VNRVJIET/MED

VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING AND

TECHNOLOGY
(AUTONOMOUS)

DEPARTMENT OF MECHANICAL ENGINEERING

LABORATORY MANUAL FOR METROLOGY LAB

LABORATORY CODE: 5ME61

B. TECH. III YEAR II SEM. (COMMON TO ME & AE)

REGULATIONS: R15

FACULTY NAME: D.SARATH CHANDRA

LIST OF EXPERIMENTS

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S.No NAME OF THE EXPERIMENT

1. MEASUREMENT OF LENGTH, HEIGHT, DIAMETER BY VERNIER

CALIPERS, MICROMETER

2. MEASUREMENT OF BORE BY INTERNAL MICROMETER AND DIAL

BORE INDICATOR

3. USE OF GEAR TEETH VERNIER CALIPERS AND CHECKING THE

CHORDAL ADDENDUM CHORDAL HEIGHT OF SPUR GEAR

4. MACHINE TOOL ALIGNMENT TEST ON A LATHE

5. MACHINE TOOL ALIGNMENT TEST ON A MILLING MACHINE

6. TOOL MAKER`S MICROSCOPE AND IT`S APPLICATIONS

7. ANGLE AND TAPER MEASUREMENT BY BEVEL PROTRACTOR, SINE

BAR

8. USE OF SPIRIT LEVEL IN FINDING THE FLATESS OF SURFACE PLATE

9. THREAD MEASUREMENT BY TWO WIRE/THREE WIRE METHOD

10. SURFACE ROUGHNESS MEASUREMENT BY SURFACE ROUGHNESS

TESTER

11.. SURFACE WEAR RESISTANCE TEST USING ELECTRO SPARK COATING

DEVICE

Note: Conduct any six experiments from the above list.

EXPERIMENT NUMBER- 01

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MEASUREMENT OF LENGTH, HEIGHT, DIAMETER BY VERNIER CALIPERS,

AND MICROMETER
AIM: 1.To Measure The Length, Height, C Of The Object Using Vernier Calipers.
2. To Measure The diameter Of The Object Using Micrometer.

INSTRUMENTS USED:
1. Vernier Calliper. 2. Micrometer 3.Specman

Objective:

The objective is to familiarize students with the use of vernier calipers, Micrometer screw gauges.
The write –up for this experiment will be submitted at the end of the laboratory period. Drawings of
the parts to be measured in the lab are available from the Teaching Assistant for the purposes of
dimensioning. No aids other than calculators are allowed to be used.

Theory:
Definition: Least Count – the smallest degree by which two measurements may be differentiated
with a particular instrument; generally considered to be of the same order as the smallest division in
the instruments’ scale. The Least Count is a measure of the accuracy of a measuring instrument.

VERNIER CALLIPER:
A vernier caliper (Figure 1) consists of a rule with a main engraved scale and a movable jaw with an
engraved vernier scale. The main scale is calibrated in centimeters (cm) with a millimeter (mm) least
count, and the movable vernier scale that divides the least count on the main scale in to 50 equal sub-
divisions. The span of the upper jaw is used to measure the inside diameter of an object such as
hollow cylinders or holes. The leftmost mark on the vernier scale is the zero mark, which is often
unlabeled. A measurement is made by closing the jaws on the object to be measured and reading
where the zero mark on the vernier scale falls on the main scale. The first two significant figures are
read directly from the main scale. This is known as the main scale reading. The next significant
figure is the fractional part of the smallest subdivision on the main scale (in this case, mm). If a
vernier mark coincides with a mark on the main scale, then the mark number is the fractional part of
the main scale division. Before making a measurement, the zero of the vernier calliper should be
checked with the jaws completely closed. It is possible that the caliper not being properly will
produce systematic error. In this case, a zero correction must be made for each reading. The least of
the vernier caliper is calculated by equation (1).

Value of the smallest division on main scale

Least Count = ______________________________________ (1).

Number of divisions on vernier scale

Measurement = Main scale reading + conceding vernier scale division *Least count (2)

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Observations

Dimension MSR VSR Measurement= =Readings

MSR+VSRXLC

Micrometer screw Gauge:

A micrometer (Figure 2) consists of a movable spindle (jaw) that advances toward another
parallel-faced jaw, called an anvil, by rotating the thimble. The thimble rotates over an engraved
sleeve or barrel that is mounted on a solid frame. Most micrometers are equipped with a ratchet, at
the far right in figure 2, which allows slippage of the screw mechanism when a small constant force
is exerted on the jaw. This permits the jaw to be tightened on an object with the same amount of
force each time. The axial main scale on the sleeve is calibrated in mm and the thimble scale is the
vernier scale and is usually divided into increments of 0.01mm. The pitch of a screw is the distance
between two consecutive screw threads and is the lateral linear distance the screw moves when
turned through one rotation. The axial line on the sleeve main scale serves as a reading line. If a
micrometer does not have 0.5 mm divisions on the main scale, you must determine whether the
thimble is in its first rotation or second. If it has 50 divisions on the thimble and completes 1 mm in
two rotations, each division on the thimble gives 0.01 mm.Measurements are taken by noting the
reading x on the main scale of the sleeve. Note thr position of the edge of the thimble on the main
scale and the position of the reading line on the thimble scale. Multiply this reading with 0.01 mm
and add to x.

Least Count = Pitch (Distance between two consecutive threads of screw) / Number of divisions on
tumble scale (3)
Measurement = Main scale reading + coinciding thimble scale division * Least count (4)

Observations:
Dimensions PSR HSR PSR+HSR * L.C Readings

Measurements
How to Use Vernier Callipers:
In the machining process, we use vernier callipers or a micrometer for taking measurements.
General analog vernier calipers as shown in Figure 1 can measure with the minimum unit of 1/20
mm. Several types of digital vernier calipers as shown in Figure 2 can measure with the
minimum unit of 1/100 mm.

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Examples
The vernier calipers can measure a side length, an outer and inner diameter, and a depth as
shown in Figures 3 to 6.
Keep a perpendicular position in measuring:
The vernier calipers must be kept the perpendicular position in measuring. Typically, when a
beginner measures the size of a complex shaped part, the result can be inaccurate as the
measuring device is often not maintained parallel to measured piece.
How to Use a Micrometer
When close tolerances are required, measurements are taken with a micrometer due to its superior
accuracy over a vernier caliper. The micrometer as shown in Figure 7 can measure with the
minimum unit of 1/1000 mm.

OBSERVATIONS:

S.NO DIAMETER TRIAL TRIAL AVERAGE MEASURED

1 2 DIAMETER

Note: Please avoid dropping the tools as this can lead to irreparable damage to the precision
instruments. The tools are coated with a light film of oil to prevent corrosion. Please do not remove
this oil. A cloth has been provided to clean your hands after use.

VERNIER CALIPER

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OUTSIDE MICROMETER

RESULTS:
The specifications of the given component are measured with vernier caliper, outside micrometer

EXPERIMENT NUMBER: 02

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MEASUREMENT OF BORE BY INTERNAL MICROMETER AND DIAL BORE

INDICATOR

AIM: 1.To measure the height of the object using vernier height gauge.
2. To measure the depth of the object using Depth gauge.

INSTRUMENTS USED
1. Surface 2. Vernier height gauge. 3. Specimens 4.Depth Gauge

THEORY

Vernier Height Gauge

Vernier height gauge is a sort of Vernier calipers equipped with a special with a base and other
attachment, which make the instrument suitable for height measurement. Along with sliding jaw
assembly arrangement is provided to carry a removable clamp.

The upper and lower surfaces of the measuring jaws are parallel to base, so that it can be used for
measurements over or under surfaces.

The vernier height gauge is mainly used in the inspection of parts and layout work. The vernier
height gauge can be used to scribe lines at certain distance above surface with a scribing attachment
in pace of measuring jaw. Dial indicators can also be attached in the clamp and many exact
measurements can be made as it exactly gives the indication when the dial tip is touching the
surface. Surface plates as datum surface are used for the above measurements.

PROCEDURE
1. Place the object and the vernier height gauge on the surface plate.
2. Note the value on the scale when the moving jaw is touching the bottom of the object.
3. Take the moving /sliding jaw to the top of the object and note down the value on the scale.
4. The difference between 3&2 will give the height of the object.

VERNIER DEPTH GAUGE

Vernier Depth Gauge is used to measure the depth of holes, slots and recesses, to locate center
distances etc. It consists of

I. A sliding head having flat and true base free from curves waviness.
II. A graduated beam known as main scale. The sliding head slides over the graduated beam.
III. An auxiliary head with a fine adjustment and a clamping screw.
An beam is perpendicular to the base in both direction and its ends square and flat. The end of
the sliding head can be set at any point with fine adjustment locked and read from the vernier
provided on it.

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PROCEDURE
1. Held the base on the reference surface.
2. Lower the beam in to the hole until it contacts the bottom surface of the hole.
3. Make final adjustment with fine adjustment screw.
4. Tighten the clamping screw and remove the instrument from the hole and take the reading in the
same way as vernies.
Least count = -------------mm.

S.NO. Main scale reading Vernier scale Measured reading=

MSR(mm) reading VSR(mm) = mm MSR+
(VSRXL.C)

PRECAUTIONS

1. The height gauges should be kept in their case when not in use.
2. Measuring jaws should be handled carefully.
3. While using the Dept gauge, it should be ensured that the reference surface, on which the
depth gauge is rested, is satisfactorily true, flat and square.

RESULT

The heights of the given objects measured with vernier height gauge are tabulated above.
The depth of the holes measured with Vernier depth gauge are tabulated above.

Bore Dial Gauge

It is used for measuring internal diameter of a hole, which is machined. The bore dial gauge consists
of one fixed measuring head and one movable measuring head. The movement of the movable
measuring rod is transmitted to dial indicator by push rod through a spring actuated hinged member.
Thus the horizontal movement of the rod is transmitted into vertical direction gives indication of
variatopn of size. The calibrated rods are made in different sizes and sometimes number of short
rods threaded at the ends are used in combination to get different desired lengths

PROCEDURE:
The measuring head is placed in contact with the surface of hole & movement of measuring head
contact point is transmitted to the amplifying mechanism by the calibrated rods and its shown on the

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dial indicator. These calibrated rods are located in tabular supports between the head and dial units.
The readings from dial indicator are tabulated

OBSERVATIONS:

S.NO DIAMETER TRIAL TRIAL AVERAGE MEASURED

1 2 DIAMETER

Note: Please avoid dropping the tools as this can lead to irreparable damage to the precision
instruments. The tools are coated with a light film of oil to prevent corrosion. Please do not remove
this oil. A cloth has been provided to clean your hands after use.

RESULTS:
The specifications of the given component are measured with Bore Dial Gauge.

EXPERIMENT NUMBER: 03

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USE OF GEAR TEETH VERNIER CALIPERS AND CHECKING THE CHORDAL

ADDENDUM CHORDAL HEIGHT OF SPUR GEAR
AIM:
To measure the thickness of gear teeth at the pitch line or chordal thickness of teeth and the
distance from the top of a tooth the chord i.e. Addendum using gear tooth caliper.

EQUIPMENT REQUIRED:
1. Gear tooth Vernier caliper
2. Spur gear of known module
3. Surface plate

THEORY:
Tooth thickness is the arc distance measured along the pitch circle from its intercept with one
flank to its intercept with the other flank of the tooth.
Tooth thickness = II m/2 where m is the module
m=D/N
N=no. of teeth
D=Pitch circle diameter of the gear.

Addendum is the radial distance from the tip of a tooth to the pitch circle.

In the most of the cases, it is sufficient to measure the chordal thickness i.e. the chord joining the
intersection of the tooth profile with the pitch circle because it is difficult to measure length of
the arc directly.

DESCRIPTION:
Tooth thickness caliper consists of a slide which moves vertically with the help of knob. The jaw
moves horizontally with the help of know there by varying the gap between them. An adjustable
tongue, each of which is adjusted independently by adjusting screw on graduated bars, measures
the thickness of a tooth at pitch line and the addendum.

calculations: m=O.D/N+2
Chordal width (W)=N.m.sin(90/N)
Chordal Height (h)=Nm/2[1+2/N-cos(90/N)]

PROCEDURE:
1. The given gear caliper is held over the gear and the slide is moved down so that it touches
the top of the gear tooth.
2. The jaws are made to have contact with the tooth on either side by adjusting the knob.
3. The reading on vertical scale i.e. addendum is noted down.
4. The reading on horizontal scale i.e. tooth thickness is noted down.
5. The above procedure is repeated for five times and readings are noted.
Least count of given caliper:
Tooth thickness
S.No. M.S.R V.S.R TOTAL = MAR +VSR X L.C.

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Addendum:
S.No. M.S.R V.S.R TOTAL = MAR +VSR X L.C.

RESULT:
The Addendum of the given spur gear =____________________
The tooth thickness of the given spur gear = _________________

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GEAR TOOTH VERNIER

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EXPERIMENT NUMBER: 04
MACHINE TOOL ALIGNMENT TEST ON A LATHE

AIM: To conduct alignment test on lathe machine .

EQUIPMENT REQUIRED:
1. Dial guge
2. Magnetic indicator holder
3. Steel rule

THEORY:

Levelling of the Machine:

Before the various tests on any machine tool are carried out, it is very essential that it should be
installed in truly horizontal and vertical planes. In horizontal plane, both longitudinal and
transverse directions are equally important. If, say, any long lathe bed is not installed truly
horizontal the bed will undergo a deflection, thereby producing a simple bend and undesirable
stresses will be introduced. If the bed is not installed truly horizontal in transverse direction,
twist will be introduced. Thus the movement of the saddal can’t be in a straight line and true
geometric cylinder can’t be generated. For proper installation and maintenance of its accuracy, a
special concrete foundation of considerable depth must be prepared. Also this must be insulated
from the surrounding floor by introducing some form of damping. The level of the machine bed
in longitudinal and transverse directions is generally tested by a sensitive spirit level. The saddle
is kept approximately in the centre of the bed support feet. The spirit level is then placed at a-a
(Fig. 16.1), the ensure the level in the longitudinal direction. It is then traversed along the length
of bed and readings at various places noted down. For test in transverse direction the level is
placed on a bridge piece to span the front and rear guide ways and then reading is noted. It is
preferable to take two readings in longitudinal and transverse directions simultaneously so that
the effect of adjustments in one direction may also be observed in the other. The readings in
transverse direction reveal any

Fig.16.1
twist or wind in the bed. It may be noted that the two guideways may be perfectly levelled in
longitudinal direction, but might not be parallel to each other. This is revealed by the test in
transverse direction.
The straightness of bed in longitudinal direction for the long beds can also be determined by
other methods, e.g., using straight edges, autocollimators or by taut wire method. But the test in
transverse direction can be carried out only by spirit level.It is desired that the front guideway

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should be convex only as the cutting forces and the weight of carriage act downward on it. If the
front guideways are concave, then the effect will be comulative. The tendency of the carriage,
under cutting forces is to lift upwards from the rear and this is prevented by a gib placed
underneath the guideways. With the result, an upward force acts on the rear guideways ; which
must, therefore, be made concave.Transverse level may be in any direction, but no twist can be
tolerated..

True Running of Locating Cylinder of Main Spindle.

Locating cylinder is provided to locate the chuck or face plate. However locating surface can’t be
threaded one as threads get worn out soon and thus introducing play in face plate or chuck. Thus
locating surface is cylindrical and this must run truly; for only then the face plate etc., can run
truly. The dial indicator is fixed to the carriage (or any other fixed member) and the feeler of the
indicator touches the locating surface. The surface is then rotated on its axis and indictor should
not show any movement of needle.

Fig.16.2
Axial Slip of Main Spindle and True Running of Shoulder Face of Spindle Nose.

Let us first distinguish between the axial play and the axial slip. Axial play means the
indispensable freedom of spindle movement in axial direction to prevent it fromseizing by
heating. The spindle is supported between two bearings. Due to running of spindle, there will be
a rise in temperature and thermal expansion of spindle would be there. If no axial play is
allowed, it would try to bend. Thus there will be no adverse effect of axial play if the direction of
cutting forces remains same. If the direction of cutting force changes, there would be some error
introduced due to movement of spindle axially in either direction. Under such conditions,
therefore, it is advisable to cut threads in one direction only.

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Fig.16.3
Axial slip is defined as the axial spindle movement which follows the same pattern and is due to
the manufacturing error. Actually this test is meant to check this error. To test this the feeler of
the dial gauge rests on the face of the locating spindle shoulder and the dial gauge holder is
clamped to the bed (Fig. 16.3). The locating cylinder is then rotated and the change in reading
noted down. The readings are taken at two diametrically opposite points. The total error
indicated by the movement of the pointer includes three main sources of errors.

(i) Axial slip due to error in bearings supporting the locating shoulder, i.e., the bearings are not
perpendicular to the axis of rotation and due to it a point on the shoulder will move axially in and
out at diametrically opposite points

(ii) Face of the locating shoulder not in a plane perpendicular to axis of rotation. (Hi)
Irregularities of front face.Due to axial slip, in screw cutting, the pitch will not be uniform due to
periodic movement of the spindle..True Running of Headstock Centre.

Headstock centre is live centre and the workpiece has to rotate with this centre. If it is not true
with the axis of movement of the spindle, eccentricity will be caused while turning a work, as the
job axis would not coincide with the axis of rotation of main spindle. For testing this error, the
feeler of the dial indicator is pressed perpendicular to the taper surface of the centre (Fig. 16.4),
and the spindle is rotated. The deviation indicated by the dial gauge gives the trueness of the
centre.

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Parallelism of the Main Spindle to Saddle Movement.

This has to be checked in both vertical and horizontal planes. In this we require the use of
mandrel. An important precaution in the use of mandrels and dial indicator is mentioned here.
The mandrel must be so proportioned that its overhang does not produce appreciable sag, or else
the sag must be calculated and accounted for. The rigidity indicator set up is also very important
and must be carefully watched. Otherwise variations in readings are recorded by pointer may be
solely due to deflection of the indicator mounting in different positions and it becomes very
difficult to detect and isolate the spurious deflection from the true variations.
If axis of the spindle is not parallel to bed in horizontal direction, a tapered surface is produced.
Any deviation from parallelism of spindle axis from bed in vertical axis will produce a
hyperboloid surface. For this test, a mandrel is fitted in the taper socket of the spindle. Mandrel
has a concentric taper shank which is close fit to the spindle nose taper. The feeler of the dial
indicator is pressed on the mandrel and the carriage is moved. The indication in horizontal plane
is given by dial (b) and in vertical plane by dial (a) (Fig.16.5).

Fig.16.5

In vertical plane the mandrel should be rising towards the free end in order to counteract the
weight of mandrel and job. But for counter-acting cutting forces, it should be lower towards free
end. In horizontal plane, mandrel should be inclined in a direction opposite to the direction of
tool pressure.
True running of taper socket in main spindle.

If the axis of tapered hole of the socket is not concentric with the main spindle axis, eccentric
and tapered jobs will be produced. To test it, a mandrel is fitted into the tapered hole and
readings at two extremes of the mandrel are taken by means of a dial indicator as shown in
(Fie.16.6.)

Fig.16.6
Parallelism of tailstock guideways with the movement of carriage.

Sometimes the job is held between head-stock and tail stock centre for turning. In that case the
job axis must coincide with the tailstock centre. If the tailstock guideways are not parallel with
the carriage movement there will be some offset of the tailstock centre and this results in taper
turning.
To check the parallelism of tailstock mideways in both the planes i.e., horizontal and vertical, a

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block is placed on the guideways as shown in Fig. 16.7 and the feeler of the indicator is touched
on the horizontal and vertical surfaces of the block. The dial indicator is held in the carriage and
carriage is moved. Any error is indicted by the pointer of dial indicator.
Movement of upper slide parallel with main spindle in vertical plane.

The dial indicator if fixed in the tool post. A mandrel is fitted in the spindle. The feeler

Fig.16.7
of the dial gauge is pressed against the mandrel in vertical plane and the upper slide is moved
longitudinally. This error is not tested in horizontal plane because there is swivelling
arrangement for taper turning.
Parallelism of tailstock sleeve to saddle movement. If the tailstock sleeve is not parallel to the
saddle movement, the height of dead centre would vary as varying lengths of sleeve are taken
out. For the jobs held between two centres, it is necessary that the central axis of the dead centre
be coaxial with the job axis in both the planes. If it is not so, the job

may be tilted up or down or in sideways due to the support of the dead centre. The test is carried
out by fixing the dial indicator on the tool post and pressing the plunger against the sleeves first
in vertical and then in horizontal plane (Fig. 16.9). The carriage is moved along the full length of
the sleeve and deviations as indicated by dial indicator are noted down. Tailstock sleeve should
be rising towards the free end in vertical plane and should be inclined towards the tool pressure
in horizontal plane.

Parallelism of tailstock sleeve taper socket to saddle movement.

A mandrel is put in the sleeve socket. The dial gauge is fixed on the tool post and plunger is
pressed against themandreland saddle is moved from one side to the other. This test is carried out
in both the horizontal and verticalplanes.
Alignment of both the centres in vertical plane.

Besides testing the parallelism of the axes individually (main spindle axis and tailstock axis) it
is-necessary to check the relative position of the axes also. Both the axes may be parallel to
carriage movement but they may not be coinciding.

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So when a job is fitted between the centres, the axis of the job will not be parallel to the carriage
movement. This test is to be carried out in vertical plane only. A mandrel is fitted between the
two centres and dial gauge on the carriage.

The feeler of the dial gauge is pressed against the mandrel in vertical plane as shown in Figure
and the carriage is moved and the error noted down.

Pitch accuracy of lead screw.

The accuracy of the threads cut on any machine depends upon the accuracy of its lead screw.
Thus it is very essential that pitch of the lead screw throughout its length be uniform

.Test for this is performed by fixing a positive stop on the lathe bed. Against the stop, the length
bars and slip gauges can be located. An indicator is mounted on the carriage and first it makes
contact against the calculated length of slip gauges. The initial loading of the dial gauge against
the slip gauge is noted. The slip gauges are then removed and the carriage is connected to the
lead screw and lead screw is disconnected from the gear train. An indexing arrangement is
utilised for rotating the lead screw and lead screw is given some revolutions so that distance
travelled by carriage is equal to the length of slip gauges. The reading of the dial indicator
against the stop is noted down in this position. It it is same as before, there is no error, otherwise
it can be recorded. In this method, care must be taken not to disturb the datum location when
changing the gauges for testing different pitch lengths.

A suitable method for recording the progressive and periodic errors is by using a suitably divided
scale, which is placed close to the line of centres. A microscope is rigidly mounted on the
carriage in a convenient position to note the readings on the scale.

Alignment of lead screw bearings with respect to each other.

The alignment of the bearings decides the position of the lead screw. Misalignment of lead screw
i.e., it not being parallel to the bed in vertical plane or horizontal plane can cause additional
stresses due to bending, when carriage is moved. Due to it the lead screw might get damaged and

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the precision of the machine is reduced :Alignment of lead screw bearing with split nut in both
the planes is also essential.

Axial slip of lead screw.

The thrust face and the collars of the lead screw (or the abuttment collar and the thrust bearing of
the screw) must be exactly square to the screw axis, otherwise a cyclic endwise movement is set
up which is of the same nature as the axial slip in the main spindle. Thus a periodic pitch error
will be additional to any true periodic errors in the pitch of the screw.

For testing the axial slip in lead screw, a ball is fitted in the end of lead screw and the feeler of
the dial gauge is pressed against the ball. The lead screw is rotated and deviation, if any, in any
direction is noted down (Fig.16.12).

Procedure:

1. Take the dial indicator and magnetic indicator holder and fix the magnetic indicator holder on
saddle

2. Adjust the dial indicator to the handle such that the plunger of dial indicator should touch the
surface to be tested

3. Now adjust the frame such that the indicator should show zero

4. Move along the surface to be tested like lathe bed guide ways

5. Note down the deflection by seeing the dial indicator and compare with the permissible error

6. Repeat the procedure for flat and prismatic front, rear ,tail stock and head stock and spindle
parallelism

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TABLE:

S.NO PARAMETER DEFLECTION LENGTH ALLOWABLE

(MM) (MM) (MM)
Carriage guide ways
1 (i)Flat
(ii)front
(iii)rear
Tail stock guide ways
2 (i)Flat
(ii)front
(iii)rear
Tail stock spindle parallel to carriage
3 movement
(i)vertical
(ii)horizontal
Cross slide guide ways
4 (i)Right
(ii)Left
Compound guide
5 (i)Right
(ii)Left

6 Run out of spindle

Precautions:
1.Calibrate the dial indicator before using it
2.Place the dial indicator properly and take properly and take readings properly
3.Set the zero of gauge accurately
4.Keep the machine off while taking the deflections.

Result: The deflections are noted down and compared with the allowable error by using dial
indicator.

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EXPERIMENT NUMBER: 05
MACHINE TOOL ALIGNMENT TEST ON A MILLING MACHINE

AIM: To conduct alignment test on milling machine .

EQUIPMENT REQUIRED:
1. Dial guge
2. Magnetic indicator holder
3. Steel rule
THEORY:

Machine tools are very sensitive to impact or shock, even heavy cast inn standards are not
always solid and rigid enough to withstand stresses due to falling during transportation, and
deformations may be set up. Although the machine is always carefully adjusted and aligned
when on the test stand or in the assembly department of the manufacturer, it is well known from
experience that erection in the workshop of the user is not always done with sufficient care and
thus inaccuracies of the work may result from the faulty erection of the machine. So the machine
should be carefully leveled up by means of a spirit level before starting with the actual trial tests.

Each trial measurement is based on the correct erection of the machine. No upright, base etc. can
be made so rigid that it will be thoroughly free from deformation resulting from faulty
erection.Machine tools for the workshop must be able to produce work pieces of given accuracy
within prescribed limits, consistently and without requiring artistic skill on the part of the
operator.

For acceptance test of a machine, its alignment test is performed and to see its dynamic stability,
which may be poor though alignment tests are right, certain specific jobs are prepared and their
accuracy checked.

The relative alignment of all parts of machine and the accuracy of the control devices and driving
mechanisms are measured under no load condition. The result of these measurements must lie
within the prescribed limits given by the manufacturer depending upon the grade of the machine
tool.

A specification for the alignment tests must comply with the following general
requirements :

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(1) The procedure for testing standard machine tools must not require more than 6 to 8 hrs of
work provided allthe tooling and measuring equipment are readily available.

(2) The permissible limits of accuracy of individual measurements must be wide enough to make
economical manufacture possible while on the other hand the cumulative error of number of
superimposed details should not be excessive.

The various tests performed on the milling machine are shown in (Fig. 16.16) and described
below.

Cutter Spindle Axial Slip or Float.

We have to distinguish between axial (or end) play and axial slip of the spindle.End play means
the indispensable freedom of a spindle moving in the axial direction to prevent it from seizing by
heating. This end play is specially important on high speed machines and it should be within the
prescribed limits.
Axial slip is denned as the axial spindle movement which may repeat positively with each
revolution as a consequence of manufacturing errors. It is only this axial sliding movement
which is to be tested, and the specified tolerance applies only to this movement.

When testing the axial slip of a spindle the feeler of the dial gauge rests on the face of the
locating spindle shoulder and dial gauge holder is clamped to the table. The locating spindle
shoulder is rotated and change in reading is noted. This is done at the two spots diametrically
opposite to each other. The total error indicated by the movement of the pointer includes three
main sources of errors.

(i) Axial slip due to error in bearing supporting the locating shoulder.

(ii) Face of the locating shoulder not in a plane perpendicular to axis of rotation. (Hi)
Irregularities of front face.

Effects of this will be that in cutting spirals, the pitch will not be constant and we will get
irregular pitch helix.If the feeler touches at the same spot where the turning tool on the emery
wheel has machined the spindle collar in the assembled machine, then the feeler will not show
any deviation. Therefore axial slip must always be tested at two points 180° apart on the collar of
the spindle.

Eccentricity of External Diameter.

The feeler is placed on the cylindrical surface of the shoulder. The locating shoulder is rotated
and any deviation in reading of dial gauge is noted.

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It is due to eccentricity of the spindle in the hole in which it fits. Due to it, vibrations are
produced and the cutter will float side ways and cut over, or under-size. Face mills may dig in
when leading edges cease to cut.

True Running of Internal Taper.

The table is set in its main position longitudinally and the mandrel 300 mm long is fixed in the
spindle taper. A dial gauge is set on the machine table and feeler adjusted to touch the lower
surface of the mandrel. The mandrel is then turned and the dial readings at two points are noted
i.e., one at the place nearest to spindle nose and other at about 300 mm from it. For shifting the
position of dial gauge from A
to B cross-slide of the machine is operated to bring the dial gauge at the bottom of the end of
mandrel. There are can be two errors :

(i) Axis of the spindle and the axis of taper may not be parallel.

(ii) Eccentricity of the taper hole which, if present, should indicate same error at both the places.
The error in first case will give different readings at two places. Due to this error, cut will not be
shared equally between teeth of cutters, and therefore vibrations and poor finish will result.

Table surface parallel with arbor rising towards overarm.

In selecting the permissible errors of horizontal milling machines, care is taken to the fact that in
the direction parallel to the cutter spindle, the work table extends towards the front face of the
knee only, and never slopes down. While working, the table tends to incline downwards under
the influence of the weight of work and cutting pressure, while the cutter arbor tends to deflect
upwards. Great importance, therefore, has always been attached to the necessity of having the
direction of table tolerance opposite to the deformation expected under cutting conditions.
Parallelism between table face and the axis of the main spindle is checked as follows :

A dial gauge is set on the machine table. A mandrel 300 mm long is fitted in the spindle taper.
The feeler of dial gauge is made to touch the lower surface of the mandrel. With mandrel in
position (mean) the readings at the maximum travel of the table surface are observed. The stand
of the dial gauge is moved and not the table itself remains stationary.

Effect of this error will be that the milled surface produced will not be square to the base and
parallel cross ways.

Surface Parallel with Longitudinal Movement.

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For this test the dial gauge is fixed to the spindle. Feeler is directed upon the surface the machine
table and latter moved longitudinally. The deviations from parallelism between the table surface
and longitudinal motion are noted down. If the table is uneven, a straight edge may be placed on
the surface. Due to this error the surface of the table will fluctuate up and down and cutter will
not take equal cuts on the job which is clamped on the table and the milled surface will not be
parallel to the base.

Traverse Movement Parallel with Spindle Axis,

(a) in horizontal plane; (b) in vertical plane. The table is set in its mean position and dial
gauge fixed on the table. The table is moved crosswise and any deviation on reading of dial
gauge is noted with feeler on one side of mandrel in horizontal plane and under the mandrel for
error in vertical plane.Due to this error, depth of cut will vary when cross slide is moved.

Central T-Slots Parallel with Longitudinal Movement.

The T-slot, particularly the central one should be well machined on the internal vertical surface
throughout its length because jigs and fixtures are located by T-slots. The general parallelism of
the central slot with the longitudinal movement of the table is checked by using a bracket 150
mm long with a tennon which enters the T-slot. Against the upper surface of the bracket in
vertical plane the feeler of the dial gauge is located. Having fixed the dial gauge to the spindle
and adjusting its feeler to the surface of the bracket the table is moved longitudinal while the
tennon block is held stationary by hand and deviations from parallelism are noted from dial
gauge. During the process the tennon slides along the slot, thus eliminating the effects of
localerror.
Due to this error, the depth of cut will not remain constant as the job will be inclined according
to inclination of T-slots with longitudinal movement and the axis of job held between tail stock
and index head will not be perpendicular to cutter.

PROCEDURE:

TABLE:

S.NO PARTS DEFLECTION(MM) LENTH(MM)

Table surface parallel to
1 horizontal moment
(i)front
(ii)rear
Knee alignment table with vertical
2 moment
(i)front
(ii)rear

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Cross slide
3 (i)front
(ii)rear

4 Spindle run out

Precautions:

1.Calibrate the dial indicator before using it

2.Place the dial indicator properly and take properly and take readings properly
3.Set the zero of gauge accurately
4.Keep the machine off while taking the deflections.

Result: The alignment test was performed on milling machine by taking dial readings to compare
with allowable error.

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EXPERIMENT NUMBER: 06
INSPECTION OF PART USING TOOL MAKERS MICROSCOPE
AIM: To measure major diameter, minor diameter and pitch of the thread profile using tool
makers micro scope.
APPARATUS: Tool machine makers microscope plug gauge
THEROY:
TOOL MAKERS MICROSCOPE: This is a versatile instrument based on optics. It consist of
a heavily hollow base incommoding the illuminating unit underneath. Work table is mounted
with cross slide equipped with accurate micrometer in two mutually perpendicular direction i.e;
Inlongitudinal and lateral direction
PRINCIPAL OF OPERATION:
A ray of light from a light source is reflected by a mirror through a 90*.It
than passes through a horizontal glass plate and which flat parts may be placed. A shadow image
of the work piece optical head and is projected by a system of a three prism to a ground glass
screen. Observation are made through an eye piece measurement are made by means of cross
lines engrained on the glass screen. The screen can be rotated through 360*, the angle of rotation
is read through an auxiliary eye piece.
APPILICATION:
For taking linear measurement such as length, width, diameter etc; the work piece is placed over
the table
PROCEDURE:
 Set the eye piece in micrometer lens table place square thread gauges on the measuring
surface of the micrometer four light on the specimen so, shadow or image will form in
optical system.
 Adjust the specimen location on the measuring table so that cross slides of eye piece are
at one end of diameter of specimen will be appears on eye piece.

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 Again the reading of the rotation scale are taken the difference of the two reading will
give the diameter of thread gauge.
 To measure internal diameter to cut wire on internal diameter at a piece where thread
ends.
 To measure the angle of thread and take. The reading and move the wire by rotating eye
piece so, that meets the out slide exactly.
 Again take the readings of difference of two readings will give angle of thread.

PRECAUTIONS:
 Do not disturb the location of specimen once placed on the measuring table throughout
the experiment.
 Take the scale readings without any problematic error.

OBSERVATION:
 By conducting the experiment we can determine the parameter of the thread involved in
the various mechanical components.
 However internal measurement of a hollow component cannot be made.
 The major required measurements of the thread profile given plug gauge are:

Major diameter = 6.005mm

Minor diameter = 4.6mm
Pitch = 1.005mm
Thread angle = 59*

RESULT:
The obtained values after measurement of the thread profile are:
Major diameter = 6.005mm
Minor diameter = 4.6mm
Pitch = 1.005mm
Thread angle = 59*

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OBSERVATION TABLES:
MAJOR DIAMETER:
Initial Reading Final Reading Difference

9+34*0.01+0.005=9.345 15+35*0.01=15.35 6.005

MINOR DIAMTER:
Initial Reading Final Reading Difference

4+97*0.01+0.005=4.975 9+57*0.01=9.575 4.6

PITCH:
Initial Reading Final Reading Difference
Number of threads=5
0.600 5.610 1.005

THREAD ANGLE:
Initial Reading Final Reading Difference

26.8 327.8 59

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EXPERIMENT-07
ANGLE AND TAPER MEASUREMENT BY BEVEL PROTRACTOR, SINE BAR

AIM:-
To measure the angle of the given wedge using Since bar & Bevel Protractor

INSTRUMENTS USED:-
1. Since bar 2. Work piece 3. Dial Gauge
4. Slip gauges 5. Bevel Protractor.
THEORY:-
The sine principle uses the ratio of the length of two sides of a right triangle in deriving a given
angle. The accuracy with which the sine principle can be put to use is dependent in practice, on
some form of linear measurement. The sine bar in itself is not a complete measuring instrument.
Sine bars in conjunction with slip gauges constitute a very good device for the precise
measurement of angles. The arrangement is based on the fact that for any particular angle θ the
sides of a right angled triangle will have precise ratio, i.e,
Sinθ = h/l
If h and l could be measured accurately, θ can be obtained accurately. The value of h is built-up
by slip gauges and value ‘l’ is constant for a given sine bar.
Sine bars are used either to measure angles very accurately or for locating any work to a
given angle within very close limits. Sine bars are made from high carbon, high chromium,
corrosion resistant steel, hardened, ground and stabilized. Two cylinders of equal diameter are
attached at the ends. The axes of these two cylinders are mutually parallel to each other and also
parallel to and at equal distance from the upper surface of the sine bar. The distance between the
axes of the two cylinders is exactly 100, 200 and 300 mm in metric system.

PROCEDURE
1. Place the work piece/wedge above the sine bar and make it horizontal with the base.
2. The dial gauge is then set at one end of the work moved along the upper surface of the
component.
3. If there is any variation in parallelism of the upper surface of the component and the
surface plate, it is indicated by the dial gauge.
4. The combination of the slip gauges is so adjusted that the upper surface is truly parallel
with the surface plate.
5. Note down the values of the slip gauges.
6. Calculate the angle using the formula.
θ=Sin-1(h/l)
7. Repeat the procedure 3 or 4 times and take the average.

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OBSERVATIONS:

S.No. HEIGHT(h) LENGTH(l) ANGLE

Bevel protractor
A universal bevel protractor is used to measure angles between two planes. This consists of stem,
which is rigidly attached to main scale and a blade, which is attached to the vernier scale and can
be rotated to read angles. To improve the accessibility, the blade can also slide.
The least count is calculated by knowing the value of the smallest division on the main scale and
number of division on the vernier scale. It should be noted that the divisions on the main scale is
in degrees and that the fractional divisions of degrees are minutes (i.e. with 60 minutes/degree,
denoted). To measure angle between two planes, rest the stem on one of the planes (reference
plane). Rotate the blade such that blade is flush with second plane. Readings are taken after
ensuring that the stem and blade are in flush with the two planes. Lock the protractor at this point
and note sown the readings.

OBSERVATIONS:
S.NO. ANGLE MEASURED

PRECAUTIONS:
1. The sine bar should not be used for angle greater than 60 0 because any possible error in
construction is accentuated at this limit.
2. A compound angle should not be formed by mis-aligning of work piece with the sine bar.
This can be avoided by attaching the sine bar and work against an angle plate.
3. As far as possible longer sine bar should be used since using longer sine bars reduces
many errors.

RESULT:
The angle of the given specimen measured with the sine bar is

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The angle of the given specimen measured with the Bevel Protractor is

SINE BAR

BEVEL PROTRACTOR

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EXPERIMENT-08
THREAD MEASUREMENT BY TWO WIRE/THREE WIRE METHOD

AIM: To measure the Major, Minor and Effective diameter of external parallel screw threads
using Floating Carriage Micrometer.

APPARATUS: Floating Carriage Micrometer EDMM-100CL, Prism (A to D), Wire (1 to

4mm), Specimen, Master, Hooks etc.

THEORY: In order to ensure the manufacture of screw threads to the specified limits laid down
in the appropriate standard it is essential to provide some means of inspecting the final product.
For measurement of internal threads thread plug gauge is used and to check these plug gauges
Floating Carriage Micrometer is used for measuring Major, Minor and Effective diameter

Measuring machine shown in the figure has “Base”with two small and one big
adjustable support knobs provided for leveling the assembled unit. Base hastwo parallel
integral “V” grooves one short and other long. Long groove is for guide pegs located at the
bottom of “Intermediate Piece” or “Carriage” (B) and smaller for a ball. One more “V” pair
is in the Centre of the base, which is provided for accommodating “Centers” (E) to hold work
piece. Carriage has two parallel “V” grooves, one to accommodate two balls and other to
accommodate one ball. Underneath the floating top (C) there is one “V” groove on one side
and flat portion on other side. Digital Micrometer is in one bracket (with less width) and dial
type fiducial on the other side lever is provided to tighten it.
DEFINITIONS RELATED TO PARALLEL SCREW THREADS
Major Diameter: The diameter of an imaginary cylinder (termed the major cylinder) which
just embraces the crests of the external thread or the roots of an internal thread.
Minor Diameter: The diameter of an imaginary cylinder (termed the minorcylinder) which
just embraces the roots of an external thread or the crests of an internal thread.

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Simple effective(or Pitch) Diameter: The diameter of an imaginary cylinder(termed the pitch
cylinder ) which intersects the surface of the thread in such manner that the intercept on an
generator of the cylinder between the points where it meets the opposite flanks of the thread
groove is equal to one half the basic of the thread . The two methods for thread measurement
as follows
Two Wire Method:
The effective diameter of a screw thread may be ascertained by placing two wires or rods of
identical diameter between the flanks of the thread, and measuring the distance over the
outside of these wires. The effective diameter is then calculated as
E=T+P

Where T= Dimension under the wires

=M—2d
M=dimension over the wires, d= diameter of each wire

The wires used are made of hardened steel to sustain the wear and tear in use. These are
given a high degree of accuracy and finish by lapping to suit different pitches. Dimension T
can also be determined by placing wires over a standard cylinder of diameter greater than the
diameter under the wires and noting the reading R1 and then taking reading with over the
gauge, say R2. Then T=S—(R1—R2).
P=It is a value which depends upon the diameter of wire and pitch of the
thread. If P= pitch of the thread, then
P= 0.9605p−1.1657d (for Whitworth thread).
P= 0.866p—d (for metric thread).
to give the effective diameter. The expression for the value of P in terms of p (pitch),
d(diameter of wire) and x (thread angle) can be derived as follows:
In Fig. since BC lies on the effective diameter line
BC= ½ pitch=½ p
OP= (d cosec x/2)∕2
PA=d (cosecx∕2−1) ∕2
PQ=QC cot x∕2=p∕4 cot x∕2
AQ=PQ−AP=(p cot x∕2)∕4 – d (cosec x∕2 −1)∕2
AQ is half the value of P
.’. P value=2AQ =p∕2 cot x∕2 −d (cosecx∕2−1)

Two wire method can be carried out only on the diameter measuring machinedescribed for
measuring the minor diameter, because alignment is not possible by two wires andcan be
provided only by the floating carriage machine. In the case of three wire method, two wire,
on one side help in aligning the micrometer square to the thread while the third placedon the
other side permits taking of readings.
Three Wire Method:

This method of measuring the effective diameter is an accurate method. In this threewires or
rods of known diameter are used; one on one side and two on the other side [Fig. (a) and (b)].
This method ensures the alignment of micrometer anvil faces parallel tothe thread axis. The
wires may be either held in hand or hung from a stand so as to ensurefreedom to the wires to
adjust themselves under micrometer pressure.

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M=distance over wires E=effective diameter

r=radius of the wires d=diameter of wires
h =height of the centre or the wire or rod from the
effective x=angle of thread.
AD = AB cosec x∕2 = r cosec x∕2
H = DE cot x∕2 = p∕2 cot x∕2
CD = ½H = p∕4 cot x∕2
H = AD−CD
r = cosec x∕2− p∕4 cot x∕2
Distance over wires=M = E+2h+2r
= E+2(r cosec x∕2 – p∕4 cot x∕2)+2r
= E+2r (l+cosecx∕2 )− p∕2 cot x∕2
or M = E+d (1+cosec x∕2) − p∕2 cot x∕2
(since 2r = 0 )

(i) In case of Whitworth thread:

X = 55°, depth of thread = 0.64 p, so that
E= D—0.64 p and cosec x∕2 = 2.1657
Cot x∕2 = 1.921
M = E+d(1l+cosec x∕2) — p∕2 cot x∕2
= D−0.64p+d(1+2.1657)−p∕2(1.921)
= D+3.1657d−1.6005p
M = D+3.1657d—1.6p
Where D=outside dia.

(ii) In case of metric threads:

Depth of thread=0.6495p So, E
= D-0.6495p.
x = 60°, cosec x∕2 = 2;cot x∕2 = 1.732
M = D−0.6495 p+d(l+2)—p∕2
(1.732) = D+3d− (0.6495+0.866)p
= D+3d—1.5155p.
PROCEDURE:
1. The diameter of setting master or a cylinder should be nearly same as the diameter of
the thread gauge to reduce error.
2. First meet the anvil of micrometer to dial gauge and rotate micrometer in forward to
rotate needle in dial by 10mm with setting its scale zero at needle positionand make digital
micrometer to zero by pressing button.
3. Put master in between centers and make dial needle to zero by moving micrometer.
Take the reading on micrometer as RS.. Similarly replace master with a threaded work piece
again second reading is taken as “R”

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4. Hang the required set of prisms (from Appendix-1 according to pitch of work piece)
on the hooks provided on both sides of standard. Take the reading on micrometer and zero
indicator in such a way that portion of prism touches master and flat portion of prism is on
micrometer & zero indicator.
5. Take reading for master as RP and work piece as Rq on micrometer as needle on dial
indicating zero.
6. Now place two small wires or cylinders in place of prism. The wires should be
choosen so that, when placed between the threads, they should contact about halfway down
theflanks. Suitable sizes of these cylinders for various threads are given atAppendix-1
7. Take the readings for master as RW and work piece as ROW on micrometer as needle
on dial indicating zero.

OBSERVATION:
D = Diameter of Setting master = ______
Dimension of work piece = 14M*2

Observation Table:
MAJOR DIAMET RS M = D ± (Difference between ‘R’ and ‘ RS’)
(M) R =

MINOR DIAMET Rp C = D ± (Difference between ‘Rp’ and ‘Rq’)

(C) Rq =

EFFECTIVE RW T = D ± (RW - ROW) =

DIAMETER (E) ROW E=T+P=

CALCULATIONS:
Major diameter:

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RS = Micrometer reading over setting master.

R = micrometer reading of threaded work piece.
M = D ± (Difference between ‘R’ and ‘ RS’)

(Note: The + or – is determined by relative size of the master and the work
piece.Use – sign as master is of greater size than work piece and vice-versa for +
sign.)
Minor diameter:

C = core or minor diameter of the work piece.

Rp = reading over master with prisms.
Rq = Reading over work piece with prisms.
C = D ± (Difference between ‘Rp’ and ‘Rq’)
Effective diameter:

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E = effective or pitch diameter

ROW = Reading measured over work piece with wires.
RW = Reading measured over setting master with wires.
T = measured dimension under cylinders.
T = D ± (RW - ROW)
E=T+P
P = Constant depending on the pitch and angle of the thread and the mean diameter of wires
used.
(Reading “P” values for different threads are given along wires with wires to be used in
Appendix -1)

RESULT :
Major Diameter =
Minor Diameter =
Effective Diameter =
CONCLUSION: Using the Floating Carriage Micrometer diameter of imaginary cylinder
i.e.
Effective or pitch diameter can be evaluated.

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EXPERIMENT-09
DETERMINATION OF SURFACE ROUGHNESS USING SURFACE
ROUGHNESS TESTER
AIM: To measure the surface roughness of a sample using the surface roughness tester
equipment
APPARATUS: surface roughness tester, sample piece
THEORY:
SURFACE FINISH: surface finish by definition is the allowable deviation from a perfectly
flat surface that is made by some manufacturing process. Whenever any process is used to
manufacture a part, there will be done roughness on the surface. This roughness can be caused by
a cutting tool making tiny grooves on the surface or by the individual grains of the grinding
wheel each cutting its own groove.
Surface texture is generally broken up into three components upon analysis
1) Roughness
2) Waviness
3) Form

All three surface finish components exist simultaneously they just overlap one another roughness
has a shorter wavelength than waviness .Which in turn has a shorter wavelength than form.
A surface roughness tester has a probe/stylus than moves along the surface of the sample while
registering the minute displacement of itself perpendicular to the surface i.e it traces the profile
of the surface as it moves along.
PROCEDURE:
1) Setup the instrument for the equipment
2) Fix the sample and adjust the probe height to touch the surface
3) Move the probe along the surface while noting the defection reading on the display
4) Record the readings

PRECAUTIONS:
1) Use the equipment very carefully as the probe is very sensitive
2) Do not tamper with the equipment

OBSERVATION:
1) Arithmetic average of absolute Ra=
2) Arithmetic average of absolute valve Ra=

RESULT:
1) Arithmetic average of absolute Ra=
2) Arithmetic average of absolute valve Ra=

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Surface roughness tester setup

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