vv vvvvvVUVUUVUUUUUUUUUUUVUVUUEeeeuevess 6 Semester Metrology Lab Experiment 1 AIM: Study of Slip Gauges along with their usage i.e. wringing of Slip Gauges APPARATUS: Slip Gauge Set, Surface plate, Soft Cloth DESCRIPTION: (i) SLIP GAUGES or GAUGE BLOCKS: Slip Gauges are the universally accepted standard of length in the industry. They are used (1) For direct precise measurement where the accuracy of the workpiece demands it, (2) For use with high- magnification comparators, to establish the size of the gauge blocks in general use, Also used for many other purposes such as checking the accuracy of measuring instruments or setting up a comparator to a specific dimension. slip gauges also known as Gauge blocks or Johannson gauges are cuboidal-shaped blocks of high- grade steel with a high finish, They are used mainly used as measuring standards in the engineering field, These are first hardened to resist wear and carefully stabilized so that they are independent of any subsequent variation in size or shape. After being hardened, blocks are carefully finished oon the measuring faces to such a fine degree of finish, flatness, and accuracy that any two such faces when perfectly clean may be wrung together. soft copy available @: wwww.RamaKantRano.com/Metrobddededded SELELELLELLELELELOOCUCdddde Metrology Lab Experiment 1 6% Semester These slip gauges are available in a variety of selected. Sets both in inch units and metric units Letter'E"is used for inch units and letter 'M' is used for metric standards. The size of any required standard is made up by combining the appropriate number of these different size blocks. f two are twisted together under pressure, they will firmly join together. This process known as wringing is very useful because it enables several gauge blocks to be assembled together to produce the required size. (li) SUP GAUGE GRADES: For general use there are five grades as under: Grade-2: This is the workshop grade. Typical uses include setting up machine tools, positioning milling cutters, and checking mechanical widths. Grade-1; Used for more precise work, such as that carried out in a good class tool room. Typical uses include setting up sine bars and sine tables, checking gap gauges, and setting dial test indicators to zero. Grade-0: This is Inspection Grade, and its use is confined to tool room or machine shop inspection. This, means that it is the inspection. department only who has access to this grade of slips. In this way, itis not possible for these slip gauges to be damaged or abused by the rough usage to be expected on the shop floor. Grade-00: ‘This grade would be kept in the standard room and would be used for work of the highest precision only. soft copy available @: www.RamaKantRane.com/MetroExperiment | 6 Semester Metrology Lab WRINGING OF SLIP GAUGES: The two slip gauges in precision measurement are joined by the process called “wringing Step 1: This is accomplished by pressing the faces into contact keeping them perpendicular such that it appears as a cross from the top. Step 2: And then imparting a small twisting motion whilst maintaining the contact pressure. The contact pressure is just sufficient in order to hold the two slip gauges in contact and no additional intentional pressure. Step 3: It is found that the phenomenon of wringing occurs due to molecular adhesion between a liquid film (whose thickness may be between 6 to 7 x 10-6 mm) and the mating surfaces. When two gauges are wrung together and the overall dimension of a pile made of two or more blocks so joined is exactly the sum of the constituent gauges. soft copy available @: www.RamaKantRana.com/MetroExperiment | 6' Semester Metrology Lab y - C ~ soft copy available @: wwww.RemaKontRona.com/Metro i Hoe ULL LULL LULU LLU Ue CUCU CUR ee eee eyMetrology Lab —_ SLIDE WITH PRESSURE PROCEDURE: (i) Firstly the Slip Gauge set must be observed in detail. The number of pieces in the set and the dimensions of the available Slip gauges must be known clearly. Agiven dimension is to be built up by the wringing minimum number of Slip Gauges The given dimension must be noted and the minimum possible sip gauge available in the set must be chosen in such a way that the last decimal value is accommodated. (Example: For a given decimal of 49.625 a slip gauge piece of 1.005 must be taken first) Now the preceding decimal places of the given dimension have to be accommodated, Hence minimum possible slip gauge dimensions available in the set are chosen. (Ex For the above dimension a slip gauge block of 1.12 mm must be chosen followed by a 1.50 mm block. The above steps are repeated to build up the given dimension. PRECAUTION: (i) Slip gauge must be handled very carefully, placed gently, and should never be dropped (i) Whenever a slip gauge is being removed from the set, its dimensions must be noted and after its use, must be replaced in the set at its appropriate place only. soft copy available @: www.RamaKantRana.com/MetroExperiment 1 6 Semester Metrology Lab (ili) Slip Gauges must be cleaned well before use and petroleum jelly must be applied after use. OBSERVATIONS: Dimension by V.C.—Dimension by Slip Gauge 4 59 Dimension by Slip Gauge Table 1.1: Observation Table Given Dimension Dimension by (mm) Slip Gauges Used | Vernier Caliper Result slip gauge set is studied and the given dimension is built up by wringing a minimum number of slip gauges. soft copy available @: www.RamaKontRana.com/Metro6% Semester Metrology Lab Experiment 2 AIM: Study and working of simple measuring instruments: Vernier calipers and micrometer Theory: VERNIER CALIPER Principle of Vernier Caliper When two scales or division slightly different in size are used, the difference between ther can be utilized to enhance the accuracy of measurement. Parts: Different parts of given Vernier Caliper are (2) Beam (It has Main Scale) (2) Fixed Jaw (3) Sliding or Moving Jaw a. (It has Vernier Scale and Sliding jaw locking Screw) (4) Fine Adjustment Clamp b._ (ithas Fine adjustment Clamp locking Screw and fine adjustment Screw) (5) Knife Edges for internal Measurement and (6) Stem or Depth Bar for depth measurements Measurements: Given Vernier Caliper can be used for External, Internal, Depth, Slot and Step measurements Classification of Vernier Caliper three types of Vernier calipers have been specified for internal and external measurement up to 200 mm with Vernier accuracy of 0.02,0.05,0.1 mm. The three types are called A, B, and C type > Type A has jaws on both side for internal and external measurement and also has a blade for depth measurement. soft copy available @: www.RamaKantRana.com/MetroExperiment 2 6" Semester Metrology Lab > ‘Type B is provided with jaw on one side for internal and external measurement. > Type C has jaws on both sides for making the and for making operations. Figure 2.1: Vernier caliper Precautions: * No play should be there between the sliding jaws on the scale, otherwise, the accuracy of the Vernier caliper will be lost. Usually the tips of measuring jaws are worn and that must be taken into account Most of the errors usually result from the manipulation of the Vernier caliper and its jaws on the workpiece. In measuring an outside diameter it should be ensured that the caliper bar and the plane of the caliper jaws are truly perpendicular to the workpiece’s longitudinal center line. It should be ensured that the caliper is not canted, tilted, or twisted The stationary caliper jaw of the Vernier Caliper should be used as the reference point and the measured point is obtained by advancing or withdrawing the sliding jaw Application: Internal as well as external linear dimensions for a length as less than 200mm can be measured with an accuracy up to + (90+0.021) um. Least count: Soft copy available @: www.RamaKantRana.com/MetroExperiment 2 6" Semester Metrology Lab Let us consider Vernier scale reading = 50 division. This division coinside with exactly 49th on the ‘main scale. So one Vernier division. division coincide with main scale _ 49 division coincide with Vernier scale 50 Therefore Difference between main scale and Vernier scale small division and one Vernier division is1-0.98=0.02 mm. Reading Let us assume that small division of the main scale is 0.025 unit. Say the Vernier scale contain 50 division and these coincide exactly 49 division of main scale. So now one Vernier division is equal 1 to 1/59 of 49 scale. Therefore the difference between one main scale small division and one Vernier division (Least count of instrument) equal 1.00 - 0.98 i.e. 0.02 unit. Observation Table: fe ‘Avera ] : ee Error in | s.No. eocae ote Dimension by | — Dimension Error % age ae Vernier (Y) Z=X-Y 4. 5, All readings are in mm Conclusion: The determined dimension by Digital Vernier Caliper (X) The Average Dimension by Simple Vernier Caliper (Y) = =X-Y Error in Dimension ——— Soft copy available @: www.RamaKantRana.com/MetroMetrology Lab Experiment 2 6% Semester MICROMETER Principle of Micrometer: een them can When two scales or divisi ee ion slightly different in size are used, the differenc be utilized to enhance the accuracy of measurement Classification: 1, Inside micrometer. Stick micrometer. Micrometer depth gauge. Thread micrometer caliper. Outside micrometer caliper. \V-Anvil micrometer caliper. Blade type micrometer. Micrometer for measuring thickness of cylinder, walls. Dial micrometer caliper. Taper-screw operated internal micrometer. Grove micrometer. Digital micrometer. Differential screw micrometer. Figure 2.2: Micrometer soft copy available @: www.RamaKantRana.com/MetroExperiment 2 6" Semester Metrology Lab Materials The frame is generally made of steel, cast steel, malleable cast iron or light alloy. The measuring faces are hardened to about 800 H.V. and aged. The material used for thimble, barrel, ratchet and other locking and clamping devices for all sizes of micrometer should be suitable quality wear resistant steel Applications 1. Internal and external diameters. 2. Long internal lengths. Depth of holes, slots and recessed areas. Thread measurement. Large work having dimensions above 250mn out of roundness condition. Fast and accurate measurement of circular formed tools, dia. and depth of all sizes. Narrow grooves, slots, keyways, recesses etc. Thickness of cylinder walls. Least Count division scale _ 0.5 smallest diviston on main seale _ 95 _ 9 1mm, es No.of division on Vernier scale 50 Reading Before taking reading anvil and spindle must be brought together carefully and the initial reading noted down. in metric micrometers the pitch of the screw thread is 0.5mm so that one revolution of the screw moves it exactly by 0.5mm. Main scale on barrel has least division of 0.5mm. The thimble has 50 division on its circumference therefore one division on thimble is = 0.5 / 50 =0.01mm Figure 2.3: Reading of Micrometer Soft copy available @: www.RamaKantRana.com/MeExperiment 2 6" Semester Metrology Lab The reading of micrometer in figure is 3.5mm on barrel and 7 divisions on thimble. = 3.5 +7 * 0.01 = 3.57mm, Errors in reading: ranges should be such eed 6, The errors in parallelism of the measuring faces of micrometer of various that the few of interference triangle observed on the two measuring faces should not exc 8 and 10 for ranges 0 to 25, 25 to 75 and 75 to 100mm. Observation Table: ; ‘Average Gaede Di S.No, | Dimension by | oimension by | Dimension oe igital Vernier (%) | icrometer (¥) cane All readings are in mm Conclusion: The determined dimension by Digital Vernier Caliper (X) ‘The Average Dimension by Micrometer (Y) = mm. Error in Dimension Z= X-¥ soft copy available @: www.RamaKantRana.com/Metro6" Semester Metrology Lab Experiment 3 AIM: To study bore gauge diameter with bore gauge. APPARATUS: Work piece, Vernier caliper and bore gauge indicator set with anvil Theory: Bore Gauge Indicator: These are the instruments designed for checking bore diameter by the comparative method. 7 instrument's principle of operation is shown in the figure. The instrument basically consists of hollow tube into which is contained a lever pivoted about one end of the lever is linked to the movable contact of the instrument i.e. the instrument has three contacts. Equally spaced along the circumference of the head. One is movable above and two fixed ones and the other ends of the lever actuate the pointer. The three contacts bear against the internal surface of the rest and properly the instrument in relation to the axis of the bore being checked. The contacts are interchangeable with roads in order to broaden the range of measurement, the smallest size. This instrument can check in the order of 11-18 cm in diameter. The range of setting is about ¢ 0.06 to +£0.22 cm with scale division values of 0.002 and 0.01 respectively. Figure 3.1: Labelled Image of a Bore Gauge Soft copy available @: www.RamaKantRang.com/Metro6" Semester Metrology Lab Figure 3.2: Image of Bore Gauge while Measuring PROCEDURE: First of all take the workpiece where the internal diameter is to be calculated Now take the Vernier calipers and place the knife edges inside the workpiece and read the reading for the internal diameter of the workpiece. See the reading that is obtained from the micrometer. If the reading is say 34.8 mm then take the anvil of size 34 mm and washers of size 0.5 mm and fit them to the body of the gauge. Now set the dial gauge indicator for zero position and then make readings at any position inside the work piece. This should be done carefully as the anvil movable screw will wear in rough handling of the gauge. The above step is repeated for different positions inside the work piece. Now set micrometer and keep the micrometer to dial gauge indicator and note down the reading Now calculate the internal diameter using given formulae i, Actual size = anvil length + washer length # (R1 R2) x m, ji, R= reading obtained in dial gauge when the same dial gauge kept in micrometer. R2= reading obtained from the work piece. Soft copy available @: www.RamaKantRana.com/Metro,Experiment 3 6" Semester OBSERVATIONS: Rough measurement of bore using A — type Vernier calipers: [ S.No. | Reading at Point 1. Reading at Point 2 ea I ‘Average reading = RESULT: Diameter obtained by using dial gauge indicator is rr Soft copy available @: www.RamaKantRana.com/Metro