Module IV

Mechanical Measurements and Equipment:

Dimensional metrology – Vernier, micrometers, LVDT; Form metrology – form tester, surface
profiler, CMM, 3D scanning; Surface metrology–optical microscopes, Laser scanning
microscopes, electron microscopy (SEM/TEM), x- ray microscopy, Raman spectroscopy;
Tool wear, workpiece quality and process metrology.
Distinguish between the working methodology of micrometer and screw 5 L3 CO3
gauge.
Define the effective diameter of thread. 2 L1 CO3
Make neatly labeled sketches of different types of screw threads. 5 L3 CO3
Illustrate with neat sketches, all the nomenclature of external and internal 5 L3 CO3
parallel screw threads.
Derive an expression for measuring simple effective diameter of external 5 CO1
screw threads
What are the various types of pitch errors on threads and explain the reasons 5 L4 CO1
for the same?
Briefly describe with necessary sketches how the following elements of 5 L2 CO1
screw threads are measured.
i) Outer diameter
ii) Effective diameter
iii) Core diameter
iv) Pitch diameter
v) Thread profile.
What is progressive error in screw thread? 2M L1 CO1
What is the ‘best size’ wire? Derive an expression for the same in terms of 10 L4 CO2
pitch and angle of thread.
Calculate the “best size wire” for checking the effective diameter of a M10 x
2.5 thread.
Explain the two-wire method of finding the effective diameter of screw 10 L3 CO2
threads?
Derive the formula for measuring the effective diameter of thread by the 10M L3 CO2
3-wire method with a neat sketch.
Explain the construction and working of Gear tooth vernier. 5 L2 CO2
Write the use of dial indicator. 2 L2 CO2
What is the difference between surface texture and integrity? Two different 5 L6 CO1
surfaces may have the same roughness value. Why?
What is the difference between primary texture and secondary texture? 5 L4 CO1
Describe the various methods of measuring surface roughness.
Define: Roundness. Name the four measurements of roundness. CO1
Describe briefly the working principle of Profile Projector. 5 L2 CO2
Write short notes on the type of surface texture. 10M L2 CO3
or
Discuss what you understand by the following terms in connection with
surface roughness measurement.
(i) Roughness
(ii) Waviness
(iii) Lay
(iv) Sampling length
(v) Cut-off length
(vi) average leveling depth and smoothness value
Elaborate on the importance of roughness and waviness in context of various 10M CO3
engineering applications.
What methods are used for measuring surface roughness? CO3
With a neat labelled sketch gives the working principle of instrument to CO2
measure surface roughness.
With the help of a neat sketch, explain the constructional and operational 10 CO2
features of Taylor Hobson Talysurf surface roughness profiler.
Sketch the block diagram of optical system of a microscope. 5 CO2
Make a neat schematic diagram of a Tool Maker’s Microscope and state its 10 CO2
working principle and applications.
Explain the construction and principle of working of a linear variable 10 CO2
differential transformer (LVDT). Explain how the magnitude and direction of
the displacement of core of an LVDT detected. Why is the residual voltage
present?
Specify two advantages and two disadvantages of LVDT. 2 L2 CO2
What is CMM? Explain the construction and working principle of column 10 L3 CO2
type or bridge type CMM. Mention the Advantages and Disadvantages.
What are the various types of CMMs? 2M CO2
List any four possible causes of error in CMM. 2M CO3
Name the types of accuracy specifications used for CMM. 2M CO3
Explain with a neat sketch the dimensional measurement using a scanning 5 CO2
laser gauge.
Name the types of lasers. 2 L2 CO3
Explain the principle of Scanning Electron Microscopy (SEM) with a neat 10 CO2
sketch. What are its applications?
Calculate the C.L.A. (Ra) value of a surface for the following data: 5 L4 CO3
The sampling length is 0.8 mm. the graph is drawn to a vertical
magnification of 15,000 and horizontal magnification of 100 and the areas
above below the datum line are 160, 90, 180 50 mm2 and 95, 65, 170, 150
mm2 respectively.
In the measurement of surface roughness heights of 25 successive peaks and 5 CO3
troughs were measured from the datum and were 35, 25, 35, 35, 40, 22, 35,
18, 42, 25, 35, 22, 36, 18, 42, 22, 32, 21, 37, 18, 35, 20, 32, 18 and 40. If the
sampling length is 25 mm determine C.L.A. and R.M.S. value.
An LVDT produces an output of 3V rms for a displacement of 50x10 cm. 10 CO2
Calculate the sensitivity of the LVDT in µV/mm. The 3kV output of the
LVDT is read on a 5V voltmeter that has a scale with 100 divisions. The
scale can be read to 0-2 divisions. Calculate resolution of the instrument in
terms of displacement in mm
The out of an LVDT is connected to a 5V voltmeter through an amplifier of 10 CO2
amplification factor 250. The voltmeter scale has 100 divisions and the scale
can be read up to l/5th of a division. An out of 2mV appears across the
terminals of the LVDT when the core is displaced through a distance of 0.5
mm.
Calculate (i) sensitivity of the LVDT, (ii) that of whole set-up, (iii) resolution
of the instrument in mm.