SHAIKH COLLEGE OF ENGINEERING AND

TECHNOLOGY, BELAGAVI

Mechanical Department

MECHANICAL MEASUREMENT AND METROLOGY

LABORATORY MANUAL
IV SEMESTER

“Education is the movement from darkness to light”

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 Introduction
The science of measurement is known as Metrology. It is derived from the Greek word Measure.
The purpose of this discipline is to establish means of determining physical quantities, such as
dimensions, temperature, force, etc. It is well-known saying that the knowledge about anything
is complete only when it can be expressed in numbers. For every kind of quantity measured,
there must be a unit to measure it and express it in numbers of that unit.

Objectives of Metrology:

The basic objective of a measurement is to provide the required accuracy at minimum. In

modem engineering plant, metrology plays a vital role. It is required to measure various
quantities in various engineering shops like Tool Room, Machine Shop, Press Shop, Plastic Shop,
Pressure Die Casting Shop, Electroplating and Painting Shop, and Assembly Shop, as also
Research, Development and Engineering Department. The further objectives in engineering
organization are
1. Thorough evaluations of newly developed products, to ensure that components designed
are within the process and measuring instrument capabilities available in the plant.
2. To determine the process capabilities and ensure that these are better than the relevant
component tolerances.
3. To determine the measuring instrument capabilities and ensure that these are adequate
for their respective measurements.
4. To minimize the cost of inspection by effective and efficient use of available facilities, and
to reduce the cost of rejects and rework through application of Statistical Quality Control
Techniques.
5. Standardization of measuring methods. This is achieved by laying down inspection
methods for any product right at the time when production technology is prepared.
6. Maintenance of the accuracies of measurement. This is achieved by periodical calibration
of the metrological instruments used in the plant.
7. Arbitration and solution of problems arising on the shop floor regarding methods of
measurement.
8. Preparation of designs for all gauges and special inspection fixtures.

Definitions and Basic Concepts:

Metrology: It is the name given to the science of pure measurements.

1. Line Standard: When the length being measured is expressed as the distance between
the two lines then it is called Line standard, e.g. scale.

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 2. End Standard: When the length being measured is expressed as the distance between
the two parallel end faces then it is called end standard. E.g. slip gauges.
3. Limits: The maximum and minimum permissible sizes within which the actual size of a
component lies are called Limit.
4. Tolerance: It is impossible to make anything to an exact size. Therefore it is essential to
allow a definite tolerance or permissible variation every specified dimension.
5. Interchangeability: lt occurs when one part in an assembly can be substituted for a
similar part which has been made to the same drawing.
6. Allowance: A difference between the hole dimension and shaft dimension for any type of
fit is called Allowance.
7. Deviation: It is defined as the algebraic difference between a size (Actual, Maximum etc.)
and the corresponding basic size.
8. Fit: When two parts are to be assembled the relationship resulting from the difference
between their sizes before assembly is called a fit.

Measurement: It is a process of comparing quantitatively an unknown magnitude with a

predefined standard.

1. Readability of an Instrument: This is the term which indicates the closeness with which
the scale of the instrument may be read.
2. Least count: It is the smallest difference between two indications that can be detected
on the instrument scale.
3. Range: It represents the highest possible value that can be measured by an instrument or
it is the difference between the largest and the smallest results of measurements.
4. Sensitivity: The sensitivity of an instrument is the ratio of the linear movement of the
pointer on the instrument to the change in the measured variable causing this motion.
5. Error: The difference between the true value and the result is known as error.

Types of error:

No measurement can be made to give an exact dimension. Fundamentally this is because

eventually the numerical value recorded depends upon the human eye reading a scale. The
reading therefore becomes an estimate, the accuracy of which depends on the accuracy of the
scale, the ability of the operator to read the scale, and in some cases the sensitivity of touch or
feel on the part of the operator. Generally the errors incurred in any measurement can be
considered to be of two distinct types, those which should not occur and can be eliminated by
careful work and attention to detail, and those which are inherent in the measuring process.
(A). Errors Which Can Be Largely Eliminated
1. Calamitous or Catastrophic Errors

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 (a) Misreading an instrument, (b) Arithmetic errors.
2. Alignment Errors
3. Errors Due to Ambient Conditions
4. Errors Due to Elastic Deformation to be measured is
(B). Errors Which Cannot Be Eliminated
1. Scale Errors
2. Reading Errors
3. Measuring Errors
(C). Compound Error

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VERNIER CALIPER

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Experiment No-1

Calibration of VERNIER CALIPER

Aim: To calibrate the given precision measuring instruments using standard slip gauges.

Apparatus: Vernier caliper, Slip gauges box etc.

Theory: Vernier caliper has two jaws. One is movable jaw and another one is fixed jaw, both of
them have flat surfaces to hold the specimen whose dimensions are required measure. The
sliding jaw moves over the rule and can be locked in any position. The vernier read is fitted with
the sliding jaw and also has a provision for fine adjustment.

Vernier Calipers is the most commonly used instrument for measuring outer and inner
diameters. It works on the principle of Vernier Scale which is some fixed units of length (Ex:
49mm)divided into 1 less or 1 more parts of the unit(Ex: 49mm are divided into 50 parts).The
exact measurement with up to 0.02mm accuracy can be determined by the coinciding line
between Main Scale and Vernier Scale.

Total Reading = M.S.R + L.C X V.C

Where:
M.S.R – Main Scale Reading
L.C – Least Count
V.C – Vernier Coincidence
These are used for both – internal and external measurement, its generate used for measuring
by closing the jaws on work surface and taking readings from main scale is examined to certain
which of its division coincide and added to the main scale reading.

Procedure:

1. To calibrate given vernier caliper select the slip gauge of any convenient dimensions.
2. Then the slip gauge is held between the opened jaws.
3. Then the sliding jaw is moved till it reaches the slip gauge. Then the fine adjustments are
made. Then other lock nut also locked.
4. The main scale reading just ahead of '0' of the vernier scale and the vernier scale
divisions which coincides with main scale division are also taken.
5. Then dimensions are calculated by adding them.
6. Now error of the vernier caliper is to be calculated by comparing this dimension with slip
gauge dimension.

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Observation:
1. Smallest division on main scale=……………mm.
2. No of division on vernier scale=…………..mm.
3. Least count=…………….mm

Tabular column:
Slip Main Vernier
Total Reading Error % Error
gauge scale scale VSR x
SI.no reading reading reading LC Rf=MSR+(VSRxLC) (Rs~Rf)
Rs (MSR) (VSR) (mm) (MM) (mm)
(mm) (mm) (mm)

Nature of graphs:

Result:
The average percentage error of given vernier caliper is found to be=………………%

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MICROMETER

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Experiment No-2

Calibration of micrometer
Aim: To calibrate the given precision measuring instruments using standard slip gauges.

Apparatus: Micrometer, Slip gauges box etc.

Theory: The micrometer screw gauge essentially consists of an accurate screw having about 10
(or) 20 threads ‘1’ cm and revolves in a fixed nut. The end of the screw forms one measuring tip
and other measuring tip is constituted with a stationary arrival in the base of the frame. The
screw is threaded for certain length and in plain afterwards. The plain portion is called sleeve
and its end is 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 fixed part
attached with the frame.

A lock nut is provided for locking a dimension by preventing the motion of spindle. Ratchet
screw is provided at the end of the thimble cap to maintain sufficient and uniform measuring
pressure 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 spindle
takes place by the notation of ratchet, in the back word movement it is positive due to shape of
ratchet.

Zero Error is the error present in the micrometer, when the anvil and spindle of micrometer
coincides with each other and there is some reading between main scale and thimble scale.

Procedure:

1. The least count of the micrometer was found.

2. The two jaws were cleaned and the micrometer was checked for zero error.
3. The given set of slip gauges, which is used as standard reference, was cleaned.
4. The slip gauge size and corresponding micrometer reading were noted down. The
difference between micrometer reading and slip gauge size is the error.

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 5. The experiment was repeated with slip gauges of different sizes within the range of the
micrometer and the readings are tabulated and corresponding errors were found.

Observation:

For micrometer of range 0-25mm

1. Smallest division on main scale =……………mm.
2. No of division on thimble scale (circular scale) =…………..mm.
3. Least count(LC) =…………….mm
4. Zero Error =……………..mm

For micrometer of range 25-50mm

1. Smallest division on main scale =……………mm.
2. No of division on thimble scale (circular scale) =…………..mm.
3. Least count(LC) =…………….mm
4. Zero Error =……………..mm

Tabular column:
Slip Main Vernier Correct
Total
gauge scale scale reading %
Micrometer Reading Error
SI.no reading reading reading Z Error
Range Y
X (MSR) (VSR) (mm)
(mm)
(mm) (mm) (mm)

2 0-25mm

2 25-50mm

Specimen calculation:
1. Total Reading Y =MSR+(VSR × LC)=…………………………mm
2. Correct reading Z = Y- Zero Error=……………………….mm
3. Error = X-Z =………………..mm
4. % Error= ×100=…………………..

Result:
The average percentage error of given micrometer is found to be=………………%
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BEVEL PROTRACTOR

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Experiment No-3

Measurement of angle using bevel protractor

Aim: To measure the taper angle of the given specimen using bevel protractor

Apparatus: Bevel Protector, Work piece, Height gauge.

Theory: 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 bevel
protractor is used to measure the various angles of both small and large components with accuracy
up to 5 minutes. The design of the universal bevel protractor type had considerably increased the
scope of angular measurement with the adjustable blades and the protractor can be indexed
through 3600. The same basic principle as in the other vernier scales was used in this instrument

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 60minutes/degree,
denoted). The vernier scale of the protractor had 24 equal divisions with 12 divisions on each side
of zero. On each side 12 divisions are marked from 0-60 and occupying 23 divisions on the main
scale. Therefore least count is ratio of one main scale division to the no of divisions on vernier
scale. LC =1/12 x 60 = 5 minutes.

Precautions: Before the use wipe the protractor and check for proper zero setting with no
clearance between the measuring blades and the toolmakers square. The index mark coincides
with the 900 graduation line on the dial. When checking a hand held work piece, use the right hand
to press the work against and to move it along the slotted blade.

Procedure:

1. The appropriate size blade to suit the given job was fixed and locked.
2. The job / component was placed by touching the reference face and the movable blade.
3. The blade was locked after ensuring the proper contact on the two faces of the job.
4. The reading was noted down corresponding to the zero of the vernier scale. (M.S.R + V.S.C x
1/12).
5. The procedure was repeated to find out all the required angles.

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Observation:
 Least count(LC) of bevel protractor=

= ×60=5 minutes. {Bcz 1˚=60min}

Tabular column:

Main scale Vernier scale

Total Reading
reading reading
Specimen SI.no (θ=M.S.R + (V.S.C x 1/12))
(MSR) (VSR)
(in degree)
(in degree) (in minutes)

Specimen1 2

Specimen2 2

Result:
1. Angle of the given specimen1 =
2. Angle of the given specimen2 =

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