MACHINE TOOLS & METROLOGY LAB III B.

TECH I SEM (MECH)-R18

EXP. :
MEASUREMENT OF LENGTHS, HEIGHTS, DIAMETERS BY VERNIER CALIPERS
MICROMETERS ETC.
AIM: 1. To measure the height of the object using vernier height gauge.
2. To measure the depth of the object using Depth gauge.
3. To measure the diameter of the object using Vernier calipers.

INSTRUMENTS USED:

1. Surface Plate 2. Vernier height gauge 3. Specimens 4.DepthGauge

THEORY: VERNIER HEIGHT GAUGE:

Vernier height gauge is a sort of Vernier calipers equipped with a special with a base
and other attachment, which make the instrument suitable for height measurement. Along
with the sliding jaw assembly arrangement is provided to carry a removable clamp.
The upper and lower surfaces of the measuring jaws are parallel to the base, so that it canbe
used for measurements over or undersurfaces.
The vernier height gauge is mainly used in the inspection of parts and layout work. The
vernier height gauge can be used to scribe lines at a certain distance above the surface with a
scribing attachment in place of measuring jaw. Dial indicators can also be attached in the
clamp and many exact measurements can be made as it exactly gives the indication when the
dial tip is touching the surface. Surface plates as datum surface are used for the above
measurements.

4
PROCEDURE:
1. Place the object and the vernier height gauge on the surfaceplate.
2. Note the value on the scale when the moving jaw is touching the bottom of the
object.
3. Take the moving /sliding jaw to the top of the object and note down the value onthe
scale.
4. The difference between 3&2 will give the height of the object.

VERNIER DEPTH GAUGE:

Vernier Depth Gauge is used to measure the depth of holes, slots and recesses, to locate
center distances etc. It consists of

1. A sliding head having flat and true base free from curveswaviness.
2. A graduated beam known as main scale. The sliding head slides over thegraduated
beam.
3. An auxiliary head with a fine adjustment and a clampingscrew.
4. A beam is perpendicular to the base in both direction and its ends square and flat.
The end of the sliding head can be set at any point with fine adjustment locked and
read from the Vernier provided onit.

PROCEDURE:
1. Held the base on the referencesurface.
2. Lower the beam into the hole until it contacts the bottom surface of thehole.
3. Make final adjustment with fine adjustmentscrew.
4. Tighten the clamping screw and remove the instrument from the hole and takethe
reading in the same way asvernier.
5. Leastcount= -------------- mm.

Main scale reading Vernier Scale Measured reading

S.NO. MSR(mm) Reading VSR(mm) = mm
MSR+ (VSR*L.C)
 PRECAUTIONS:

1. The height gauges should be kept in their case when not inuse.
2. Measuring jaws should be handledcarefully.
3. While using the Dept gauge, it should be ensured that the reference surface, on
which the depth gauge is rested, is satisfactorily true, flat andsquare.

RESULT:
 The heights of the given objects measured by vernierheight gauge are tabulatedabove.
 The depth of the holes measured by Vernier depth gauge is tabulatedabove.

ADVANTAGES
:
 Height gauges may also be used to measure the height of an object by using the
underside of the scriber as thedatum.
 The datum may be permanently fixed or the height gauge may have provision to adjust
the scale, this is done by sliding the scale vertically along the body of the height gauge
by turning a fine feed screw at the top of the gauge; then with the scriber set to the same
level as the base, the scale can be matched toit.
 This adjustment allows different scribers or probes to be used, as well as adjustingfor
any errors in a damaged or resharpenedprobe.
APPLICATIONS:
 These are used to mark out lines and widely used on surface plates and on machine
tables.
 The height gauge with an indicator attachementis used for checking for surfaceholes.
 The height is scribe attachment is used to mark reference lines and location on castings
andforgings.
 Ideal for marking and measuring work for molds, jigs, andtooling.
 Sliding main carriage for fast, easyadjustment.
 Easy to read scale using 3x magnifyinglens.
 Carbide tippedscribe.
 Made of stainless steel for rust protection.
 Dial Indicator mounting arm accepts φ6mm, φ8mm,and dovetail typeindicators.

VIVA-VOICE QUESTIONS:
 What is the difference between vernier height gauge, vernier depth gauge, andvernier
caliper?
 A height gauge is a measuring device used either for determining the height of objects, or
for marking of items to be workedon.
 What is the purpose of vernier heightgauge?
 What is the least count of vernier heightgauge?
 What are the various types of linear measuringinstrumen
EXP:
MEASUREMENT OF BORES INTERANAL MICROMETERS AND DIAL BORE
INDICATORS.
AIM:
The objective is to familiarize students with the use of vernier calipers, Micrometer screw
gauges. The write –up for this experiment will be submitted at the end of the laboratory period.
Drawings of the parts to be measured in the lab are available from the Teaching Assistant for
the purposes of dimensioning. No aids other than calculators are allowed to be used.

THEORY:
Least Count – the smallest degree by which two measurements may be differentiated with a
particular instrument; generally considered to be of the same order as the smallest division in
the instruments‘ scale.

The Least Count is a measure of the accuracy of a measuring instrument.

VERNIER CALLIPERS:
A vernier caliper consists of a rule with a main engraved scale and a movable jawwith
an engraved vernier scale. The main scale is calibrated in centimeters (cm) with a millimeter
(mm) least count, and the movable vernier scale that divides the least count on the main scale in
to 50 equal sub-divisions. The span of the upper jaw is used to measure the inside diameter of
an object such as hollow cylinders or holes. The leftmost mark on the vernier scale is the zero
mark, which is often unlabeled. The measurement is made by closing the jaws on the object to
be measured and reading where the zero mark on the vernier scale falls on the main scale. The
first two significant figures are read directly from the main scale. This is known as the main
scalereading.

The next significant figure is the fractional part of the smallest subdivision on the
main scale (in this case, mm). If a vernier mark coincides with a mark on the main scale, then
the mark number is the fractional part of the main scale division. Before making a
measurement, the zero of the verniercalliper should be checked with the jaws completely
closed. It is possible that the caliper not being properly will produce systematic error. In this
case, a zero correction must be made for each reading. The least of the vernier caliper is
calculated byequation
A large range of measurements can be made using the one measuring device.
Against The majority of vernier calipers do not provide sufficient accuracy for close tolerance
measurements.
In the machining process, we use verniercallipers or a micrometer for taking
measurements. General analog vernier calipers can measure with the minimum unit of 1/20
mm. Several types of digital vernier calipers can measure with the minimum unit of 1/100mm.

MRCET DEPARTMENT OF MECHANICAL ENGINEERING

7
 Value of the smallest division on main scale
1) LeastCount=

Number of divisions on vernier scale

2) Measurement = Main scale reading + conceding vernier scale division ×Leastcount

PROCEDURE:
Least Count:
Least count is the minimum distance which can be measured accurately by the Instrument. Least
Count of Vernier Caliper is the difference between the value of main scale division and Vernier
ScaleDivision.
Thus Least Count = (Value of Smallest Division on Main Scale)- (Value of Smallest Division
on Vernier Scale) = 1-49/50 = 0.02 mm. (or) Least Count = (Value of Minimum Division on the
Main Scale)/ (Number of Division on Vernier Scale ) = 1/50 = 0.02 mm
The given component is fixed between the jaws firmly, i.e.. in between fixed jaw and
movable jaw.
The reading is to be noted down. Procedure for taking the Reading:
1. After closing the jaws on the work surface, take the readings from the main as well as
Vernier Scale. To obtain the reading , the number of divisions on the main scale is first readoff.

‗Ihe Vernier Scale is then examined to determined which of its division coincide or most
coincident with a division on the main scale.
2. Before using the instrument should be checked by zero error. The zero line on VernierScale
should coincide with zero on the main scale.
3. Then take the reading in mm on main scale to the left of zero on slidingscale.
4. Now Count the no. of divisions on Vernier Scale from zero to a line which exactlyCoincides
with any line on the mainscale.
Thus total reading = [ Main scale reading ] + [No. of divisions with a division on Main Scale ]
X Least Count. ( OR ) TR = MSR + VC X LC
5. Take the reading for 4times.

OBSERVATIONS :

Total Reading= MSR+

S. No MSR VSR (VSRXLC)

MICROMETER SCREW GAUGE:

THEORY:
A micrometer consists of a movable spindle (jaw) that advances toward another
parallel-faced jaw, called an anvil, by rotating the thimble. The thimble rotates over an
engraved sleeve or barrel that is mounted on a solid frame. Most micrometers are equipped
with a ratchet, at the far right in figure 2, which allows slippage of the screw mechanism when
a small constant force is exerted on the jaw. This permits the jaw to be tightened on an object
with the same amount of force each time. The axial main scale on the sleeve is calibrated in
mm and the thimble scale is the vernier scale and is usually divided into increments of
0.01mm.

The pitch of a screw is the distance between two consecutive screw threads and is the
lateral linear distance the screw moves when turned through one rotation. The axial line on the
sleeve main scale serves as a reading line. If a micrometer does not have 0.5 mm divisions on
the main scale, you must determine whether the thimble is in its first rotation or second. If it has
50 divisions on the thimble and completes 1 mm in two rotations, each division on the thimble
gives 0.01mm.
Measurements are taken by noting the reading x on the main scale of the sleeve. Note the
position of the edge of the thimble on the main scale and the position of the reading line on the
thimble scale. Multiply this reading with 0.01 mm and add to x
3) Least Count = Pitch (Distance between two consecutive threads of screw) ÷ Numberof
divisions on thimblescale
4) Measurement = Main scale reading + coinciding thimble scale division ×Leastcount
How to Use a Micrometer
When close tolerances are required, measurements are taken with a micrometer due to its
superior accuracy over a vernier caliper. The micrometer as can measure with the minimum unit
of 1/1000mm.

PROCEDURE:
The work piece is held between the 2 anvils without undue pressure.
This is Accomplished by having a retched drive to turn the thimble when the anvils contact each
other directly or indirectly through work piece placed in between the ratchet tips over the screw
cap without moving the screw forwards and thus avoids unduepressure.
Least Count = Pitch of the screw/ No. of Divisions on Circular Scale. If Pitch of screwis
mm and Circular Scale has 50 divisions on it, then Least Count = 0.5 / 50 ~ 0.01mm
In measuring, the dimension of work piece the main scale upto the leveled edge of thimble andno.
of divisions of thimble scale to axial line on barrel are observed addition of two givenresult.

OBSERVATIONS:

S.No PSR HSR PSR+(HSRXLC) READINGS

BORE DIAL GAUGE:

THEORY:
It is used for measuring internal diameter of a hole, which is machined. The bore dial
gauge consists of one fixed measuring head and one movable measuring head. The movement
of the movable measuring rod is transmitted to dial indicator by push rod through a spring
actuated hinged member. Thus the horizontal movement of the rod is transmitted into vertical
direction gives indication of variatopn of size. The calibrated rods are made in different sizes
and sometimes number of short rods threaded 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 of measuring
head contact point is transmitted to the amplifying mechanism by the calibrated rods and its
shown on the dial indicator. These calibrated rods are located in tabular supports between the
head and dial units. The readings from dial indicator are tabulated

OBSERVATIONS:

TRIAL TRIAL MEASURED

S.NO DIAMETER AVERAGE
1 2 DIAMETER

Note: Please avoid dropping the tools as this can lead to irreparable damage to the precision
instruments. The tools are coated with a light film of oil to prevent corrosion. Please do not
remove this oil. A cloth has been provided to clean your hands after use.

RESULTS:

The specifications of the given component are measured with vernier caliper, outside
micrometer & bore dial gauge.
ADVANTAGES OF VERNIER CALIPER

Vernier Calipers are precision measuring instruments with a higher accuracylevel.

It is one of the best caliper to measure least count of any object. However there are certain
number of advantages and disadvantages about these instruments which are
discussedbelow.

Vernier Caliper is very important tool in manufacturing industry and has lot of benefits.

Precision&accuracyaretwohallmarksofVernier calipers,thisinstrumenthasrobust
tendency to give precise and accurate measurements of variousdimensions.

TwinScales:

Main or primary scale and Vernier or secondary scale are constructed together into the
measuring equipment, an additional measuring gadget like a ruler or tape measure is not
needed.

Adaptability forMeasurements:

Vernier calipers can be used for variety of applications. It can measure inner, outer, steps
and depth dimensions of any geometrical objects.

Strength:

Majority of manufacturers make Vernier calipers by using pure stainless steel to give
strength and durability. As we know stainless steel have a higher strength & corrosion
protection and hence by following standard manufacturing processes, Vernier Calipers
can sustain for a life time.

Price:

Vernier calipers are very common, there are many suppliers available in the market.
Therefore the prices are very competitive now and these are readily available in cheap
prices as well.

DISADVANTAGES OF VERNIER CALIPER

Good Vision IsNeeded:

As quite evident, the Vernier scale of a Vernier caliper is significantly small component.
With improper vision or improper angle of vision it is quite difficult to properly read or
identify measurements. To avoid such mistakes normally Good vision or a right light
with magnifying glass would be recommended while taking readings.
 Learning A VernierCaliper:

All of us know that the Vernier scale is a specialized precision measuring tool; user
should make an effort to learn how to read from a Vernier caliper before going to
take measurements.

Prospect OfErrors:

While acquiring several numbers of measurements, user might end up committing

error. To avoid this prospect of errors extra attentiveness is needed.

Availability OfAlternates:

Digital calipers are best alternate to Vernier calipers that can yield more accurate
values with no prospect of errors as in manual Vernier Calipers

ADVANTAGES OF MICROMETER:

More accurate thanrules.

Greater precision thancalipers.
No parallaxerror
Relativelyinexpensive.
Endmeasurement

DISADVANTAGES OF MICROMETER:
Short measuringrange
End measurementonly
Single puroseinstrument.
Limited wear area of anvil and spindletip.

APPLCATIONS:
It can be used to measure diameter of a wire, thickness of a thin metal sheet,etc
These instrument are used to check round work piecesaccurately.
It is also used to check wall thickness of thepipe.
VIVA-QUESTIONS:

What is the least count of a Vernier caliper having 20divisions on Vernier scale,
matching with 19 divisions of main sale?
What type of micrometer is used for measuring longer internallength?
How to maintain constant pressure inmicrometer?
What is the purpose of adjusting nuts in amicrometer?
What is the range of dial boregauge?
What is the least count of digitslverniercaliper?
Explain briefly about the different types ofmicrometers?
What is the least count of a micrometer and how is itdetermind?
What are VernierCalipers?
What is Micrometer?
What is the Least Count of Vernier & Outside Micrometer?
What are applications of Vernier & Outside Micrometer?
What are the errors in Vernier & Outside Micrometer?
Compare Vernier & Outside Micrometer .
What are the precautions required during use of inside micrometer & dial Boreindicator.
Which one is more precise when compared to inside micrometer & dial boreIndicator.
What are the applications of inside micrometer & dial bore indicator?
How do you find the least count of inside micrometer?
What are the other instruments for measuring bores?
EXPERIMENT NO.:

ANGLE MEASUREMENT USING BEVEL PROTACTOR & SINE BAR

AIM:
To measure the angle of the given wedge using Sine bar & Bevel Protractor

INSTRUMENTS USED:

1. Sine bar 2. Work piece 3. Dial Gauge 4. Slip gauges 5. BevelProtractor.

SINE BAR:

THEORY:
The sine principle uses the ratio of the length of two sides of a right triangle in
deriving a given angle. The accuracy with which the sine principle can be put to use is
dependent in practice, on some form of linear measurement. The sine bar in itself is not a
complete measuring instrument. Sine bars in conjunction with slip gauges constitute a very
good device for the precise measurement of angles. The arrangement is based on the fact
that for any particular angle θ the sides of a right angled triangle will have precise ratio, i.e,

Sinθ= h/l
If h and l could be measured accurately, θ can be obtained accurately. The value of h
isbuilt-up by slip gauges and value ‗l‘ isconstant for a given sine bar.

Sine bars are used either to measure angles very accurately or for locating any work
to a given angle within very close limits. Sine bars are made from high carbon, high
chromium, corrosion resistant steel, hardened, ground and stabilized. Two cylinders of equal
diameter are attached at the ends. The axes of these two cylinders are mutually parallel to
each other and also parallel to and at equal distance from the upper surface of the sine bar.
The distance between the axes of the two cylinders is exactly 100, 200and

.
 PROCEDURE:

1. Place the work piece/wedge above the sine bar and make it horizontal with thebase.
2. The dial gauge is then set at one end of the work moved along the upper surface of
the component.
3. If there is any variation in parallelism of the upper surface of the component andthe
surface plate, it is indicated by the dialgauge.
4. The combination of the slip gauges is so adjusted that the upper surface is truly
parallel with the surfaceplate.
5. Note down the values of the slipgauges.
6. Calculate the angle using the formula.
-1

θ=Sin (h/l)
7. Repeat the procedure 3 or 4 times and take theaverage.

OBSERVATIONS:

S.No. HEIGHT(h) LENGTH(l) ANGLE

BEVEL PROTRACTOR:

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 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 60
minutes/degree, denoted). To measure angle between two planes, rest the stem on one of the
planes (reference plane). Rotate the blade such that blade is flush with second plane. Readings
are taken after ensuring that the stem and blade are in flush with the two planes. Lock the
protractor at this point and note sown thereadings.
OBSERVATIONS:

S.NO. ANGLE MEASURED

PRECAUTIONS: 0
1. The sine bar should not be used for angle greater than60 in
construction is accentuated at thislimit. because any possible error
2. A compound angle should not be formed by mis-aligning of work piece with the sine
bar. This can be avoided by attaching the sine bar and work against an angleplate.
3. As far as possible longer sine bar should be used since using longer sine bars reduces
manyerrors.
RESULT:
1. The angle of the given specimen measured with the sine baris
2. The angle of the given specimen measured with the Bevel Protractoris
ADVANTAGES:
The bevel protractor is used to establish and test angles to very close tolerances. Itreads
o o
to 5 minutes or 1/20 and can be used completely through 360 .
For checking a Vblock
For measuring Acuteangle..

APPLICATIONS:

The hypotenuse is a constant dimension—(100 mm or 10 inches in the examplesshown).

The height is obtained from the dimension between the bottom of one roller and the
table'ssurface.
The angle is calculated by using the sine rule. Some engineering and metalworking
reference books contain tables showing the dimension required to obtain an angle from 0-
90 degrees, incremented by 1 minuteintervals.
The two rollers must have equal diameter and be truecylinders.
For cheking inside face of bevel face of groundface.
Measure angles veryaccurately.
What is the use of angleplates?

VIVA - QUESTIONS:

Name some angle measuringdevices?

What is the least count of mechanical BevelProtractor?

What is the least count of optical BevelProtractor?

What is a sinebar?

What are the limitations of Sinebar?

What is the difference between the sine bar and sinecenter?

What is the use ofV-block?

How do you specify sinebar?

Experiment No.
GEAR TOOTH VERNIER CALLIPER
AIM:
To measure the thickness and height of gear teeth at the pitch line or chordal thickness of
teeth and the distance from the top of a tooth the chord using gear tooth caliper.

EQUIPMENT REQUIRED:
1. Gear tooth Verniercaliper
2. Gear of knownmodule
3. Surfaceplate

THEORY:
Tooth thickness is the arc distance measured along the pitch circle from its intercept
with one flank to its intercept with the other flank of the tooth.
pdNd1
Module, m =(d/N) =( 1/dP)
Where d = Pitch Circle Diameter(pcd)
N = Number of teeth on given gear dp
= DiametralPitch
Diametral Pitch, dp = (N/d) = (N+2)/D
Where D = Outside Diameter of Gear

Theoretical Thickness, Wt = N m sin (90/N)

Chordal Height or depth, h = N m
% Error = (Wt– Wm)/Wtx 100

Addendum is the radial distance from the tip of a tooth to the pitch circle.
In the most of the cases, it is sufficient to measure the chordal thickness i.e. the chord
joining the intersection of the tooth profile with the pitch circle because it is difficult to
measure length of the arc directly.

Tooth thickness caliper consists of a slide which moves vertically with the help of knob.
The jaw moves horizontally with the help of know there by varying the gap between them.
An adjustable tongue, each of which is adjusted independently by adjusting screw on
graduated bars, measures the thickness of a tooth at pitch line and the addendum.
1. The given gear caliper is held over the gear and the slide is moved down so that it
touches the top of the geartooth.
2. The jaws are made to have contact with the tooth on either side by adjusting the
knob.
3. The reading on vertical scale i.e. height is noteddown.
4. The reading on horizontal scale i.e. tooth thickness is noteddown.
5. The above procedure is repeated for five times and readings arenoted.
Least count of given caliper:

TOOTH THICKNESS

TOTAL = MSR +(VSR x L.C. )

S.No. M.S.R V.S.R

HEIGHT:

S.No. M.S.R V.S.R TOTAL = MSR +(VSR X L.C)

RESULT:

The Height of thegivenspecimen =_

The tooth thickness of thegivenspecimen =

ADVANTAGES:
The method and simpleexpensive.
However it needs different setting for a variation in number of teeth for a givenpitch.
Accuracy is limited by the least count of instrument.
The wear during use is a concentrated on thetwojaws.
The caliper has to be calibarated at regular intervals to maintain the accuracymeasurement.

APPLICATIONS:
Can be used for measuring hobs, form and threadtools
Adjusted independently by screws on the graduatedbars
Thickness of a tooth at the pitch line is measured by an adjustable jaw after the
addendum is set by the adjustabletongue
VIVA QUESTIONS:
What are the applications of Gear toothverniercaliper?
How do we check the profile of a Geartooth?
Define various elements of agear?
What is Chordaladdendum?
What is chordal thickness of geartooth
What are the various parts of gear tooth Vernier? v) Differentiate gear tooth Vernierfrom
ordinaryVernier?
What are the different types ofgears?
What are the various tests conducted ongears?
What is the other parameter to be measured in gear by using other testingequipment?
What is rolling geartest?
What are the various quantitative test ongears?
What is the use of gear tooth verniercaliper?
Explain why chordal width of spur gear is an important dimension tomeasure?
EXPERIMENT NO.

TOOL MAKER’S MICROSCOPE

AIM: To measure the pitch & angle of the screw thread.

APPARATUS: Tool makers microscope, screw thread specimen

THEORY:
Tool makers microscope is based on the Principle of optics. The microscope consists of
a heavy-duty hallow-duty hallow base, which accommodates the illuminating unit
underneath, and above this on the top surface of the base, the work table carriage is
supported on ball and controlled by micrometer screws. Projecting up from the rear of the
base is a column, which carries the microscope unit and various interchangeable eyepieces.
The chief applications of the tool room microscope are as follows
1. The determination of relative position of various points onwork.
2. Measurement of angle by using a protractoreyepiece.
3. Comparison of thread forms with master profiles engraved in theeyepiece,
measurement of pitch and effectivediameter.

SPECIFICATION:
MAGNIFICATION : 30X (Standard)
OBJECTIVE :2X
EYEPIECE : W.F.15X with crossrectile
FIELD OFVIEW : 8mm. (approx)
WORKINGDISTANCE :80mm
OBSERVATIONTUBE : monocular inclined at 30degree
STAND :largeandheavybaseprovideextraoverallrigiditytothe
instrument

MEASUREMENT STAGE : 150X150.

Size travel up to 50mm in each direction, least count 6 minutes.

CONSTRUCITON OF MICROSCOPE
BASE:
The study base rest on three support two of which are adjustable for leveling the instrument.
The base has built in all electrical transformers and their control panel and transmitted
illuminator with green filter.
ARM:
The arm has a groove guide on which the microscope tube is vertically adjusted by rack and
pinion system.
FOCUSSING MECHANISM:

The course focusing movement provided in the microscope tube separately. The coarse
motion is knurled knob on both side of the tube and ha as the total travel of 200mm. Itsalso
lock any position by lever, this movement is characterized by its exceptionally smooth and
accurate precision. The vertical travel or measurement up to 10mm, thickness can be read by
the depth dial gauge. The thickness is being measured with the difference of two different
focusing of object. The least count of gauge is0.01.
EYEPIECE PROTRACTOR
This unique protractor head graduated 0 to 360 degree with adjustable vernier reading to
6 minutes cross line incorporated in the protractor head rotating in the optical axis of the
microscope the cross linegraticule is replaceable with many other measuringgraticules.

MEASURING STAGE
The stage plate is of 150 X 150 mm having very smooth and precise movements in both
axis with special ball racers arrangements. The travel of the stage is 25mm. in both direction
with precise imported micrometer head, least count 0.01 or 0.005mm. The stage has two T-
slots for mounting accessories like rotary stage, center holding device attachment and V-
blocketc.

ROTARY STAGE
A rotating stage is fixed in T-slots of square plate having 360 degree graduations on its
periphery with vernier reading to6 minute, and lock screw. All types of horizontal angular
measurements can be done with this stage.

ILLUMINATING SYSTEM
Two possible range of illuminating system are provided with standard equipment to
meet every application, operated through 6 volts solid state variable light control built in
transformer.

1. Sub-stage transmitted light from a bottom source providing collimated green

filter halogen light for viewing contours and transparentobjects.
2. Surface incident illuminator for shadow free lighting, for high powerexamination
of opaqueobjects.

PROCEDURE:
MEASUREMENT OF SCREW THREAD PITCH

1. The image of the thread profile is set so that some of the profile coincides with the
cross hair as seen on the ground-glass screen.
2. The reading on thimble of the longitudinal micrometer screw is noteddown.
3. Then the part is traversed by the micrometer screw until a corresponding point on
the profile of the next thread coincides with the crosshairs.
4. The reading on thimble is again noted and the difference in two readings gives the
actual pitch of thescrew.
MEASUREMENT OF ANGLE OF THREAD

1. It is determined by rotating the screen until a line on the screen coincides with one
flank of the threadprofile

2. The angle of screen rotation is noted and then the screen is further rotated till the
same line coincides with the other flank of thread. The difference in two angular
readings gives the actual angel of thread on thescrew.

PITCH OF THE THREAD

S. No. Initial micrometer Final micrometer Pitch of the thread B-A

readings on thread pitch readings on thread (mm)
A(mm) pitch B(mm)

FLANK ANGLE OF THE THREAD:

S. No. Intial flank angle A Final flank angle B Flank angle = B-A (Deg)
(Deg) (Deg)

PRECAUTIONS:

1. The coincidence on the component & cross hairs must be carefullymatched.

2. Eyepieces are to be handledcarefully.
3. Don‘t expose eyes directly to the lightsource.

RESULT:

The pitch and flank angle of the given object is measured with toolmakers microscope are
tabulated.
 ADVANTAGES:
As compared to the optical comparators, a tool maker‘s microscope is preferred
whenthe z-axis height information isrequired.
The stage can be equipped with linearscales.
They can easily adapt to both cameras CCTV's for photo documentationrequirements.
The toolmakers microscope offers a variety of optical techniques Moreover, it
canuseoptics, which offer higher magnification resolution for better
measuringaccuracy.
It is ideal for measurements of hardness testindentations.
APPLICATIONS:

Determining relativepositions

Here, the microscope is used elative positions of different points by simply measuring the travel
that is necessary for bringing a second point to the position that was formerly occupied by the
first and so forth.

Measuringangles

Using this microscope, it is possible to measure the angles by using the protractor eyepiece.
This allows for the angles of the object to be viewed and determined. This is where the
microscope is used to do comparison of the thread forms, measuring of the pitch and diameter.
Here, the microscope achieves this using the master profiles engravings in the eyepiece.

Comparing with ascale

This is where the images of the object are compared with the scale in the projection screen.

VIVA-QUESTIONS:

What are the applications of Toolmakersmicroscope?

State the principle involved in Toolmakersmicroscope?
How to change the magnification in Toolmakersmicroscope?
Experiment No. :

SURFACE ROUGHNESS MEASUREMENT

AIM:

To measure the surface roughness of a given specimen

APPARATUS: SURF TEST301

Introduction:

Surface Roughness is like a fingerprint left behind by the manufacturing process.

1. The surface irregularities of small wavelength are called primary texture or

roughness these are caused by direct action of the cutting elements on the material
i.e., cutting tool shape, feed rate or by some other disturbances such as friction, wear
orcorrosion.
2. The surface considerable wavelength of a periodic character are called secondary
texture or waviness. These irregularities result due to inaccuracies of slides, wear of
guides, misalignment of centers, non-linear feed motion, vibrations of any kindetc.

Elements of Surface Texture

Actual Surface: It refers to the surface of apart which is actually obtained after manufacturing
process.

Nominal surface: A nominal surface is theoretical, geometrically perfect surface which does
not exist in practice, but it is an average of the irregularities that are superimposed on it.
Profile: It defined as contour of any section through a surface.

Lay: It is the direction of predominant surface pattern produced by the tool marks or scratches,
generally surface roughness is measured perpendicular to the lay. Sampling Length: It is the
length of the profile necessary for the evaluation of the irregularities to be taken in to account

Roughness Height: This is rated as the arithmetical average deviation expressed in micro-
meters normal to an imaginary center line, running through the profile Roughness Width:
Roughness width is the distance parallel to the normal surface between successive peaks or
ridges that constitute the predominant pattern of the roughness.
Measuring instruments:

1. Profilograph

This is an optical instrument and is used for direct measure of the surface quality. The
principle of operation is shown in fig.1 A finely pointed stylus mounted in the pickup unit, is
traversed across the surface either by hand or motor drive. The work to be tested is placed on the
table of the instrument. It is traversed by means of a lead screw. The stylus, which is pivoted to
a mirror, moves over a tested surface. A light source sends a beam of light through lens and a
precision slit to the oscillating mirror. The reflected beam of light is directed to a revolving
drum, upon which a sensitized film is arranged. The drum is rotated through 2-bevel gears from
the same lead screw. A profilograph will be obtained from the sensitized film, that may be
subsequently analyzed to determine the value of the surfaceroughness.

2. Tomlinson surfacemeter

This is purely a mechanical lever operated piece of equipment. The diamond stylus on
 the recorder is held by spring pressure against the surface of a lapped steel cylinder. The stylus
attached to the bodyof the instrument by means of a leaf spring and it has some height
adjustment. The lapped cylinder is supported on one side by the stylus and on the other by two
fixed rollers as shown in fig.2
The stylus is restrained from all motions except the vertical one by the tension in the coil
and leaf spring. The tensile forces in these two springs also keep the lapped cylinder in
horizontal positon. Alight arm is attached to the lapped steel cylinder, and it carries at its tip a
diamond scriber which leans against a smokedglass.
While traversing across the surface of the job, any vertical movement of the stylus
caused by the surface irregularities causes the lapped cylinder to roll. Thus, vertical movement
coupled with horizontal movement produces a track on the glass magnifies in vertical direction
and there being no horizontal magnification.

3. Taylor-Hobson-Talysurf

Taylor-Hobson-Talysurfis a stylus and skid type of instrument working on carrier

modulating principle. Its response is more rapid and accurate as compared to Tomlinson
Surface Meter. The measuring head of this instrument consists of sharply pointed diamond
stylus of about 0.002mm tip radius and skip or shoe which is drawn across the surface by means
of a motorized drivingunit.
In this instrument the stylus is made to race the profile of the surface irregularities, and
the oscillatory movement of the stylus is converted in to changes in electric current by the
arrangement as shown in fig.3 The arm carrying the stylus forms an armature which pivots
about the centrepiece of E-shaped stamping. On two legs of (outer pole pieces) the E-shaped
stamping there are coils carrying an a.c current. These two coils with other two resistances form
an oscillator. As the armature is pivoted about the central leg, any movement of the stylus
causes the air gap to vary and thus the amplitude of the original a.c current flowing in the coils
is modulated. The output of the bridge thus consists of modulation only as shown in fig3 this is
further demodulated so that the current now is directly proportional to the vertical displacement
of the stylus. The demodulated output is caused to operate a pen recorder to produce permanent
record and the meter to give numerical assessmentdirectly.

DESCRIPTION OFSURFTEST SJ-301

The surftest SJ-301 is a stylus type surface roughness measuring instrument developed
for shop floor use. The SJ-301 is capable of evaluating surface texture with variety of
parameters according to various national standards and international standard. The
measurement results are displayed digitally/graphically on the touch panel, and output to the
built-inprinter.

The stylus of the SJ-301 detector unit traces the minute irregularities of the work piece

29
surface. Surface roughness is determined from the vertical stylus displacement produced during
traversing over the surface irregularities. The measurement results are displayed
digitally/graphically on the touch panel.
OBSERVATIONS:

Specimen. Ra Rq Rz Rt Rsk Rku

No. Microns Microns Microns Microns
1.
2.
3.

Result: The various roughness parameters for different specimens are tabulated.

ADVANTAGES:
The main advantage of such instruments is that the electrical signal available can be
processed to obtain any desired roughness parameter or can be recorded for displayor
subsequentanalysis.
Therefore, the stylus type instruments are widely used for surface texturemeasurements
inspite of the followingdisadvantages.
DISADVANGES:
These instruments are bulky andcomplex.
They are relativelyfragile.
Initial cost ishigh.
Measurements are limited to a section of a surface. (v) Needs skilled operatorsfor
measurements.
Distance between stylus and skid and the shape of the skid introduce errors in
measurement for wavysurfaces.
APPLICATIONS:
Low-coherence profilometersdeliver fast, reliable, and non-contact 3D surface
measurements – with precision better than 1 µm. Surfaces are rapidlycharacterized
in terms of shape, roughness, flatness, waviness, and other surfacequalities

High-speed scanning: 1,000 to 30,000 points/sec andhigher

Real-time feedback on manufacturing or coating processes: application data is

typically forwarded to process controlsoftware

Easy visual inspection: depth profiles, 2D cross-sections (B-scans or C-scans) and3D

surfacemaps.
VIVA –QUESTIONS:

Define the following terms a) Roughness b) Waviness c) Lay d) SamplingLength

Explain the terms Ra , Rz ,RMS.
What are the various methods of measuring surfaceroughness?
Explain the use of dial boregauge?
What is the principle involved in spritlevels?
What is primary texture?
What is secondary texture?
What isLay?
What do you mean by traversing length and sampling length?
Define Ra, Rq and Ry vi) What is calibration ? and why is it necessary for roughness
measurement?
Experiment No.:

MEASUREMENT OF SCREW THREAD PARAMETERS USING

TWO WIRE METHOD BY FLOATING CARRIAGE MICROMETER

Aim: To measure the screw thread parameters using two wire method by Floating carriage
micrometer.

Apparatus: Micrometer, micrometer stand, a set of two wires, pitch gauge and Screw thread
specimen.
Screw Threads Terminology:

Screw thread. A screw thread is the helical ridge produced by forming a continuous helical
groove of uniform section on the external or internal surface of a cylinder or cone. A screw
thread formed on a cylinder is known as straight or parallel screw thread, while the one formed
on a cone or frustum of a cone is known as tapered screw thread.
External thread. A thread formed on the outside of a work piece is called external thread
e.g., on bolts or studs etc.
Internal thread. A thread formed on the inside of a work piece is called internal thread e.g. on a
nut or female screw gauge.
Multiple-start screw thread. This is produced by forming two or more helical grooves, equally
spaced and similarly formed in an axial section on a cylinder. This gives a ‗quick traverse‗
without sacrificing core strength.
Axis of a thread. This is imaginary line running longitudinally through the centre of the screw.
Hand (Right or left hand threads). Suppose a screw is held such that the observer is looking
along the axis. If a point moves along the thread in clockwise direction and thus moves away
from the observer, the thread is right hand; and if it moves towards the observer, the thread is left
hand.
Form, of thread. This is the shape of the contour of one- complete thread as seen in axial
section.
Crest of thread. This is defined as the prominent part of thread, whether it is external or
internal.
Root of thread. This is defined as the bottom of the groove between the two flanks of
the thread, whether it be external or internal.
Flanks of thread. These are straight edges which connect the crest with the root.
Angle of thread {Included angle). This is the angle between the flanks or slope of
the thread measured in an axial plane.
Flank angle. The flank angles are the angles between individual flanks and the
perpendicular to the axis of the thread which passes through the vertex of the fundamental
triangle. The flank angle of a symmetrical thread is commonly termed as the half- angle of
thread.
Pitch. The pitch of a thread is the distance, measured parallel to the axis of the thread, between
corresponding points on adjacent thread forms in the same axial plane and on the same side of
axis. The basic pitch is equal to the lead divided by the number of thread starts. On drawings of
thread sections, the pitch is shown as the distance from the centre of one
thread crest to the centre of the next, and this representation is correct for single start as
well as multi-start threads.
Lead. Lead is the axial distance moved by the threaded part, when it is given one complete
revolution about its axis with respect to a fixed mating thread. It is necessary to distinguish
between measurements of lead from measurement of pitch, as uniformity of pitch measurement
does not assure uniformity of lead. Variations in either lead or pitch cause the functional or virtual
diameter of thread to differ from the pitchdiameter.
Procedure:
1. Fix the given screw thread specimen to the arrangementblock.
2. Measure the pitch of the given thread using pitch gauges and also note down theangle
of the thread based on Metric or WithWorth.
3. Measure the maximum diameter of the screw thread usingmicrometer.
4. Calculate the best wire to be used by using the givenequation.
5. Consider the available wires and fix the two wires to one end on micrometer Anvil and one
wire towards anotheranvil.
6. Measure the distance over the wire properly by usingmicrometer.
7. Calculate the effective diameter of the screwthread.
8. Find out the error in effective diameter of the screwthread.

Observations:
1. Least Count of theMicrometer= mm.
2. Initial error in themicrometer= mm.
3. Pitch of the threadp= mm.
4. Best size of the wire usedd= mm.

Results:
The following parameters are found as follows;
1. MajorDiameter= mm
2. MinorDiameter= mm
3. EffectiveDiameter= mm.

ADVANTAGES:
 Very accurate, assuming correct flank angle Can be used on all external threads
Suitable for machine set-up and processcontrol.
 Inspects full thread profile and pitch Can be used with a minimum of trainingAssuming
correct use of both GO and NO-GO gauges the component can be judged ‖good‖ or‖bad

 Measures the total thread geometry (diameters andpitch).

 When set up easy to use. Fixtures for both external and internalthreads.
 Suitable for machine set-up and processcontrol
DISADVANTAGES:
 Only suitable for external threads Requires a calculation to find the correct
measurement result Measuring wires must be bought to suit the relevant micrometer
spindle diameter N.B. there are 3 standard micrometer spindle diameters – Ø8mm
(5/16‖), Ø6,5 and Ø6,35 mm (1/4‖) ―Only‖ measures thread pitchdiameter.
 Only reveals if the component is ‖good‖ or ‖bad‖ – not the relationship to the tolerance Time
consuming when setting up the machine and performing process control Difficult/expensive
to calibrate Manufacturing tolerances and wear on the gauges usually give less tolerance on
the actual components to be inspected Can only be used for the specific thread and tolerance
stated on thegauge.
 Relatively expensive as it can only be used for the designatedthread.
 Requires a reference component for correct setup.
 One wrong dimension on the threaded component can give a false indication
i.e. an incorrect pitch will give a false reading as will an incorrect flankangle.
APPLICATIONS:

 Certify set plug gages and working thread pluggages

 Monitor the wear on working thread plug gages
 Monitor and control pitch diameter variation during threadfabrication
 Use in conjunction with Go and No Go ring gages to control thread sizes to the
most demandingspecification
 Determine out of roundness and taper that may exist in threadedparts
 Eliminate the cost and time involved in using outside calibrationservices
 Reducemeasurementtimetoafractionoftimenormallytakingusingthetraditional
three-wiremethod.

VIVA-QUESTIONS:

 What is the least count of dialindicator?

 Name some angle measuringdevices?
 Why do we use Feelergauges?
 What are slip gauges and why do we usethem?
 What are slip gauges and why do we usethem?
 Explain zero error and zero correction in case ofmicrometers?
 What are the precautions to be taken while using slipgauges?