Measurement of Threads and

Gears
Measurement of screw thread elements
• Measurement of screw thread elements is necessary not only for
manufactured components, but also for threading tools, taps, threading
hobs, etc.
Measurement of major diameter
• The simplest way of measuring a major diameter is to measure it using a screw thread
micrometer.
• While taking readings, only light pressure must be used, as the anvils make contact with
the screw solely at points and any excess application of pressure may result in a slight
deformation of anvil due to compressive force, resulting in an error in the measurement.
• However, for a more precise measurement, it is recommended to use a bench micrometer.
• A major advantage of a bench micrometer is that a fiducial indicator is a part of the
measuring system.
• It is thus possible to apply a pressure already decided upon by referring to the fiducial
indicator.
• However, there is no provision for holding the workpiece between the centres, unlike a
floating carriage micrometer. The inspector has to hold the workpiece by hand while the
readings are being taken.
Bench Micrometer
Contd…
• The machine is essentially used as a comparator.
• To start with, the anvil positions are set by inserting a setting cylinder.
• A setting cylinder serves as a gauge and has a diameter that equals the OD of the screw
thread being inspected.
• Now, the setting cylinder is taken out, the workpiece is inserted between the anvils, and
the deviation is noted down on the micrometer head.
• Since the position of the fixed anvil will remain unaltered due to the setting of the fiducial
arrangement, the movable anvil will shift axially depending on the variation in the value
of OD of the screw being inspected.
• In order to sense deviations on either side of the preset value, the movable anvil will
always be set to a position, which can detect small movements in either direction.
• The error, as measured by the micrometer head, is added to or subtracted from, as the
case may be, the diameter of the setting cylinder to get the actual value of OD.
Contd…
• Measurement of the OD of internal threads is trickier, as it is
cumbersome to take measurements using conventional instruments.
• An easier option is to employ some indirect measurement techniques.
• A cast of the thread is made, which results in a male counterpart of the
internal thread.
• Now, the measurement can be carried out using techniques used for
external threads. The cast may be made of plaster of Paris or wax.
Measurement of minor diameter
• The best way of measuring a minor diameter is to measure it using a
floating carriage micrometer.
• The carriage has a micrometer with a fixed spindle on one side and a
movable spindle with a micrometer on the other side.
• The carriage moves on a finely ground ‘V’ guideway or an anti-friction
guideway to facilitate movement in a direction parallel to the axis of the
plug gauge mounted between centres.
• The micrometer has a non-rotary spindle with a least count of up to 0.001 or
0.002 mm.
• The instrument is very useful for thread plug gauge manufacturers; in gauge
calibration laboratories, established under NABL accreditation; and in
standard rooms where in-house gauge calibration is carried out.
Contd…
• Minor diameter is measured by a comparative process, wherein small V-
pieces that make contact at the root of the threads are used.
• The selection of V-pieces should be such that the included angle of a V-
piece is less than the angle of the thread.
• V-pieces are placed on each side of the screw with their bases against the
micrometer faces.
• As in the previous case, the initial reading is taken by mounting a setting
cylinder corresponding to the dimension being measured.
• Then, the threaded workpiece is mounted between the centres and the
reading is taken.
• The difference in the two readings directly gives the error in the minor
diameter.
Measurement of effective diameter
• Since it is a notional value, it cannot be measured directly,
• To be determined by the means of measuring it in an indirect way.
• Thread measurement by wire method is a simple and popular way of
measuring the effective diameter.
• Small, hardened steel wires (best-size wire) are placed in the thread
groove, and the distance over them is measured as part of the
measurement process.
• There are three methods of using wires: one-wire, two-wire, and three-
wire methods.
One wire method
• If a standard gauge of the same dimension as the theoretical value of dimension over wire is
available.
• First of all, the micrometer anvils are set over the standard gauge and the
dimension is noted down.
• Thereafter, the screw to be inspected is held either in hand or in a fixture,
and the micrometer anvils are set over the wire.
• Micrometer readings are taken at two or three different locations and the
average value is calculated.
• This value is compared with the value obtained with the standard gauge.

• The resulting difference is a reflection of error in the effective diameter of the screw. An
important point to be kept in mind is that the diameter of the wire selected should be such that
it makes contact with the screw along the pitch cylinder.
Two wire method
• Two steel wires of identical diameter are placed on opposite flanks of
a screw
• The distance over wires (𝑀) is measured using a suitable micrometer.
• Then, the effective diameter,
• 𝐷𝑒 = 𝑇 + 𝑃
• where 𝑇 is the dimension under the
wires and 𝑃 is the correction factor.
• And, 𝑇 = 𝑀 − 2𝑑
• where d is the diameter of the best-size
wire.
Contd…
• These relationships can be easily derived by
referring to Figure.
• The two wires of identical diameter are so
selected that they make contact with the
screw thread on the pitch line.
• The aforementioned equations are valid
only if this condition is met.
• Since AG accounts for the correction factor only on one side of the screw, we have to
multiply this value by 2 in order to account for that on the opposite flank.
• Therefore, total correction factor is as follows:
• P = 2 AG = p/2 cot (x/2) − d[cosec(x/2) − 1]
• Although it is possible to measure the value of M, the distance over the wires, using a
handheld micrometer, this method is prone to errors.
Composite method of gear inspection
• Composite action refers to the variation in centre distance when a gear
is rolled in tight mesh with a standard gear.
• It is standard practice to specify composite tolerance, which reflects
gear runout, tooth-to-tooth spacing, and profile variations.
• Composite tolerance is defined as the allowable centre distance
variation of the given gear, in tight mesh with a standard gear, for one
complete revolution.
• The Parkinson gear testing machine is generally used to carry out
composite gear inspection.
Parkinson Gear Tester
• It is a popular gear testing machine used in metrology laboratories and
tool rooms.
• The gear being inspected will be made to mesh with a standard gear,
and a dial indicator is used to capture radial errors.
• A standard gear is mounted on a fixed frame, while the gear being
inspected is fixed to a sliding carriage.
• The two gears are mounted on mandrels, which facilitate accurate
mounting of gears in machines so that a dial indicator will primarily
measure irregularities in the gear under inspection.
Contd…
• A dial indicator of high resolution is used to measure the composite error, which reflects errors due
to runout, tooth-to-tooth spacing, and profile variations.
• To start with, the two gears are mounted on respective mandrels and the slide comprising the
standard gear is fixed at a convenient position.
• The sliding carriage is moved along the table, the two gears are brought into mesh, and the sliding
carriage base is also locked in its position.
• Positions of the two mandrels are adjusted in such a way that their axial distance is equal to the
gear centre distance as per drawings.
• However, the sliding carriage is free to slide for a small distance on steel rollers under a light
spring force.
• A vernier scale attached to the machine enables measurement of the centre distance up to 25 μm.
• The dial indicator is set to zero and the gear under inspection is rotated.
• Radial variations of the gear being inspected are indicated by the dial indicator.
• This variation is plotted on a chart or graph sheet, which indicates the radial variations in the gear
for one complete rotation.
Measurement of pitch
• Pitch is the distance between corresponding points on equally spaced
and adjacent teeth.
• Pitch error is the difference in distance between equally spaced
adjacent teeth and the measured distance between any two adjacent
teeth.
Pitch-measuring instruments
• These instruments enable the measurement of chordal pitch between
successive pairs of teeth.
• The instrument comprises a fixed finger and a movable finger, which can be
set to two identical points on adjacent teeth along the pitch circle.
• The pitch variation is displayed on a dial indicator attached to the
instrument.
• In some cases, the pitch variation is recorded on a chart recorder, which can
be used for further measurements.
• A major limitation of this method is that readings are influenced by profile
variations as well as runout of the gear.
Pitch-checking instrument
• A pitch-checking instrument is essentially a dividing head that can be used to
measure pitch variations.
• The instrument can be used for checking small as well as large gears due to its
portability.
• It has two probes— one fixed, called the anvil, and the other movable, called the
measuring feeler.
• The latter is connected to a dial indicator through levers.
• The instrument is located by two adjacent supports resting on the crests of the
teeth.
• A tooth flank is butted against the fixed anvil and locating supports. The
measuring feeler senses the corresponding next flank.
• The instrument is used as a comparator from which we can calculate the adjacent
pitch error, actual pitch, and accumulated pitch error.
Measurement with gear tooth callipers
• This is one of the most commonly used methods and perhaps the most accurate one.
• It has two vernier scales, one horizontal and the other vertical. The vertical vernier gives
the position of a blade, which can slide up and down.
• When the surface of the blade is flush with the tips of the measuring anvils, the vertical
scale will read zero.
• The blade position can be set to any required value by referring to the vernier scale.
• It is clear that tooth thickness should be measured at the pitch circle (chord thickness
C1C2 in the figure).
• Now, the blade position is set to a value equal to the addendum of the gear tooth and
locked into position with a locking screw.
• The calliper is set on the gear in such a manner that the blade surface snugly fits with the
top surface of a gear tooth.
• The two anvils are brought into close contact with the gear, and the chordal thickness is
noted down on the horizontal vernier scale.