Saranathan College of Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

Metrology and Measurements

Laboratory Manual
V Semester B.E. Mechanical Engineering

Name:_______________________________________

Batch No: __________ Sem __________ Sec ________

Course Name ____________________________________

Course Code _____________________________________

 ANNA UNIVERSITY, CHENNAI

R – 2017 B.E. MECHANICAL ENGINEERING

ME8513 METROLOGY AND MEASUREMENTS LABORATORY LTPC 0032

LIST OF EXPERIMENTS

1. Tool Maker’s Microscope

2. Comparator
3. Sine Bar
4. Gear Tooth Vernier Caliper
5. Floating gauge Micrometer
6. Co ordinate Measuring Machine
7. Surface Finish Measuring Equipment
8. Vernier Height Gauge
9. Bore diameter measurement using telescope gauge
10. Bore diameter measurement using micrometer
11. Force Measurement
12. Torque Measurement
13. Temperature measurement
14. Autocollimator
 Index Page
Ex. Page
Date Name of the Exercise Signature
No. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
EX. NO :
DATE :

CALIBRATION OF MICROMETER

AIM :

To calibrate the given micrometer.

REQUIREMENTS:

1. Micrometer (0 – 25 mm) least count = 0.01mm

2. Set of slip gauges (0.5 to 100mm) (1 Set - 83Nos)
3. Micrometer stand.

DESCRIPTION:

The micrometer screw gauge essentially consists of an accurate screw having about 40
threads per inch and revolves in a fixed nut. The end of the screw forms one measuring tip and other
measuring tip is constituted by a stationary anvil in the base of the frame. The screw is threaded for
certain length and is plain onwards. The plain portion is called Sleeve and its end is the measuring
surface. The spindle is advanced or retracted by turning a thimble connected to the spindle. The
spindle is a slide fit over the barrel and Barrel is the fixed part attached with the frame. The barrel is
graduated in unit of 0.5mm. The thimble has got 50 divisions around its periphery on circular portion.

A locknut is provided for locking a dimension by preventing motion of the spindle. Ratchet
stop is provided at the end of the thimble cap to maintain sufficient and uniform measuring pressure,
so that standard conditions of measurement are attained. Ratchet stop consists of an overriding clutch
held by a weak spring when the spindle is brought into contact with the work at the correct measuring
pressure, the clutch starts slipping and no further movement of the spindle takes place by rotation of
ratchet. In the backward movement it is positive due to the shape of ratchet.

OUTSIDE MICROMETER

1
TABULATION

Actual Value (mm) Error = Actual

Combination of
Sl. Nominal Value Value-
slip gauges
No. (mm) MSR + (PSR x LC)+(VSD x LC) Nominal Value
(mm)
± ZE (mm)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

2
PROCEDURE:

1. Check the micrometer for smooth running over its whole range.
2. Clean the anvils carefully.
3. Close the anvils and note the zero error. Also note the least count.
4. Determine the progressive error of the micrometer by choosing standard slip gauges for the
whole range (0-25mm). Let the increments in the initial and the final ranges as small as
possible.
5. Determine the error of the micrometer.
6. Plot the graphs between the nominal value vs. error.
7. Record the maximum and minimum error values.

OBSERVATION :

Range of micrometer = 0 - 25 mm

0.5
Least count = = 0.01 mm
50
Zero error =

Zero correction =

GRAPH: Nominal value Vs. error.

RESULT:
The given micro meter is calibrated using standard slip gauges.

3
 VERNIER CALIPER

TABULATION:

Nominal Combination of slip Actual Value (mm) =

Error = Actual Value –
Sl. No. Value gauges MSR + ( VSR X LC)
Nominal Value (mm)
(mm) (mm) ± ZE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

4
EX NO. :
DATE :

CALIBRATION OF VERNIER CALIPER

AIM:

To calibrate the given ordinary type and dial type vernier caliper.

REQUIREMENTS:

1. Vernier caliper (dial type 0-200mm) of least count = 0.02 mm

2. Vernier caliper (ordinary type 0-200 mm) of least count = 0.02 mm
3. Set of slip gauges (0.5 to 100mm) - 83 Nos.

DESCRIPTION:

The principle of vernier caliper is that when two scales divisions slightly different in size are
used the difference between them can be utilized to enhance the accuracy of measurement. Thus
vernier caliper essentially consists of two steel rules and these can slide along each other. The main
scale is engraved on a solid „L‟ shaped frame; vernier scale has got 50 divisions. One end of the frame
consists of a fixed jaw, which is shaped into a contact tip at its extremity.

A sliding jaw which moves along the guiding surface provided by the main scale is coupled
to a vernier scale. The sliding jaw at left extremity contains another measuring tip. When two
measuring tip surfaces are in contact with each other, scale shows zero reading. The finer adjustment
of the movable jaw can be done by the adjusting screw.

OBSERVATION:

Range -0-150 mm

1 Main Scale Division = 1 mm

49
1 Vernier Scale Division =
50
49
Least count = 1M.S.D - 1 V.S.D = 1 = 0.02 mm
50
PROCEDURE:

1. Check the Vernier caliper for zero error

2. Take a standard slip gauge, place between the fixed and movable jaws of the vernier caliper
and note the corresponding reading.
3. Repeat the above step for different slip gauges combinations and tabulate the error.
4. The same procedure is to be repeated for dial type vernier and the readings to be tabulated as
below.
5. A graph between nominal value Vs. error to be drawn.

5
 DIAL TYPE

Nominal Combination of slip Actual Value (mm) =

Error = Actual Value –
Sl. No. Value gauges MSR + ( VSR X LC)
Nominal Value (mm)
(mm) (mm) ± ZE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

6
GRAPH : Nominal value Vs error.

RESULT:
The given ordinary and dial vernier caliper is calibrated using standard
slip gauges.

7
TABULATION :
MAJOR DIAMETER
Final Actual Nominal Error =
Initial
S.No. Reading diameter Diameter Actual - Nominal
Reading (mm)
(mm) (mm) (mm) (mm)
1.
2.
3
4.
5.
6.

MINOR DIAMETER
Final Actual Nominal Error =
Initial
S.No. Reading diameter Diameter Actual - Nominal
Reading (mm)
(mm) (mm) (mm) (mm)
1.
2.
3
4.
5.
6.

PITCH
Final Nominal Error =
Initial Actual Pitch
S.No. Reading Pitch Actual - Nominal
Reading (mm) (mm)
(mm) (mm) (mm)
1.
2.
3.
4.
5.
6.

8
EX.NO. :
DATE :

SCREW THREAD INSPECTION USING PROFILE PROJECTOR

AIM :

To check the outer diameter and pitch of the screw thread using profile projector.

REQUIREMENTS :

1. Screw thread.
2. Profile projector.

DESCRIPTION :

The profile projector consists of

a) A projector having light source, a condenser, a collimating lens to direct the light
passed into the optical system.
b) A work holding table, which is of movable type.
c) A projector optic including both mirrors and lenses.
d) A screen where the image is projected. It has got two micrometer heads of the range 0
to 25 mm. which enable to measure in horizontal as well as in vertical direction.

PROCEDURE :

1. The range of micrometer is 0 to 25 mm and keeps it around 12.5, so that we can

measure in either direction.
2. Adjust the screw on the table such that the crest of the screw coincides with the
horizontal cross line and take the initial reading. Move the micrometer till the
horizontal cross line coincides with the crest of the thread on the other side. Now take
the final reading. The difference between the two readings will gives the outer
diameter and this is to be repeated at five different locations over the entire thread.
3. Adjust the screw tread on the table such that the vertical cross line coincides with the
crest of the one thread and note the reading.
4. Move the micrometer till the cross line vertically coincides with the crest of next
thread and the reading is to be noted. The difference in readings gives the pitch and
this is to be repeated at five different places. The readings are tabulated and error is to
be found out.

GRAPH :

Position Vs error in major diameter

Position Vs error in minor diameter
Position Vs error in pitch.

RESULT :

The outer diameter and pitch of the screw thread values are noted and verified using
profile projector.

9
TABULATION

SL. Slip gauge Total slip Dial gauge(mm) Remarks

NO. combination (mm) gauge(mm)
Initial Reading Final Reading

10
EX. NO.:
DATE :
TAPER ANGLE MEASUREMENT USING SINE BAR

AIM:

To measure the angle of the taper plug gauge with the sine bar.

REQUIREMENTS:

1. Sine bar (length -200 mm.).

2. Slip gauges (0.5 - 100mm) - (1 Set - 83 Nos.)
3. Taper plug gauge.
4. Dial gauge (L.C. - 0.01mm).
5. Dial stand.

PROCEDURE:-

1. Place the sine bar on the surface plate

2. Keep the plug gauge whose external taper is to be determined, over the sine bar.
3. Ensure that there is no movement of the plug gauge by pressing the small end of the plug gauge
downward. Introduce a slip gauge of suitable size at other end.
4. Raise the small end of the plug gauge by placing proper slip gauges as shown in tha above figure
such that the top surface of the plug gauge becomes parallel to the surface plate. This is verified
by running a dial indicator along the top surface of the plug gauge. There should not be any
deviation in the pointer of the dial gauge.
5. Note down the height of the slip gauge ( h) and the length of the sine bar (l).
6. Using the formula calculate the taper angle

h
Sin  =
l
h
 = Sin 1   ( Angle per side)
l
Taper angle of the given specimen= 2 

RESULT:

The angle of the taper plug gauge is measured with the sine bar.

Taper angle using by sine bar (2θ) =

11
 TABULATION:-

Gear Outer Diameter Plug Diameter -1

Outer
Outer SL.NO MSR+VSR diameter
SL.NO MSR+VSR diameter (mm)
(mm)
1.
1.
2.
2.
3.
3.
Average =
Average =
Plug Diameter -2

Outer
SL.NO MSR+VSR diameter
(mm)
1.
2.
3.
Average =

Plug Average

WHOLE DEPTH

Nominal Actual Error = Actual-Nominal

SL.NO.
(mm). (mm). (mm).
1
2
3
4
5
AVERAGE =

PITCH CIRCLE DIAMETER

Nominal Distance over Plug-Plug Diameter = Actual Error = Actual - Nominal

SL.NO.
(mm). (mm). (mm)

1
2
3
4
5
Average=

12
EX. NO.:
DATE :

GEAR INSPECTION USING GEAR TOOTH VERNIER

AIM :

To inspect the given gear for error in pitch circle diameter and whole depth.

REQUIREMENTS:

1. Gear tooth vernier. (L.C. - 0.02mm)

2. Standard plugs (1 set)
3. Gear specimen.
4. Rubber bands.
5. Vernier caliper. (0-200 mm. L.C. - 0.02mm)

DESCRIPTION:

Gear tooth vernier: It is used to measure the thickness of gear tooth at pitch line or chordal
thickness of tooth and the distance form top of the tooth to the root. The thickness of a tooth at pitch
line and the addendum is measured by an adjustable tongue each of which is adjusted independently
by adjusting screw on graduated bars. The pitch circle diameter and whole depth of the gear are found
out using the test plug method where the actual values are noted. Nominal values are found out by
calculations.
GEAR TOOTH VERNIER

13
14
PROCEDURE:

1. Determine the best plug diameter using the formula given below.
2. Take two standard plugs whose diameters are close to the determined value.
3. Place the plugs in diametrically opposite tooth spaces and measure the distance over the plugs
using vernier caliper.
4. Also measure the whole depth using the gear tooth vernier.
5. Compare the determined values of pitch circle diameter and whole depth against nominal
value.
OBSERVATION:
Number of teeth Z =
OuterDiameter
Module „m‟ =
Z 2

Pressure angle θ = 20˚

FORMULAE REQUIRED:-

Nominal Pitch circle diameter = m z

Nominal whole Depth = 2.157 × m
m
Best Plug Diameter =  Cos 20
2
GRAPH:

Position Vs Whole Depth error &

Position Vs Pitch Circle Diameter error.

RESULT:

The following values are calculated by the help of gear tooth vernier

Nominal Whole Depth =

Actual Whole Depth =

Nominal Pitch Circle Diameter =

Actual Pitch Circle Diameter =

Error in Whole Depth:- Error in Pitch Circle Diameter:-

Maximum error- Maximum error

Minimum error- Minimum error-

15
FORMULAE:-

Theoretical base tangent length.

       S 
Wt = N  m  Cos  tan         
  2 N   N 
Where,
N - Actual number of teeth in the gear specimen,
m - Module of the gear specimen,
θ - Pressure angle (20º) of the gear specimen,
   
Ø - Pressure angle  , radians ,
 180 
S - Number of teeth (take S = 4).

Wt
Theoretical pitch length (Pt) = = mm.
 1
S  
 2
We
Measured pitch length (Pe) = = mm.
 1
S  
 2
Wt
The chordal thickness Ct = = mm.
2S  1
We
Ce = = mm.
2S  1
Percentage of error = {(Ct ─ Ce ) / Ct } x 100 =

TABULATION

Sl.NO. Theoretical base Measured base Theoretical chordal Measured chordal

tangent length, Wt tangent length , thickness, Ct (mm) thickness, Ce (mm)
( mm) We (mm)
01
02
03
04
05
AVERAGE= AVERAGE=

16
EX. NO.:
DATE :
TOOTH SPAN MICROMETER

AIM :

To determine the thickness of the gear tooth.

REQUIREMENTS:

1. Tooth span Micrometer ( 0 – 25mm)

2. Gear specimen.

DESCRIPTION:

This instrument is used to measure the variation in the base tangent length W (a straight line
connecting the point of contact of two unlike tooth flanks by two parallel measuring surfaces). The
tooth span micrometer differs from conventional external micrometer in that its anvil and spindle are
fitted with replaceable disc type cups. The micrometer is available in measuring capacities 0 – 25, 25
– 50, 50 – 75 and 75 – 100mm.

TOOTH SPAN MICROMETER

PROCEDURE:

A base tangent length variable determined by computing the mean value of measurement
made in several position of the gear with the nominal value computed by a formula. Variation of the
base tangent measure in difference position defines the mutual positioned accuracy of gear tooth.

RESULT

The thickness of the chordal tooth is calculated using tooth span micro meter

The Chordal Tooth Thickness =

17
 TABULATION

d1 d2 Slip gauge Height (H) Diameter

Method (mm) (mm) (mm) (mm) (DB) (mm)

Two ball

DL ds Slip gauge Height (H) Diameter

Method
(mm) (mm) (mm) (mm) (DB) (mm)

Four ball

d3 d4 Slip gauge Height (H) Diameter

Method
(mm) (mm) (mm) (mm) (DB) (mm)

Two ball

FORMULA:
DB  d S  2  H ( DL  d S )  H 2
DB = diameter of the bore
DS = diameter of small steel balls
DL = diameter of larger steel balls
H = height of High Point of steel ball

Case (III) (Two balls with Slip gauge insert method)

procedure:

1. Place the specimen on the surface plate.

2. Place the steel balls as shown in figure.
3. Insert the slip gauge till you get a perfect fit.
4. DB = (d3 + d4 + slip gauge), gives the diameter of the bore.

18
EX.NO. :
DATE :

MEASUREMENT OF BORE DIAMETER

AIM:

To measure the bore diameter of the given specimen.

REQUIREMENTS:

1. Standard steel balls 25mm, 20mm, 15mm, 10mm and 5mm.

2. Dial gauge (L.C.– 0.01mm)
3. Slip gauge
4. Dial gauge stand
5. Surface plate

PROCEDURE:

1. Place the specimen on the surface plate.

2. Put the standard steel ball of larger diameter inside.
3. Place the smaller steel ball over the larger diameter steel ball.
4. Measure the height of point of steel ball using dial indicator or slip gauge.

Case (I) --- (Two ball method)

(if d1 & d2 are greater than diameter of bore)
d1 & d2 - diameter of standard steel balls
H - Height of High Point of steel ball from surface plate.

Bore diameter

d 1  d2
DB   H (d 1  d 2 )  H 2
2
Case (II) (Four ball method)

PROCEDURE:

1. Place three standard steel balls of same diameter (Note: The diameter should be less
than half the bore diameter).
2. Over the three balls put a larger diameter steel ball (Note: The larger diameter ball
should be less than 0.75 of the bore diameter).
3. Measure the height of High Point of steel ball (H) using dial indicator and slip gauge.

RESULT:

The bore diameter of the given specimen is measured using standard steel balls, slip
gauges and dial indicator.

19
Vernier High Gauge

20
EX. NO. :
DATE :

MEASUREMENT OF “V” – Block Parameter

AIM:

To measure the various parameters of V – block.

REQUIREMENTS:

1. V – block
2. Vernier height gauge (0 – 300mm)
3. Vernier caliper (0 – 20mm)
4. Bevel protractor
5. Surface plate

DESCRIPTION:

The V – blocks are generally used for the purpose of checking the roundness of
cylindrical work pieces, marking center accurately and used to locate components in some of
the work holding devices.

PROCEDURE:

1. Clean the V – block.

2. Place the V – block over the surface plate.
3. Measure the length and breadth of the V – block.
4. Measure the angle of the V – block.
5. Measure the depth of the V – block.

RESULT:

The following parameters of V – block is measured using vernier high gauge

1. Length of the V – block = mm

2. Height of the V – block = mm
3. Breadth of the V – block = mm
4. Angle of the V – block face – 1 =
5. Angle of the V – block face – 2 =
6. Groove depth = mm
7. Side face height – 1 = mm
8. Side face height – 2 = mm
9. Top face land = mm

21
22
EX. NO:
DATE:

23
24
25
TABULATION:

MAJOR DIAMETER

Nominal Error = Actual Value –

Initial Reading Final Reading Actual
S.No. Diameter Nominal Value
(mm) (mm) diameter (mm)
(mm) (mm)

1.

2.

4.

5.

6.

MINOR DIAMETER

Nominal Error = Actual Value –

Initial Reading Final Reading Actual
S.No. Diameter Nominal Value
(mm) (mm) diameter (mm)
(mm) (mm)

1.

2.

4.

5.

6.

26
27
 PITCH

Nominal Error = Actual Value –

Initial Reading Final Reading Actual Pitch
S.No. Pitch Nominal Value
(mm) (mm) (mm)
(mm) (mm)

1.

2.

3.

4.

5.

6.

DEPTH OF THE THREAD

Nominal
Error = Actual Value –
Initial Reading Final Reading Actual Thread Thread
S.No. Nominal Value
(mm) (mm) depth (mm) depth
(mm)
(mm)

1.

2.

3.

4.

5.

6.

28
GRAPH :

Position Vs error in major diameter; Position Vs error in minor diameter; Position Vs error in
pitch.
Position Vs error in depth of the thread.

RESULT:

The following parameters of threaded specimen is calculated by the help of Tool makers
microscope

Minor Diameter:

Major Diameter:

Pitch of the Thread:

Depth of the Thread:

29
TABULATION:

Sub Group OBSERVED MEASUREMENT (mm) X R

X1 X2 X3 X4 X5

Mean X= Ra =

FORMULAE REQUIRED:

X1  X2  ...  X5
X= R = X max - Xmin
5

X1 + X 2 + ..... + X 5 R1 + R 2 + ..... + R n
X = Ra =
5 N
Ra
Note:- n= no. of samples in each subgroup ; N= No.of subgroups ; =
d2
Tolerance
Process Capability = --------------------
6

CONTROL LIMITS:-
X Chart U.C.L = X +A2R a L.C.L = X - A2 R a
R Chart = U.C.L = D4 R a L.C.L = D3 R a

A2, d2 , D3& D4 are to be taken from SQC Table.

For n = 5: A2 = 0.58 ; d2 = 2.326 ; D3 = 0 ; D4 = 2.11

30
EX. NO :
DATE :

MECHANICAL COMPARATOR (PROCESS CAPABILITY)

AIM:

To inspect the given machined parts and determine the process capability and draw the X and R
chart.

REQUIREMENTS:

a. Specimen 25 Nos.
b. Mechanical comparator
c. Slip gauges
d. Dial gauge (0.010mm).

PROCEDURE:

1. Divide the given lot of specimen into subgroups of the sample size 5.
2. Set the comparator for the nominal value of the dimension which is to be checked.
3. Observe the dimension (x) of the specimen, group vise, and determine X and R.

Mechanical Comparator

4. Calculate X and Ra .
5. Calculate the UCL and LCL values for both X and R charts.
6. Plot Control charts for X and R charts.

GRAPH:-
Sub group Vs X and sub group Vs R.

RESULT:
The given samples have been inspected and process capability calculated

31
 TABULATION:

NO. OF
NO. OF
SPECIMEN ACCEPTED NO. OF REWORKED
SL NO. REJECTED
VALUE PIECES PIECES(YELLOW)
PIECES(RED)
(GREEN)
1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

32
EX. NO.:
DATE :
ELECTRONIC COMPARATOR

AIM:

To check the tolerance of the given sample using Electronic comparator.

REQUIREMENT:

1. Electronic Comparator.
2. Probe.
3. Sample 25 Nos.
4. Slip gauge.

SPECIFICATION:

Weight : 6.6 Ib. (3 Kg )

Length : 3.54” (90 mm)
Measuring range, English : + 0.01 + 0.003” +0.001” +0.0003” + 0.0001”
-readout : 0.0005” 0.0001” 0.0005” 0.00001” 0.000005”
-distance between graduation : 1.45 mm. 2.15mm. 1.45mm. 2.15mm. 1.45mm.
Measuring range, metric : +300m +100m +30m +10m +3m
- readout : 10m 5m 1m 0.5m 0.1m
-distance between graduation : 1.45 mm. 2.15mm. 1.45mm 2.15mm. 1.45mm
Indication error of the instrument : max 2 % of the measuring range Stability after 3000 hours
-Zero position : max. displacement 1% of the range
-amplification : max.variation 1%
Temperature limits : 32 to122˚F (0˚ to 50˚ c)
Permissible : +15% : -20%
Mains Voltage : 220V -30mA; 110V - 60mA; 50 or 60Hz

SETTING OF INSTRUMENT FOR SINGLE MEASUREMENT:

1. Gauge head „A‟ is to be fixed on the measuring fixture.

2. Zero setting Knob is to be set to the middle of its capacity (screw to the top)
3. Set the master piece.
4. The adequate measuring range is to be chosen.
5. By mechanical displacement of gauge head, bring the indicating needle near zero or near
actual value of the master piece.
6. This operation is facilitated by setting the gauge head on a larger measuring range at the
beginning.
7. By electrical setting, using zero setting Knob, bring the indicating needle to zero or to the
actual value of the master piece.
8. Tolerance limits are to be set.
9. Test the specimens using the comparator whether they are with in the allowable tolerance
limits.
10. No zero reset is required when switching the ranges, provided its zero was set at the
smallest range.

33
 ELECTRONIC COMPARATOR

OBSERVATION:

Nominal value =

Tolerance given =

34
RESULT:

The use of electronic has been studied and the given samples are inspected

No. of pieces accepted =

No. of pieces rejected =

No. of pieces to be Reworked =

35
TABULATION:

(Ea)
R (En) Nominal Error = (Actual-
S.NO Rs (mm. ) Actual Effective Dia
( mm.) Effective Dia (mm. ) Nominal) (mm )
( mm. )

01

02

03

04

AVG= AVG=

S.NO S (mm) R1 ( mm.) S – R1 (mm) Actual Major Dia. (mm) F

01

02

03

04

AVG=

36
EX. NO.:
DATE :

MEASUREMENT OF EFFECTIVE DIAMETER OF SCREW THREAD

(USING FLOATING CARRIAGE MICROMETER)

AIM : To the check the effective diameter and the major diameter of the screw thread.

REQUIREMENTS:

1. External screw thread.

2. Cylindrical standard.
3. Measuring wires.
4. Floating carriage micrometer.

DESCRIPTION:

This equipment is primarily used for measuring the major, minor and effective diameter of
thread gauge and threaded components. The instrument has an accuracy of 0.0025mm.
This equipment consists of a sturdy cast iron base mounting two accurately aligned and
adjustable centers at right angles to the axis of the centers is a freely moving measuring carriage
mounted on „V‟ guide ways and carrying a micrometer and highly sensitive fudicial indicator. This
carriage permits measurements to be taken along the center line and at right angels to the work.

FIGURE

PROCEDURE:

1. Floating carriage micrometer is on a firm bench and leveled by means of the adjustable screw
in the base.

37
 2. Set the reading on the micrometer to read 5 mm and place the cylindrical standard as shown
in fig-a ( S)
3. Then instrument is to be purely set over the suitable cylindrical standards and the selected
wire as shown in fig-b.
4. Note the reading ( Rs) of the micrometer.
5. Replace the standard by the work piece on the micrometer as shown in fig-c
6. Note the reading on the micrometer (R1)
7. Now note down the reading on the micrometer((R) by placing the selected wires over the
work piece as shown in the fig-d
8. Repeat steps 5to 7 step (fig-d) at 4 different places across the length of the work piece to get
different Rs and R
9. Tabulate the reading and calculate Nominal and actual diameters and effective diameters
10. Draw the necessary graphs. (positionVs error.)

FIGURE

Fig –a Fig-b

Fig –c Fig-d

38
FORMULAE:

MAJOR DIAMETER MEASUREMENT:

S = micrometer reading over standard

RS = micrometer reading of standard with wires
R1 = micrometer reading over work piece
R = micrometer reading over work piece with wires
D = Diameter of standard (20.002mm)
d = standard wire diameter (1.35mm)
P = pitch of the thread (2.5 mm)
X = included angle of thread (for metric thread 60º)

Actual Major Diameter of Work Piece

F = D - Difference between S & R1

Nominal effective dia( En ) = F – 0.6495 × P

Actual Effective Dia

EA = D - Difference between (RS – A) and R

A = 0.86602 P – d (for metric thread)
P X
Best Wire Diameter =  Sec 
2 2

GRAPH: Position Vs error in effective diameter

RESULT:

The following effective diameter of the given screw thread is checked and the readings are tabulated.

i. Nominal effective diameter ( En) =

ii. Actual Effective Diameter ( En)=

iii. Major diameter (F) =

39
Tabulation

Loading

Indicated
Measured Theoretical
Reading
S.No Weight (kgs) Unbalanced Unbalanced % Error
(kgs)
Voltage (mV) Voltage(mV)

Unloading

Indicated
Measured Theoretical
Reading
S.No Weight (kgs) Unbalanced Unbalanced % Error
(kgs)
Voltage (mV) Voltage(mV)

40
EX. NO.:
DATE

FORCE MEASUREMENT USING STRAIN GAUGE

AIM :

To measure force using Strain gauge set up

REQUIREMENTS:

1) Strain Gauge
2) Physical weights
3) Power supply

PROCEDURE:

- Ensure the instrument is switched off.

- Connect the transducer to the panel using cables.
- Switch on the main supply of the instrument.
- Select 4 arm configuration using switch provided on the front panel.
- Now with the help of Coarse and Fine potentiometers adjust meter reading to zero.
- Now the set up is ready for experiment.
- Now add weights in the weight pan. Note down the meter reading.
- Add weights in steps and note the corresponding indicated reading.
- Similarly note down the indicated readings by removing the weights.
- Prepare tabulation as below.

CALCULATIONS:

a) Length of the cantilever from the centre of the Gauge to the loading hook center L –
17.5 cm
b) Thickness of the Cantilever=t=0.455 cm
c) Width of the Cantilever = b =2.4 cm
d) Modulus of Elasticity ( for Mild Steel) = 2x10 6 kg/cm2
e) Gauge Factor = 2

Stress = M / Z
where M=Length of cantilever (L) X applied load ( in kg) and Z= 1/6 b t2
STRAIN = Stress / Modulus of Elasticity
R/ R = Gauge factor x Strain, EOUTPUT = EEXCR X R/ R Volts

%Error = (Theoretical unbalance voltage – Measured unbalance voltage ) /

Theoretical unbalance voltage
GRAPH:

A graph is plotted between the weight and the indicated reading( ascending order & descending
order)

RESULT:
Thus the Force is measured by loading the force sensor with weights and the error is
found. % Error:

41
Tabulation :

Loading:

Load Indicated
Actual/ Applied Percentage of
S.No. Applied Torque
Torque (Kg-m) Error
(Kg) (Kg-m)

Unloading:

Load Indicated
Actual/ Applied Percentage of
S.No. Applied Torque
Torque (Kg-m) Error
(Kg) (Kg-m)

42
EX. NO.:
DATE :

MEASUREMENT OF TORQUE USING TORQUE SENSOR

Aim :
To measure the torque by loading the torque sensor with weights using a digital
torque indicator.To plot the indicated torque vs actual torque.

Apparatus required :

1. Torque sensors. 2. Digital torque indicator. 3. Cantilever beam. 4. Connecting probe.

Working principle :

Torque sensors are of 2 types, namely

(a) In line torque sensors. b)Reaction torque sensors.
In line torque sensors are used to measure torque developed by rotating machineries such as
motors, turbines, etc; Reaction sensors are used to measure torsional forces.

Traditionally, torque sensors are bonded with strain gauges. When there is force acting on the
sensor, the strain gauge material undergoes a deformation and hence a change in the
resistance of the material. Wheatstone bridge present in the digital torque indicator could
sense the change in the resistance. After signal conditioning and A/D (analog to digital)
conversion the torque in Kg-M is indicated.

Experimental set-up :

A cantilever beam of exactly 1 m is attached to the torque sensor. A weighting pan is

connected to the beam. The output of the torque sensor is connected to digital torque
indicator.

Experimental procedure :

1. Connect the torque sensor output to the indicator and verify the indicator reads zero.
This is done without any loading. If the indicator does not indicate zero, then
adjustment is made on the potentiometer to read zero.
2. The set-up is now ready for the torque measurement.
3. Load the cantilever beam in steps of 1kg-m and note the torque indicated by the
indicator.
4. Theoretical value is also calculated by multiplying the weight and the length of the
beam (1 m span).
5. The readings are tabulated and the error percentage is calculated.
Percentage of error = (Applied torque – Indicated Torque) / Applied Torque

Graph:
Actual Torque Vs Indicated Torque
Result :
Thus the torque is measured by loading the torque sensor with weights and the error is
found. % Error:

43
TABULATION:

HEATING

SL. NO Glass thermometer reading RTD reading Percentage error

COOLING

SL. NO Glass thermometer reading RTD reading Percentage error

CALCULATION:

Glass thermometer reading – RTD reading

Percentage error = ----------------------------------------------------------- x 100
Galss thermometer reading

44
EX NO :
DATE:
TEMPERATURE MEASUREMENT USING RTD

AIM:

To measure the temperature of the water bath using Resistance Temperature Detector and compare it
with the observed value of a Standard Glass Thermometer

REQUIREMENTS:

1. RTD
2. Water Bath
3. Digital temperature indicator
4. Glass thermometer
5. Connecting Probes

DESCRIPTION:

RTD working principle:-

Resistance of a metal element such as platinum, copper, nickel ,etc increases with increases with
temperature. This principle is used in resistance thermometer. In general,the resistance Rt of a metallic
conductor at a temperature “t” can be represented in terms of R0 at a temperature 00 C by the
following equation

Rt = R0 ( 1+α1 t 1+ α2 t 2 +…….+αntn)

A high value of “n” is desirableie., when the temperature changes by a small amount there should be
substantial change in resistance by means of a wheat stone bridge. The bridge can be calibrated to
thermometer and can be used by representing its resistance from 260 to 11000 C

PROCEDURE:

1. Connect the RTD to power source and verify whether it reads the room temperature ( around
28-30 0 C), which is verified by standard glass thermometer, otherwise the potentiometer
present at the back panel of the instrument is adjusted to read room temperature.
2. Connect the power to the temperature source (water bath) and set the temperature say 500C.
by using rheostat.
3. The raise in temperature of the water bath is measured with both RTD and standard glass
thermometer.
4. The values are measured and tabulated for each 10 0 C raise of water bath.
5. After the water bath has attained a temperature say 700 C, the water bath is allowed to cool
and the above procedure is repeated. The cooling process readings are compared with
heating process.

GRAPH:

A graph is plotted for indicated temperature and standard temperature

RESULT:

Thus the temperature of the water bath is measured using RTD. Readings are measured with the
temperature using Standard Glass Thermometer and percentage error is calculated

45
 Observed Data:
Table (1): Variation of rise/fall angle along surface.

1 2 3 4 5 6 7

Difference Rise (-) or Cumulative

Position of Auto-coll. Adjustments Errors from Straight
From 1st Fall (+) Rise / fall
to bring to zero line
reflector Reading (mm)
Reading (mm)

mm Min Sec

50

100

150

200

250

300

350

400

450

500

46
EX. NO.:
DATE
AUTO COLLIMATOR

Introduction

An autocollimator is an optical instrument that is used to measure small angles with very high
sensitivity. As such, the autocollimator has a wide variety of applications including precision
alignment, detection of angular movement, verification of angle standards, and angular monitoring
over long periods.

Objectives:

- To measure straightness of a beam with the use of Auto-Collimator.

- To identify the principle of Auto-Collimator device.
- To be able to draw conclusions about straightness error using graphical methods and least
square method.

Apparatus:

1) auto collimator
2) straight edge with 50mm marked intervals.

Theory:

Increasing demand for product reliability and efficiency has placed a corresponding emphasis
on the geometric integrity of components and their assembly. In engineering applications, one often
comes across the problems of measurement, of-geometrical parameters such as alignment,
straightness, squareness, flatness, etc.

At many places it is required that the surfaces must be perfectly straight, e.g., in a lathe it is
desired that tool must move in a straight path to generate perfect cylinder and it is possible .only when
the controlling guideways are themselves straight. Also straight line or plane is the basis of most
methods of measurements. The quality of straightness in precision engineering is represented by
straight edge.

The fundamental principle about straightness measurement is given by Bryan. According to

Bryan principle, a straightness measuring system should be in line with the functional point at which
straightness is to be measured. If this is not possible, either the slideways that transfer the
measurement must be free or angular motion or angular motion data must be used to calculate the
consequences of the offset.

Definition of straightness of a line in two planes.

A line is said to be straight over a given length, if the variation of the distance of its points from two
planes perpendicular to each other and parallel to the general direction of the line remains within the
specified tolerance limits; the reference planes being so chosen that their intersection is parallel to the
straight line joining two points suitably located on the line to be tested and the two points being close
to the ends of the lengths to .be measured.

The tolerance on the straightness of a line is defined as the maximum deviation in relation to the
reference straight line joining the two extremities of the line to be checked (Fig. 1).

47
 Fig. 1: Profile of surface with respect to reference straight line.

It is the usual practice to state the range of measurement, i.e. the length to be checked; and the
position of the tolerance in relation to the reference straight line. In most cases, the parts very close to
the ends, which most often have local errors of no great importance, may be neglected.

Auto-collimators are sensitive and inherently very accurate optical instruments for the measurement
of small angular deviations of a light reflecting flat surface. The auto- collimator has its own target
which is projected by collimated light beams on a remotely placed surface and the reflected target
image is observed in the ocular of the instrument.

The auto-collimator is stationed at the end of the bed with a rigid support base. The movement of the
reflector along the bed will cause the reflected image of the target to deflect according to the angular
error of the bed.
The autocollimator is a flat mirror mounted in a short tube made to fit a Newtonian telescope focuser,
and set accurately perpendicular to the tube‟s axis. Centered in it is a small peephole or pupil that you
look through.
Principles of operation

Tests for straightness can be carried out by using spirit level or auto-collimator. The straightness of
any surface could be determined by either of these instruments by measuring the relative angular
positions of number of adjacent sections of the surface to be tested.

So first a straight line is drawn on the surface whose straightness is to be tested.

Then it is divided into, a number of sections, the length of each section being equal to the length of
spirit level base or the plane reflector's base in case of auto-collimator. Generally the bases of the
spirit level block or reflector are fitted with two feet so that only feet have line contact with the
surface and whole of the surface of base does not touch the surface to be tested. This ensures that
angular deviation obtained is between the specified two points. In this case length of each section
must be equal to distance between the centre lines of two feet. The spirit level can be used only for the
measurement of straightness of horizontal surfaces while auto-collimator method can be used on
surfaces in any plane.

In case of spirit level, the block is moved along the line on the surface to be tested in steps equal to the
pitch distance between the centre lines of the feet and the angular variations of the direction of block
are measured by the sensitive level on it.
Angular variation can be correlated in terms of the difference of height between two points by

48
knowing the least count of level and length of the base.

In case of measurement by auto-collimator, the instrument is placed at a distance of 0.5 to 0.75 meter
from the surface to be tested on any rigid support which is independent of the surface to be tested.

Cumulative heaight

Lines of first reading used as datum

Fig. 2: Steps of taking the readings.

The parallel beam from the instrument is projected along the length of the surface to be tested.

A block fixed on two feet and fitted with a plane vertical reflector is placed on the surface and the
reflector face is facing the instrument.

The reflector and the instrument are set such that the image of the cross wires of the collimator
appears nearer the centre of the field and for the complete movement of reflector along the surface
straight line, the image of cross-wires will appear in the field of eyepiece, the reflector is then moved
to the other end of the surface in steps equal to the centre distance between the feet and the tilt of the
reflector is noted down in second from the eyepiece.

The autocollimator projects a beam of collimated light. An external reflector reflects all or part of the
beam back into the instrument where the beam is focused and detected by a photodetector. The
autocollimator measures the deviation between the emitted beam and the reflected beam. Because the
autocollimator uses light to measure angles, it never comes into contact with the test surface.

Visual autocollimators rely on the operator's eye to act as the photodetector. Micro-Radian visual
autocollimators project a pinhole image. The operator views the reflected pinhole images through an
eyepiece. Because the human eye acts as the photodetector, resolution will vary among operators.
Typically, people can resolve from 3 to 5 arc-seconds. Because the human eye is able to discern
mutiple images simultaneously, visual autocollimators are suitable for measuring multiple surfaces
simultaneously. This makes them ideal alignment instruments in applications like aligning laser rod
ends or checking parallelism among optics. Visual autocollimators can also be equipped with an
eyepiece reticle for aid in lining up test optics to a master reference.

49
PROCEDURE

1. Clean the surface plate or table.

2. Position the auto-collimator in line with the reflector. Switch on the lamp in the
autocollimator, the alignment between the auto-collimator and reflector should be checked at
both extremes of the operational distance to make certain that the target graticule is contained
within the eyepiece field.
3. Fix a guide strip to control the horizontal displacement of the reflector and minimise the
movement of the target graticule.

4. Mark off the positions along the surface plate equal to the pitch positions on the reflector base
(in this case 50 mm). Column 1 should indicate this position.
5. At the initial position takes the reading and tabulates (column 2)

6. Move the carriage (reflector) to the next position and again tabulate the reading.
7. This method is to continue until the final outward position is recorded.

8. The remainder of the table should be filled by adopting the following procedure:

• Column 3 This is the variations of the tilt occurring between the position at which the
reading is taken and the original position.

• Column 4 The angular position in column 3 is converted into a linear measure (1 second =
0.5 micro m). Insert a zero at the top of the column to represent the datum.
• Column 5 This is the cumulative algebraic sum of the displacements. Calculate the mean

• displacement this is the amount by which the displacement must be adjusted to relate them
to the zero datum. Plot the values of column 5 versus column 1.
• Plot the values column 7 versus column 1

1 min of arc = 1π x 50 = 0.007mm

(360*60)

50
GRAPH:
1. Position (vs) Cumulative rise (or) fall (mm)
2. Position (vs) Error (mm)

RESULT:
Thus the straightness error of given surface was measured using Auto Collimator.

51
 Tabulation

VERNIER RANGE OF MICROMET

S.N MICROMETER ERROR
READING TELESCOPE ER RANGE
O READING (mm) (mm)
(mm) GAUGE (mm) (mm)

52
EX. NO.:
DATE :

BORE DIAMETER MEASUREMENT USING TELESCOPE GAUGE

Aim:
To Measure the Bore diameter of given component using Telescope gauge

ApparatusRequired
1. Micrometer
2. Given component
3.Telescope gauge
4. Vernier Caliper

Description

Telescopic gauge is used to find out the internal diameter of pipe, cylinder bore and slots.
This gauge has ratchet locking at top, handle, body and telescopic operated plungers. A telescoping
gauge is an indirect measuring device, the head of which can be positioned inside holes or openings
and then extended to touch the walls.

These are a range of gauges that are used to measure a bore's size, by transferring the internal
dimension to a remote measuring tool. They are a direct equivalent of inside calipers and require the
operator to develop the correct feel to obtain repeatable results.

Procedure
 Select appropriate size of telescopic gauge
 Press the plunger in the barrel and lock the ratchet
 Place the gauge in cylinder bore to check internal diameter
 Turn the ratchet, plungers will exert equal pressure on both side of the cylinder wall.
 Hold the telescopic gauge parallel to the ground
 Lock the telescopic gauge, plunger remains open and occupied the internal diameter
 Slowly remove the telescopic gauge and read the dimension in external micrometer
 This gives main reading of cylinder bore
Result

Thus the Bore diameter of given component are measured using Telescope gauge.

53
 TABULATION:

VERNIER MEASURING MICROMETER MICROMETER BORE ACTUAL

S.NO READING RANGE RANGE READING READING READING
(mm) (mm) (mm) (mm) (mm) (mm)

54
EX. NO.:
DATE :

BORE DIAMETER MEASUREMENT USING BORE GAUGE WITH DIAL

INDICATOR

Aim:
To Measure the Bore diameter of given component using Bore gauge with dial indicator

ApparatusRequired
1. Micrometer
2. Given component
3. Bore gauge with dial indicator
4. Vernier Caliper

Description
It is used for measuring internal diameter of a hole, which is machined. The bore
dialgauge consists of one fixed measuring head and one movable measuring head.
Themovement of the movable measuring rod is transmitted to dial indicator by push
rodthrough a spring actuated hinged member. Thus the horizontal movement of the rodis
transmitted into vertical direction gives indication of variation of size. Thecalibrated rods are
made in different sizes and sometimes number of short rodsthreaded 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
ofmeasuring head contact point is transmitted to the amplifying mechanism by thecalibrated
rods and its shown on the dial indicator. These calibrated rods are locatedin tabular supports
between the head and dial units. The readings from dial indicatorare tabulated.

Result

Thus the Bore diameter of given component are measured using Bore gauge with dial
indicator.

55
TABULATION:

BORE DEPTH DEPTH

MICROMETER ERROR
S.NO SIZE VERNIER MICROMETER
RANGE (mm) (mm)
(mm) (mm) READING (mm)

56
EX. NO.:
DATE :

MEASUREMENT OF BORE DEPTH USING VERNIER DEPTH GAUGE AND

DEPTH MICOMETER

Aim:
To Measure theBore depth of given component using Vernier depth gauge and Depth
micrometer

ApparatusRequired
1. Micrometer
2. Given component

3. Bore gauge with dial indicator

4. Vernier Caliper

Description
Vernier Depth Gauge
Vernier Depth Gauge is used to measure the depth of holes, slots and recesses, tolocate center
distances etc. It consists of
1. A sliding head having flat and true base free from curves waviness.
2. A graduated beam known as main scale. The sliding head slides over the
graduated beam.
3.An auxiliary head with a fine adjustment and a clamping screw.
4. A beam is perpendicular to the base in both direction and its ends square andflat. The end
of the sliding head can be set at any point with fine adjustmentlocked and read from the
Vernier provided on it.

57
Micrometer Depth Gauge
It is used for measuring the depth of holes, slots and recessed areas. It has got one shoulder
which act as reference surface and is held firmly and perpendicular to the center line of the
hole. Here also for larger ranges of measurements, extension rod are used. The screw
micrometer depth gauge has range of 20mm or 25mm. The length of the micrometer depth
gauge varies from 0to 225mm.The rod is inserted through the top of the micrometer. The rod
is marked after every 10mm so that it could be clamped at any position in using this
instrument, firth it must be insured that the edge of the hole is free from barrel

PROCEDURE
Vernier Depth Gauge
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 Vernier.
58
Micrometer Depth Gauge
1. To measure the depth of any material, use the micrometer depth gauge.
2. Take the sample piece, the length of the rod varies from 0 to 225mm.
3. Various rods are used as per requirement at the certain limit that gauge will move as it is
by rotating screw in clockwise direction.
4. Tight the screw and measure the main scale and circular scale also adding the initial value
of rod this gives MSR, VSR and TSR by adding LC
5. Note down reading by following procedure.
Result

Thus the Bore depth of given component are measured using Vernier depth gauge and
Depth micrometer.

59
Tabulation

Method Ra1 Ra2 Ra3 Average

Standard
specimen

60
EX. NO.:
DATE :

MEASUREMENT OF SURFACE ROUGHNESS - USING SURFACE ROUGHNESS

TESTING MACHINE
AIM
To measure surface roughness of the specimen using surface roughness testing
machine.

APPARATUS REQUIRED

1. Surface roughness testing machine

2. Standard Specimen

THEORY

ROUGHNESS – a quantitative measure of the process marks produced during the creation of
the surface and other factors such as the structure of the material. The action of the cutting
tool, chemical action, polishing, lapping, and the structure of the material all contribute to the
roughness of the surface.

PROCEDURE:

Tactile assessment :

It is a comparison of the surface roughness of the given specimen with a standard

specimen. The comparison is done by touching the surface with your fingernail & then
comparing it with the gauges to establish the roughness value of the sample. Now, each
specimen is specified for a certain process, i.e each specimen has a different colour indicating
a different process used in manufacturing the tested surface as milling, grinding, turning. etc.

Result
Using Standard specimen, the estimated value of Ra = ………….. microns.

61
62
 Saranathan College of Engineering, Trichy - 12.
Department of Mechanical Engineering

Contents
Staff
Ex. Name of the Experiment
Date Marks Signature
No Cycle 2

10

11

63
64
 Saranathan College of Engineering, Trichy - 12.
Department of Mechanical Engineering

Contents
Staff
Ex. Name of the Experiment
Date Marks Signature
No Cycle-1

65