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Sample 21975

This document provides a summary of a textbook on engineering metrology. [1] The textbook covers metrology topics for the third semester of the second year diploma in mechanical engineering according to the MSBTE 'I' scheme syllabus. [2] It includes chapters on the introduction to metrology, measurement instruments, gauges and comparators, screw thread and gear metrology, surface texture and form metrology. [3] The textbook aims to help students understand fundamental metrology concepts through the use of figures, examples, and practice problems. It provides concise yet comprehensive coverage of the syllabus in a clear and easy to understand manner.

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0% found this document useful (0 votes)
105 views

Sample 21975

This document provides a summary of a textbook on engineering metrology. [1] The textbook covers metrology topics for the third semester of the second year diploma in mechanical engineering according to the MSBTE 'I' scheme syllabus. [2] It includes chapters on the introduction to metrology, measurement instruments, gauges and comparators, screw thread and gear metrology, surface texture and form metrology. [3] The textbook aims to help students understand fundamental metrology concepts through the use of figures, examples, and practice problems. It provides concise yet comprehensive coverage of the syllabus in a clear and easy to understand manner.

Uploaded by

smrtyfaizan786
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 16

A Text Book Of

ENGINEERING
METROLOGY
(22342)

Semester - III
SECOND YEAR DIPLOMA IN MECHANICAL ENGINEERING

As Per MSBTE's ‘I’ Scheme Syllabus

VINOD THOMBRE-PATIL
B.E. (Mech.) M. Tech. (Energy Technology)
Vice-Principal and Head of Department - Mechanical,
S. H. Jondhale Polytechnic, Dombivili

Price ` 165.00

N4429
Engineering Metrology ISBN 978-93-87686-96-0
First Edition : June 2018
© : Author
The text of this publication, or any part thereof, should not be reproduced or transmitted in any form or stored in any computer storage system or device for
distribution including photocopy, recording, taping or information retrieval system or reproduced on any disc, tape, perforated media or other information storage
device etc., without the written permission of Author with whom the rights are reserved. Breach of this condition is liable for legal action.
Every effort has been made to avoid errors or omissions in this publication. In spite of this, errors may have crept in. Any mistake, error or discrepancy so
noted and shall be brought to our notice shall be taken care of in the next edition. It is notified that neither the publisher nor the author or seller shall be
responsible for any damage or loss of action to any one, of any kind, in any manner, therefrom.

Published By : Polyplate Printed By :


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Note : Every possible effort has been made to avoid errors or omissions in this book. In spite this, errors may have crept in. Any type of error or mistake so noted,
and shall be brought to our notice, shall be taken care of in the next edition. It is notified that neither the publisher, nor the author or book seller shall be responsible
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Dedication …

In the loving memory of my Father,


Late Mr. S. T. Thombre – Patil,
Hon’ble Advocate, Jalna

Thanks to my Wife,
“Mrs. Apeksha Vinod Thombre – Patil,
(M.E. EXTC),
Asst. Professor”

and Beloved Son,


“Abhishek”
Preface …
I am glad to present the book entitled “Engineering Metrology” for IInd Year (Third Semester)
Diploma in Mechanical Engineering as per the “I” Scheme code syllabus prescribed by MSBTE.

I have observed the students facing extreme difficulties in understanding the basic principles and
fundamental concepts without adequate solved problems along with the text. To meet this basic
requirement of students, sincere efforts have been made to present the subject matter with
frequent use of figures and lots of numerical examples.

I am thankful to Mr. Dineshbhai Furia, Mr. Pradeepbhai Furia, Mr. Jigneshbhai Furia,
Mr. Shashikant Patel, Mr. Malik Shaikh, Mrs. Manasi Pingle, Mrs. Anjali Muley, Ms. Chaitali Takle,
Mr. Ravindra Walodare of Nirali Prakashan along with their staff members for bringing this
publication timely to the Market.

I must acknowledge special gratitude to Mr. Raosaheb Patil Danve (M.P. and BJP Chief -
Maharashtra), Er. Sagar Jondhale (Director, Jondhale Educational Group), Dr. Ram Reddy, (Principal,
LRTCOE, Mumbai), Dr. R. G. Tated (Principal, Sandip Foundation, Nashik), Prof. Shinde N. N. (HOD –
Energy Technology, DOT, SUK), Prof. Hemant Sarje (Dean, Fabtech Technical Campus, Sangola), Dr.
Nehte (Principal, Father Agnel), Dr. Pable M. J. (G. P. Bandra), Prof. R. B. Sholapurkar, (Principal, Virar
Polytechnic), Dr. Manoj Chavan (Principal, Shete Polytechnic, Kasara), Prof. Taskar (Principal, G.P.,
Jintur), Prof. Kantute (Principal, SBM, Mumbai), Prof. Bavaskar (Principal, Muchala Polytechnic,
Thane), Prof. Tandon (Principal, BVIT, Mumbai), Prof. Mange Amar (Principal, Pillai Polytechnic,
Rasayani), Prof. Tambe (Principal, Shantiniketan Polytechnic, Panvel), Prof. Padmavat (Principal, IET,
Aurangabad), Prof. Anoop Kumar and Prof. Sawant (H.O.D., S.S.J.P., Ambernath), Prof. S. N. Mahajan
(H.O.D., V.B.V.P., Vasai), Prof. Lonkar, Prof. Ansari, Prof. Salunkhe, Prof. Sanghvikar, Prof. Khandekar,
Prof. Ambadekar, Prof. P. P. Chaudhari, Prof. Shele, Prof. Pandit, (G.P., Thane), Prof. Nehal Muchala
(HOD, Thakur Polytechnic), Prof. Sable, Prof. Wagh (Tasgaonkar Polytechnic, Karjat), Prof. M. G.
Bagale, Prof. Killedar (G.P., Solapur), Prof. Kamble (Navjeevan Polytechnic), Prof. A. S. Dayma, Prof. K.
A. Jawalkar, Prof. S. S. Bhadane (HOD, Asangaon) and many more, who have extended their
co-operation and suggestions time to time.

I specially thank my students for motivating and encouraging me from time to time.

Any errors or suggestions for the improvement of this book brought to notice will be thankfully
acknowledged and incorporated in the next edition.

Vinod Thombre - Patil


Syllabus ...
Unit 1 - Introduction to Metrology (Marks 10, Hours 06)
1.1 Definition of Metrology, Objectives of Metrology
1.2 Categories of Metrology, Scientific Metrology, Industrial Metrology, Legal Metrology
1.3 Need of Inspection, Precision, Accuracy, Sensitivity, Readability, Calibration, Traceability, Reproducibility
1.4 Sources of Errors, Factors Affecting Accuracy
1.5 Selection of Instrument, Precautions while using an Instruments for getting Higher Precision and
Accuracy
1.6 Concept of Least Count of Measuring Instrument
Unit 2 - Standards and Comparators (Marks 10, Hours 10)
2.1 Definition and Introduction to Line Standard, End Standard, Wavelength Standard and their Comparison.
2.2 Slip Gauge and Its Accessories.
2.3 Definition and Requirement of Good Comparator, Classification, Use of Comparators.
2.4 Construction and Working Principle of Comparators - Dial Indicator, Sigma Comparator, Pneumatic
Comparator - High Pressure Differential Type.
2.5 Relative Advantages and Disadvantages.
Unit 3 - Limits, Fits, Tolerances and Gauges (Marks 12, Hours 08)
3.1 Concepts of Limits and Fits, Deviation and Tolerances
3.2 Basic Terminology, Selective Assembly, Interchangeability
3.3 Indian Standard (IS 919-1993) Fits, Types of Fits, Hole and Shaft Basis System, Guide for Selection of Fit
3.4 ISO System of Limit and Fit, (Numerical on finding the Limit and Tolerances of Hole and Shaft Assembly)
3.5 Gauges: Limit Gauges, Taylors Principle of Gauge Design Plug, Ring Gauges, Snap Gauge, Adjustable
Snap Gauge
Unit 4 - Screw Thread Measurements and Gear Measurement (Marks 12, Hours 08)
4.1 Screw Thread Terminology, Errors in Threads and Pitch
4.2 Measurement of Different Elements such as Major Diameter, Minor Diameter, Effective Diameter, Pitch
Diameter, Best Size of Wire, Two Wire Method, Thread Gauge Micrometer
4.3 Working Principle of Floating Carriage Micrometer
4.4 Introduction to Tool Maker's Microscope, Applications and Working Principle
Gear Measurement
4.5 Analytical and Functional Inspection of Gear, Measurement of Tooth Thickness by Constant Chord
Method and Base Tangent Method by Gear Rolling Tester/Parkinson's Gear Tester.
4.6 Measurement of Tooth Thickness by Gear Tooth Vernier and Profile Projector Errors in Gears such as
Backlash, Run Out.
Unit 5 - Linear and Angular Measurement (Marks 12, Hours 08)
5.1 Concept of Linear Measurement and Its Instruments: Surface Plate, V-block, Calipers, Combination Set,
Depth Gauge, Vernier Instruments, Micrometer Instruments, Slip Gauges.
5.2 Concept of Angular Measurement
5.3 Instruments for Angular Measurements
5.4 Use and Working of Universal Bevel Protractor, Sine Bar, Spirit Level
5.5 Principle of Working of Clinometers, Angle Gauges (With Numerical on Setting of Angle Gauges), Angle
Dekkor as an Angular Comparator
Unit 6 - Other Measurements (Marks 14, Hours 08)
6.1 Primary and Secondary Texture, Terminology of Surface Texture as per IS 3073-1967, CLA, Ra, RMS, Rz
Values and their Interpretation, Symbol for Designating Surface Finish on Drawing
6.2 Various Techniques of Qualitative Analysis, Working Principle of Stylus Probe Type Instruments, Surface
Roughness Tester, Interferometry
6.3 Parallelism, Straightness, Squareness, Roundness, Run out, Alignment Tests of Lathe and Drilling,
Machine Tools as per IS Standard.
6.4 Flatness Testing using Monochromatic Light Source with Optical Flat, Introduction to CMM.
,,,
Contents ...
1. Introduction to Metrology 1.1 - 1.14
1.1 Metrology 1.1
1.1.1 Scope of Metrology 1.1
1.1.2 Activities of Metrology 1.2
1.1.3 Objectives or Necessity of Metrology 1.2
1.1.4 Categories or Types of Metrology 1.2
1.2 Inspection 1.3
1.3 Accuracy and Precision 1.4
1.3.1 Accuracy 1.4
1.3.2 Factors Affecting the Accuracy 1.4
1.3.3 Precision 1.4
1.4 Difference Between Accuracy and Precision 1.5
1.5 Sensitivity, Readability, Repeatability, Reproducibility 1.6
1.6 Calibration 1.7
1.7 Traceability 1.7
1.8 Magnification 1.7
1.9 Error and Sources of Errors in Measurements 1.8
1.9.1 Classification of Errors/Sources of Errors 1.8
1.10 Difference between Systematic and Random Errors 1.10
1.11 Factors to be Considered While Selecting a Suitable Measuring Instrument 1.11
1.12 Essential Characteristics for an Accurate Measuring Instrument 1.11
1.13 Characteristics of Measuring Instrument for Giving Precise Measurements 1.11
1.14 Precautions While Using an Instrument 1.11
1.15 Concept of Least Count of Measuring Instruments 1.12
• Important Points 1.12
• Practice Questions 1.13
• MSBTE Questions and Answers 1.13

2. Standards and Comparators 2.1 - 2.24


2.1 Standards 2.1
2.2 Line Standard 2.1
2.2.1 Characteristics of Line Standard 2.2
2.2.2 Calibration of Line Standards 2.2
2.3 End Standard 2.2
2.3.1 Characteristics of End Standard 2.2
2.4 Difference between Line Standard and End Standard 2.3
2.5 Linear Measurement 2.3
2.6 Wavelength Standards 2.4
2.6.1 Advantages of Wavelength Standard 2.4
2.6.2 Difference between Line‚ End and Wavelength Standards 2.5
2.7 Slip Gauges or Johannsen Gauges 2.6
2.8 Wringing and Enforced Adhesion 2.7
2.9 Applications of Slip Gauge 2.8
2.10 Protector Slips 2.8
2.11 Manufacture of Slip Gauges 2.9
2.12 Precautions while Using Slip Gauges 2.9
2.13 Slip Gauge Accessories 2.9
2.14 Comparators 2.10
2.14.1 Necessity/Advantages of Comparators 2.11
2.14.2 Requirements / Characteristics of Good Comparator 2.11
2.14.3 Applications of Comparators 2.11
2.14.4 Classification of Comparators 2.12
2.15 Mechanical Comparator 2.12
2.15.1 Dial Indicator 2.12
2.15.2 Sigma Comparator 2.15
2.16 Advantages and Disadvantages of Mechanical Comparators 2.17
2.17 Pneumatic Comparator 2.17
2.17.1 Advantages of Pneumatic Comparators 2.18
2.17.2 Disadvantages of Pneumatic Comparator 2.18
2.17.3 Applications of Pneumatic Comparator 2.19
2.18 Comparison Between Mechanical and Pneumatic Comparator 2.19
2.19 Comparison Between Comparator and Measuring Instrument 2.19
• Important Points 2.22
• Practice Questions 2.22
• Numerical Problems for Practice 2.23
• MSBTE Questions and Answers 2.23

3. Limits, Fits, Tolerances and Gauges 3.1 - 3.30


3.1 Terminology 3.1
3.2 Tolerance 3.2
3.2.1 Need of Tolerance 3.2
3.3 Systems of Tolerance 3.3
3.3.1 Difference between Unilateral and Bilateral System 3.4
3.4 Limits of Size 3.4
3.5 Deviation 3.5
3.6 Basic Shaft and Basic Hole 3.6
3.7 Allowance 3.6
3.8 Difference between Tolerance and Allowance 3.7
3.9 Fits 3.7
3.10 Clearance Fit 3.7
3.11 Transition Fit 3.8
3.12 Interference Fit 3.9
3.13 Designation of Fits 3.9
3.13.1 Interpretation of Designated Fit 3.10
3.14 Interchangeability 3.10
3.14.1 Advantages of Interchangeability 3.11
3.15 Selective Assembly 3.11
3.16 Hole Basis and Shaft Basis System 3.12
3.16.1 Hole Basis System 3.12
3.16.2 Shaft Basis System 3.12
3.16.3 Difference Between Hole Basis System and Shaft Basis System 3.13
3.16.4 Preference of Using Hole Basis System Over Shaft Basis System 3.14
3.17 “GO” and “NO GO” Limit Gauges 3.14
3.17.1 Advantages of Limit Gauges (GO and NO GO) 3.15
3.17.2 Principle of GO and NO GO Gauges 3.15
3.18 Classification of Gauges 3.15
3.19 Taylor’s Principle 3.16
3.20 Indian Standards for Design of Gauges 3.17
3.21 Plain Plug Gauges 3.18
3.22 Plain Ring Gauges 3.19
3.23 Snap Gauge 3.19
3.24 Advantages of Gauges over Measuring Instruments 3.20
3.25 Disadvantages of Gauges as Compared to Measuring Instruments 3.20
3.26 Difference between Precision Measuring Instruments and Gauges 3.21
3.27 Difference between Comparator and Gauge 3.21
3.28 Difference between Measuring Instrument, Comparator and Gauges 3.21
3.29 Material for Gauges 3.22
3.30 IS 919 - 1993 3.22
3.31 Multi Gauging Machine 3.23
• Important Points 3.29
• Practice Questions 3.29
• MSBTE Questions and Answers 3.30

4. Screw Thread Measurements 4.1 - 4.22


4.1 Introduction to Screw Thread Measurement 4.1
4.1.1 Uses of Threads 4.1
4.2 Types of Screw Threads 4.1
4.2.1 External Threads and Internal Threads 4.2
4.3 Terminology of Screw Threads 4.2
4.4 Various Instruments used to measure Characteristics of Screw Thread 4.3
4.5 Construction and Working Principle of Floating Carriage Dial Micrometer 4.4
4.6 Applications of Floating Carriage Dial Micrometer 4.6
4.7 Measurement of Major Diameter of External Thread 4.6
4.8 Measurement of Minor Diameter of External Thread 4.7
4.9 Measurement of Effective Diameter of External Thread using Two Wire Method 4.8
4.9.1 Derivation of ‘P’ in Terms of Pitch (p) and Wire Diameter (d) 4.9
4.10 Measurement of the Effective Diameter of Screw Plug Gauge using ‘Three Wire Method’ 4.11
4.11 Best Size Wire 4.12
4.12 Measurement of Pitch of External Thread 4.14
4.13 Pitch Measurement using Optical Projection or Tool Maker’s Microscope 4.14
4.14 Pitch Measuring Machine 4.15
4.15 Measurement of Major Diameter of Internal Thread 4.16
4.16 Measurement of Minor Diameter of Internal Threads 4.17
4.16.1 Using Taper Parallels 4.17
4.16.2 Using Rollers and Slip Gauges 4.17
4.17 Screw Thread Errors 4.17
4.17.1 Periodic Errors 4.18
4.17.2 Drunkenness or Drunken Thread Error 4.19
4.17.3 Progressive Pitch Error 4.19
4.17.4 Irregular Erratic Pitch Errors 4.20
4.18 Screw Thread Micrometer 4.20
• Important Points 4.21
• Practice Questions 4.21
• MSBTE Questions and Answers 4.21
5. Gear Measurement 5.1 - 5.20
5.1 Introduction to Gears 5.1
5.2 Gear Terminology 5.1
5.3 Involute tooth profile 5.4
5.4 Involute Measuring Machine 5.5
5.5 Inspection of Gears 5.5
5.6 Tooth Thickness Measurement 5.6
5.6.1 Methods of Measuring Tooth Thickness 5.6
5.6.2 Measurement of Tooth Thickness by Gear Tooth Vernier Caliper
using Chordal Thickness Method 5.7
5.6.3 Procedure to Calculate Theoretical Value of Chordal Thickness
and Chordal Addendum 5.9
5.6.4 Limitations/Demerits of Chordal Thickness Method 5.9
5.7 Constant Chord Method 5.10
5.7.1 Procedure to Evaluate Mathematical Formulae for Calculating Theoretical Values
of Constant Chord (AB) and Its Depth from Tip 5.11
5.8 Base Tangent Comparator Method / Tangent Micrometer 5.12
5.8.1 Uses of Tangent Micrometer 5.13
5.9 Master Gears 5.13
5.10 Composite Method of Gear Checking 5.13
5.10.1 Applications of Composite Gear Testing 5.13
5.11 Parkinson Gear Tester 5.13
5.11.1 Advantages of Parkinson's Gear Tester 5.15
5.11.2 Limitations of Parkinson’s Gear Tester 5.15
5.12 Rolling Gear Test 5.15
5.12.1 Advantages of Rolling Gear Test 5.16
5.13 Sources of Errors in Manufacturing Gear 5.16
5.14 Various Types of Errors in Gears 5.16
5.15 Runout Checking 5.16
5.16 Lead Checking 5.17
5.17 Backlash, its Significance and Checking 5.18
5.18 Concentricity of Teeth 5.19
5.19 Other Errors in Gears 5.19
• Important Points 5.19
• Practice Questions 5.20
• MSBTE Questions and Answers (As Per 'G' Scheme) 5.20

6. Linear Measurement 6.1 - 6.18


6.1 Introduction to Linear Measurement 6.1
6.2 Classification of Linear Measuring Instruments 6.1
6.3 Surface Plate 6.2
6.3.1 Desirable Properties of Material used for making Surface Plates 6.2
6.3.2 Most commonly used Materials for Surface Plate 6.2
6.3.3 Precautions to be taken‚ while using Surface Plate 6.2
6.4 V-Block 6.3
6.4.1 Applications of V-block 6.4
6.4.2 Features of V-block 6.4
6.4.3 Precautions to be Taken‚ While Using V-block 6.4
6.5 Calliper 6.4
6.6 Practical Example illustrating Use of Calliper for Transferring Dimension from Job to a Steel Rule 6.5
6.7 Classification of Callipers On the Basis of Constructional Features 6.6
6.7.1 Difference between a Firm Joint Calliper and Spring Type Calliper 6.6
6.8 Classification of Callipers on The Basis of Use 6.6
6.9 Practical Examples Illustrating Use of Outside and Inside Callipers 6.8
6.10 Vernier Caliper 6.9
6.11 Vernier Height Gauge 6.11
6.12 Vernier Depth Gauge 6.12
6.13 Combination Set 6.13
6.14 Introduction to Micrometer 6.14
6.15 External Micrometer 6.14
6.16 Micrometer Depth Gauge 6.16
• Important Points 6.17
• Practice Questions 6.18

7. Angular Measurement 7.1 - 7.22


7.1 Introduction 7.1
7.2 Instruments for Angular Measurements 7.1
7.3 Universal Vernier Bevel Protractor 7.1
7.4 Spirit Level 7.3
7.4.1 Uses of Spirit Level 7.5
7.4.2 Errors in the Use of Spirit Level 7.5
7.5 Sine Bar 7.6
7.5.1 Uses of Sine Bar to Measure Angle of Component 7.6
7.5.2 Sources of Errors in Angular Measurement by Sine Bar 7.8
7.5.3 Factors Affecting Accuracy of a Sine Bar 7.9
7.5.4 Features of Sine Bar, which Have Tolerances for Accuracy 7.9
7.5.5 Precautions in Use of Sine Bars 7.9
7.5.6 Justification “Why it is Not Preferred to Use Sine Bar for Measuring Angles Greater than 45°”7.9
7.5.7 Measurement of Angle of a Taper Plug Gauge with the Help of a Sine Bar 7.10
7.5.8 Limitations of Sine Bar 7.11
7.6 Clinometer 7.11
7.6.1 Uses of Clinometers 7.12
7.7 Angular Standards or Angle Gauges 7.12
7.7.1 Applications of Angle Gauges 7.13
7.7.2 Difference between Angle Gauges and Slip Gauges 7.13
7.8 Angle Dekkor 7.14
• Important Points 7.21
• Practice Questions 7.21
• Numerical Problems for Practice 7.21
• MSBTE Questions and Answers 7.22

8. Measurement of Surface Finish 8.1 - 8.16


8.1 Importance of Surface Finish 8.1
8.2 Primary Texture 8.2
8.3 Secondary Texture 8.2
8.4 Difference between Primary Texture and Secondary Texture 8.3
8.5 Important Terms of Surface Finish 8.3
8.6 Ra Value 8.4
8.7 Ten Point Height Irregularities (Rz) 8.5
8.8 Methods of Measuring Primary Texture 8.6
8.9 Surface Finish Symbol 8.7
8.10 Various Methods of Surface Finish Measurement 8.8
8.11 Stylus Probe Instruments/ Stylus Type Surface Texture Measuring Instruments 8.9
8.12 Dr. Tomilson’s Surface Meter 8.10
8.13 Profilometer 8.11
8.13.1 Advantages of Profilometer 8.12
8.13.2 Limitation of Profilometer 8.12
8.13.3 Application of Profilometer 8.12
8.14 Taylor Hobson Talysurf 8.12
8.15 Advantages and Disadvantages of Direct Instrument Measurement / Quantitative Methods 8.13
• Important Points 8.14
• Practice Questions 8.15
• Numerical Problems for Practice 8.15
• MSBTE Questions and Answers 8.15

9. Machine Tool Testing 9.1 - 9.24


9.1 Alignment Test or Geometrical Test 9.1
9.2 Performance Test or Practical Test 9.1
9.3 Difference between Alignment Test and Performance Test 9.2
9.4 Parallelism 9.2
9.5 Straightness 9.3
9.5.1 Test for Straightness by using Spirit Level and Auto-collimator 9.4
9.6 Squareness 9.5
9.7 Squareness Testing 9.7
9.8 Roundness 9.8
9.9 Circularity 9.8
9.10 Difference between Roundness and Circularity 9.8
9.11 Measurement of Roundness 9.8
9.11.1 Rotating on Centres 9.8
9.12 Co-axiality 9.9
9.13 Run-out 9.9
9.14 Flatness using Optical Flat 9.9
9.15 NPL Flatness Interferometer 9.11
9.16 Various Tests to be Carried Out on Lathe, Milling and Drilling Machines 9.12
9.17 Alignment Tests on Lathe Machine 9.13
9.18 Alignment Tests on Milling Machine 9.16
9.19 Alignment Tests on Drilling Machine 9.18
9.20 Introduction to Co-ordinate Measuring Machine (CMM) 9.21
• Important Points 9.23
• Practice Questions 9.24
• MSBTE Questions and Answers 9.24
,,,
Engineering Metrology (22342)

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