and infrared pyrometer. Here in
our experiment we use infrared pyrometer gun or infrared thermometer.An infrared thermometer is a
device that measures the infrared radiation – a type of electromagnetic radiation below the visible
spectrum of light - emitted by an object. The most basic design of infrared thermometers consists of a
lens to focus the infrared thermal radiation onto a detector, which converts the radiant energy into an
electric signal. This configuration facilitates temperature measurement from a distance, without the
need for contact with the object to be measured.

Procedure:
1. Before starting of the machining process measure and note the temperatures of both the
workpiece and cutting tool by pointing pyrometer at it.
2. Mark 100 mm length on the workpiece and clamp it in to the head stock using chuck key.
3. Start the rough turning the workpiece over 100 mm length.
4. Continue the turning process further by increasing the depth of cut, mean while, measure and
note the temperature at different regions specified afore. (i.e primary, secondary and machined
surface )
5. Progress the same steps of measuring the temperature at the specified regions and also non
machined surface region too (temperature readings can be recorded nearly at 5 or more
different locations over 100 mm turning length).
6. Calculate the mean temperature of distinctive regions and specify them.
7. Finally note the temperature readings of both workpiece and cutting tool after completing the
machining.

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Measurement:
) READINGS , OC
TEMPERATURE

Before Machining During Machining After Machining

Trail. No
Primary Secondary Machined
Workpiece Cutting Tool Workpiece Cutting Tool
Zone Zone Surface

Result:

1. The average temperatures of workpiece and cutting tool before machining are________.
2. The average temperature during machining at
a. Primary zone is __________.
b. Secondary zone is ________.
c. Machined surface is _______.
3. The average temperatures of workpiece and cutting tool after machining are _________.

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Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

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Experiment No. 9
MEASUREMENT OF TAPER
) ANGLE USING BEVEL

PROTRACTOR

AIM: To find out the taper angle of given work piece by using Bevel Protractor.

APPARATUS: Surface Plate, Bevel Protractor, Tapered work piece.

THEORY:
Bevel protractor is used for measuring and lying out of angles accurately and precisely within 5
minutes. The protractor dial is slotted to hold a blade which can be rotated with the dial to the required
angle and also independently adjusted to any desired length. The blade can be locked in any position.
It is the simplest instrument for measuring the angle between two faces of component. It consists of
base plate attached to the main body and an adjustable blade which is attached to a circular plate
containing vernier scale. The adjustable blade is capable of rotating freely about the centre of the main
scale engraved on the body of the instrument and can be locked in the any position. It is capable of
measuring from zero to 3600. The vernier scale has 24 divisions coinciding with 23 main scale
divisions. Thus the least count of the instrument is 51. This instrument is most commonly used in
work shop for angular measurements. Note the reading, magnifying lens has been provided for easy
reading of the instrument. Main scale is circular and is graduated in degrees on the circular body. Main
scale graduations are all around the circular body which is attached to fixed base blade. Fixed base
blade also called as stock is attached to circular body of bevel protractor as shown in figure. Once the
reading is fixed, blade clamp fixes the reading. Blades are about 150 mm long or 300mm long, 13mm
wide and 2mm thick. Its ends are beveled at angles of 45 degree and 60 degree. Vernier scale is also
marked on turret which can rotate all over the fixed body. Adjustable blade can pass through the slot
provided in turret. So as the turret rotates, adjustable blade also rotates full 360 degrees. There are 12
graduations of Vernier scale starting from 0 to 60 on both sides of zero of Vernier scale as shown in
figure.

Procedure:
1. Note down the least count of the Bevel Protractor.
2. Keep the work piece on the surface plate.
3. Fix the slide of Bevel Protractor to the Turret.
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4. Keep one of the surfaces of the specimen on the working edge and rotate the turret. Remove the
slide on to the other surface.
)
5. Fix the centre, after matching the both the faces and note down the reading.
6. Repeat the experiment for different faces.
Measurement:
1. Least count of the bevel protractor = ___________

S.NO Main Scale Reading, Deg Vernier Scale Reading, Min Final Reading
1
2
3
4
5

RESULT:

By using the bevel protractor, the taper angle of the given specimen is determined as _____________.

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Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)

IIITDM Kurnool Department of Mechanical Engineering

Experiment No. 10
SURFACE ROUGHNESS MEASUREMENT
) USING
SURFACE ROUGHNESS TESTER
AIM: To measure the surface finish of the given components using Talysurf Surface roughness
tester.
Apparatus Required:
 Talysurf meter
 Surface plate
 Adopter for vernier height gauge
THEORY:
On any surface, imperfections are bound to be there and these take the form of a
succession of hills and valleys which vary both in height and in spacing and result in a kind of
texture which in appearance or feel is often characteristic of the machining process and
accompanying defects. The several kinds of departures are there on the surface and these are due
to various causes.
Methods of Measuring Surface Roughness:
 Surface inspection of comparison methods
 Direct instrument measurements
In comparative methods the surface texture is assessed by observation of the surface. But
these methods are not reliable as they can be misleading, if comparison is not made with surfaces
produced by same techniques. The various methods available under comparison method are: (i)
Touch Inspection (ii) Scratch Inspection (iii) Microscopic Inspection (iv) Visual Inspection (v)
Surface Photographs (vi) Reflected Light Intensity

Direct Instrument Measurements enable to determine a numerical value of the surface finish
of any surface. Nearly all instruments used are stylus probe type of instruments. These operate on
electrical principles.
Taylor – Hobson Talysurf:
Talysurf is an electronic instrument working on carrier modulating principle. The measuring head of
this instrument consists of a diamond stylus of about 0.002mm tip radius and skid or shoe which is
drawn across the surface by means of a motorized driving unit(gear box), which provides three
motorized speeds giving respectively X20 and X100 horizontal magnification and a speed suitable
for average reading. A neutral position in which the pick-up can be traversed manually is also
provided. In this case the arm carrying the stylus forms an armature which pivots about the centre
piece of E-shaped stamping as shown in fig. On two legs of the E-shaped stamping there are coils
carrying an a.c. current. These two coils with two other resistances form an oscillator. As the
armature is pivoted about the central leg, any movement of the stylus causes the air gap to vary and
thus the amplitude of the original a.c. current flowing in the coils is modulated. The output of the
bridge thus consists of modulation only as shown in fig. this is further demodulated so that the
current now is directly proportional to the vertical displacement of the stylus only. The demodulated
output is caused to operate a pen recorder to produce a permanent record and a meter to give a
numerical assessment directly. In record of this statement the marking medium is an electric

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discharge through a specially treated paper which blackens at the point of stylus so this has no
distortion due to drag and the record strictly rectilinear one. The experimental set up of surface
)
measurement is as shown below.

PROCEDURE:

• The finished component is placed on the surface plate.

• Talysurf tester is fixed to the vernier height gauge using adopter at a convenient
height.
• Make sure that the stylus probe touches the work piece.
• Fix the sampling length in the tester.
• Then the power button is pressed so that the probe moves on the surface to and fro.
• Take the readings of the surface roughness directly from the instrument.

PRECAUTIONS:
• The surface to be tested should be cleaned properly.
• The tester should be fixed to the height gauge properly so that the movement of the
probe is exactly parallel to the surface of work.
• Make sure that the probe gently touches the work.

RESULT:

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Quality Inspection and product validation B.Tech II Year – II Semester – (2019-2020)