ALAGAPPA CHETTIAR GOVERNMENT COLLEGE OF ENGINEERING AND

TECHNOLOGY- KARAIKUDI 630 003

(A Government Autonomous Institution, Affiliated to Anna University)

DEPARTMENT OF MECHANICAL ENGINEERING

22MEL55

METALLURGY AND METROLOGY LABORATORY

LABMANUAL

STUDENT NAME :

:
ROLL.NO / REG.NO

YEAR / SEMESTER :

ACADEMIC YEAR :
 CONTENTS

EX. Page
Date Name of the Experiment Marks Sign
NO No
 EX.NO: STUDY OF TERMINOLOGIES IN METROLOGY AND
DATE : MEASUREMENTS

AIM:
To study about the various terminologies used in Metrologyand measurements.

(1) Metrology:
Metrology is the science of measurement associated with the evaluation of its uncertainty.
Metrology is mainly concerned with the establishment reproduction, conservation and transfer
of units of measurement and their standards.

(2) Accuracy:
Accuracy is defined as the ability of instrument to respond to a true value of a measured
variable under the reference conditions. It refers to how closely the measured value appears
the true value.

(3) Precision:
Precision is defined as the degree if exactness for which an instrument is defined or intended
to perform. It refers to the consistency of measurement when the measurement is carried out
under identical conditions at a short interval of time.

(4) Repeatability:
Repeatability is the closeness of agreement among a number of consecutive measurements of
the output for the same value of input under the same operating conditions.

(5) Sensitivity:
Sensitivity of an instrument is defined as the ratio of the magnitude of output to the magnitude
of input variable to which the instrument responds.

(6) Error:
Error is the difference between the measured value and the true value.
Error = Measured value – True value
The error is measured can be expressed either as an absolute error or a relative error.

(7) Standard:
Standard is a physical representation of a unit of measurement. A known accurate
measurement of physical quantity is termed as standard. All instruments are calibrated at the
time of manufacture against measurement standard. A standard means known accurate measure
of physical quantity.

(8) Resolution:
The smallest change in a measured variable to which the instrument can respond is known as
resolution.
(9) Tolerance:
Tolerance can be designed as the magnitude of permissible variation of a dimension or other
measured or control criterion from the specified value. Tolerance has to be allowed because
of the inevitable human failings and machine limitations which prevent ideal achievements
during fabrication.

(10) Least Count:

The least value which can be measured by using any measuring instrument is known as least
count. (i.e.) It is the value of which the measurement can accurately be measured.

(11) Range of Span:

Range is the minimum and maximum values of a quantity for which an instrument is designed
to measure.

(12) Linearity:
The ability to produce the input characteristics symmetrically and linearly is said to linearity.
It can be defined as the maximum deviation of the output of the measuring system
from specified straight line applied to a plot of data points on curve of measured value
versus the measured input value.

(13) Hysteresis:
It is the difference between the indications of a measuring instrument when the same value of
the measured quantity is reached by increased or by decreasing that quantity. The
phenomenon of hysteresis is due to the presence of any friction as well as to the properties of
elastic elements.

(14) Roundness:
Roundness is defined as a condition of a surface of revolution (like cylinder, cone or sphere)
where all points of the surface intersected by any plane perpendicular to a common axis in
case of cylinder and cone are equidistant from the axis.

(15) Straightness:
A line is said to be straight over a given length if the variation of the distance of its points
from the planes perpendicular to each other and parallel to the general direction of the line
remains within the specified tolerance limits.

RESULT:
Thus the various terminologies in metrology and measurements are studied.
 EX.NO:. CALIBRATION AND MEASUREMENT OF GIVEN DATE:
SPECIMEN USING LINEAR MEASURING
INSTRUMENTS VERNIER CALIPER

AIM:

To calibrate and measure the dimension of givens specimen using linear measuring
instrument Vernier caliper.

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

1. Vernier Caliper (L.C=0.02mm, Range: 0 – 150mm)

2. Specimen

3. Surface plate

4. slipgauges

THEORY:

 The Vernier Caliper consists of two scales: one is fixed and the other is movable.
 Fixed and movable jaw: The fixed scale is called as main scale which is calibrated on L-
shaped frame and carries a fixed jaw. The movable scale, called vernier scale slides over the
main scale and carries a movable jaw. The movable jaw as well as the fixed jaw carries
measuring tip. When the two jaws are closed the zero of Vernier scale coincides with the zero
of main scale. For precise setting of the movable jaw an adjusting screw is provided.
 Lock nut: An arrangement is provided to lock the sliding scale on the fixed main scale.

 Graduated beam: Main scale markings are there on graduated beam.

 Blade or Depth probe: Measures depth..

 The two inner jaws areusedformeasuring tubediameters, inside tube diameters of any tubes or
pipes, and the outer jaws which are used to measureouter dimensionslike length, diameterof
tubes, and all these things.
Leastcount calculation

1 main scale division = 1 mm.

Thereis 50 equal division in verniear scale.

0-50 division in verniear scale is coinside with 49th division in mainscale 50

verniear scale division = 49 main scale division = 49 mm

∴ 1 vernier scale division = 49 mm=0.98 mm

50
Least count of vernier caliper = 1 main scale division -1 vernier scale division
=1mm - 0.98 mm =0.02 mm
∴ least count of vernier caliper =0.02 mm
CALIBRATION TABULATION:
Least Count Of Vernier Scale = 0.02 mm

S. Slipgauge Vernier scale reading in mm ERROR %

N reading OF
O Main Vernier Scale Vernier Total reading ER
scale Coincidence Scale =MSR +VSR R
reading VSC reading OR
MSR VSR = VSC X LC
mm mm div mm mm

AVERAGE

SPECIMEN MEASUREMENT TABULATION:

S.no Specimen Vernier scale reading in mm Actual

dimensio n
of the
Mainscale Vernier Scale Vernier Scale Total reading =MSR specimen
reading Coincidence reading +VSR
MSR VSC VSR = VSC X LC
mm
mm div mm

CALCULATION :

1) TR= [MSR + (VSC X LC)]

2) ERROR= Slip Gauge Reading – Total Reading
3) AR= TR±ERROR
TR- Total Reading
MSR-Main Scale Reading
VSC-Vernier Scale Coincide
LC-Least Count
AR-Actual reading
PROCEDURE :

1. Clean the measuring faces: Ensure that the measuring faces, including the jaws and the
depth probe, are clean and free from any debris or contaminants that may affect the
accuracy of measurements.

2. Open the caliper jaws: Slide the sliding beam away from the fixed jaw to fully open the
jaws. This creates a gap wide enough to accommodate the object you want to measure.

3. Position the object: Place the object you want to measure between the jaws of the
Vernier caliper. Make sure the object is positioned securely and centrally, so it doesn't
wobble or affect the measurement accuracy.

4. Close the jaws: Gradually slide the sliding beam towards the fixed jaw, closing the jaws
until they are snugly fitted around the object. Be careful not to apply excessive force that
could deform the object or damage the caliper.

5. Read the main scale: Look at the main scale on the fixed jaw and identify the marking
that aligns with the zero mark on the sliding beam. This gives you the whole number part
of the measurement.

6. Read the Vernier scale: Locate the Vernier scale on the sliding beam. Observe the
Vernier scale divisions and find the one that aligns most closely with a division on the
main scale. Note the Vernier scale value associated with this alignment

7. Determine the Vernier scale reading: Identify the difference between the Vernier scale
division and the corresponding main scale division. This difference represents the fraction or
decimal part of the measurement.

8. Add the readings: Add the main scale reading (whole number part) to the Vernier
scale reading (fraction or decimal part). This gives you the precise measurement
value.

9. Finalize the measurement: Depending on the desired unit of measurement (e.g.,

inches, millimeters), make sure to note the appropriate unit along with the
measurement value.
RESULT:

Thus vernier caliper instruments are calibrated and dimension of the given specimen is
measured.
 EX.NO.: CALIBRATION AND MEASURE OF GIVEN SPECIMEN DATE:
USING LINEAR MEASURING INSTRUMENTS
MICROMETER

AIM:
To calibrate and measure the dimension of givens specimen using linear measuring instrument
Micrometer

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

1. Micrometer (L.C=0.01mm, Range: 0 – 150mm)

2. Specimen

3. Surface plate

4. slipgauges

THEORY:

• The end of the screw forms one measuring tip and the other measuring tip is
constituted by a stationary anvil in the base of the frame.

• The screw is threaded for certain length and is plan afterwards. The plain portion is called
sleeve and its end is the measuring surface.

• The spindle is advanced by turning thimble connected to the spindle.

• The spindle is aside fit over the barrel and barrel is the fixed part attached with fraThe barrel is graduated
in unit of 0.05 cm.i.e.20 division per cm, which is the lead of the screw for one complete revolution.
• The thimble has got 25 divisions around its periphery on circular portion. Thus it sub- divides
each revolution of the screw in 25 equal parts; i.e. each division corresponds to
0.002 cm.

.
Leastcount calculation:

Least count = Pitch/No.of division on the circular scale

=
Pitch is defined as the one rotation of spindle or thimble how much linear distance it is travelled is called
pitch.

Pitch = Distance moved/No.of rotation

PITCH=0.5 mm

Least count = 0.5/50 = 0.01 mm

 ∴ least count=0.5/50=0.01 mm

PROCEDURE:

1. The micrometer is checked for zero error.

2. The given component is held between the faces of the anvil and spindle.

3. The spindle is moved by rotating the thimble until the anvil and spindle touches the
cylindrical surface of the component.

4. Fine adjustment is made by ratchet. The main scale reading and thimble scale reading are
noted.

5. Two are more reading are taken at different places of the component.

6. The readings are tabulated and calculated

CALIBRATION TABULATION:
Least Count Of screw gauge = 0.02 mm

S.NO Slip Micrometer reading in mm ERRO %

gauge R OF
reading Pitch scale Circular/hea Circular Scale Total reading ERROR
reading d Scale reading =PSR +CSR
PSR Coincidence CSR = CSC X
CSC LC
mm mm
mm div mm

AVERAGE

SPECIMEN MEASUREMENT TABULATION:

s.no dimension of micrometer reading in mm Actual

the Specimen dimension
of the
pitch scale Circular/head Circular Scale Total reading =PSR specimen
reading Scale reading +CSR
PSR Coincidence CSR = CSC X LC
CSC
mm mm
div
mm

CALCULATION :

1) TR= [PSR + (CSC X LC)]

2) % OF ERROR=SLIP GAUGE READING-TOTAL READING/SLIP GAUGE

READING
3) ERROR= Slip Gauge Reading – Total Reading
4) AR= TR±ERROR
TR- Total Reading
MSR-Main Scale Reading
VSC-Vernier Scale Coincide
LC-Least Count
AR-Actual reading

4
RESULT

Thus Micrometer instruments are calibrated and dimension of the given

specimen is measured.
EX.NO: CALIBRATION AND USE OF LINEAR MEASURING DATE :
INSTRUMENTS
BY MECHANICAL COMPARATOR

AIM:

To check the dimensions of a component with a standard dimension component using

mechanical comparator

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

1. Mechanical comparator
2. Dial indicator
3. Specimens
4. Slip gauge set

THEORY:

MECHANICAL COMPARATOR

It is one of the most widely used mechanical comparator.

It consists of a dial connected to plunger projecting at its bottom.

The plunger moves upward when a very slight upward pressure as applied. The mechanism
has a system connected to the toothed rack.

A compound gear is provided to connect toothed rack to pointer. A helical spring is used to
bring back the plunger to its original position. When pressure is released the pointer moves.
The indicator is adjusted to zero by rotating dial rim.

The minimum reading of dial is 0.01mm. A revolution counter in form of a small dial is
provided to indicate the total travel by stem.

Sequence of Operations:

1. Preparation: Ensure that the mechanical comparator is clean and in good working
condition. Check for any signs of damage or wear.

2. Mounting or attachment: Depending on the type of comparator, mount it onto a

suitable base or fixture. For example, a dial indicator may be attached to a magnetic
base or a mechanical height gauge may be mounted on a stable surface.

3. Positioning and alignment: Position the mechanical comparator in a way that

allows it to access the part or feature you want to measure. Align the comparator with
the surface or feature to be measured, ensuring proper contact and alignment.

4. Zero-setting: Set the indicator or reference point to zero or the desired reference
position. This can be done by rotating the dial face or using the zero adjustment
feature provided on the comparator.
 5. Measurement: Activate the measuring mechanism of the comparator. For example,
in the case of a dial indicator, apply gentle pressure to the contact point or probe,
allowing it to make measurement value indicated.

6. Repeatability and averaging: For increased accuracy, repeat the measurement

multiple times at different positions or orientations on the part or feature. Take care to
ensure consistent contact and alignment with each measurement. Average the
results to obtain the most accurate representation of the measurement value.

7. Recording and reporting: Record the measurement value, along with the
appropriate unit of measurement (e.g., inches or millimeters), and any other relevant
information for documentation or reporting purposes.

8. Maintenance: After use, clean the mechanical comparator and store it properly in a
protective case or box to prevent damage and maintain its accuracy.

Procedure:

1. Clean the instruments and its accessories by fine cotton cloths

2. Measure the basic size of the given specimen by using Vernier Caliper

3. Place the slip gauge on the mechanical comparator

4. Now set the basic size of the work piece in the mechanical comparator and set the dial
indicator in zero position and remove the slip gauge from the mechanical comparator

5. The given specimen is placed under the plunger of mechanical comparator and note
down the variation in height of the component is noted from reading of dial gauge.

6. The same procedure repeated for all the components respectively.

7. Tabulate the readings

RESULT :

The dimensions of the specimens were checked by using mechanical comparator

TABULATION:

Least count of Mechanical comparator= 0.001 mm

Sl.No Standard Mechanical ComparatorReading (mm) Actual Error Inference

Specimen Size
Dimension SCR LCR TR=(IDR+ODR)*LC Specimen
(mm)
div div mm

Calculation :
Actual Size Specimen(mm)= Standard Specimen Dimension ± Mechanical Comparator Reading
TR- total reading

IDR – Inner Dial Reading

ODR- Outer Dial Reading

10
 EX.NO.: MEASUREMENT OF GIVEN BORE USING DATE:
LINEAR MEASURING INSTRUMENT BORE
DIAL GAUGE

AIM:

To measure the diameter of the given bore using bore dial gauge

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

dial bore gauge, vernier caliper, workpiece

DESCRIPTION:

Dial bore indicator consists of dial test indicator, bore gauge and set of measuring heads and space washers.

Dial test indicator:

It is a small indicating device used for linear measurements. It uses mechanical means such as
gears and pinions or levers for magnification. It is a simplest type of mechanical comparator. It measures the
displacement of its plunger or a stylus on a circular dial by means of a rotating pointer. Dial indicator converts linear
displacement into a radial movement to measure over a small range of movement for the plunger. The radial arm
magnification principle is used here. These indicators are prone to errors caused by errors that are magnified through
the gear train.

Bore gauge:

It consists of one fixed measuring head and one movable measuring head. The horizontal
movement of measuring head is transmitted to dial indicator by push rod through a spring actuated hinged member.
Different lengths of measuring heads are provided to check different sizes of bores. The reading that is obtained from
the gauge is indicated by dial indicator. The reading in dial indicator is multiplied with its least count to get actual
deviation with respect to the nominal diameter of the bore. The actual size of the bore can be calculated by subtracting
the deviation from the nominal diameter.

PROCEDURE:

1. Mount the dial indicator on the bore gauge.

2. Measure the approximate diameter of the hole of the given specimen using vernier caliper.

3. Select the appropriate measuring head available from the set based on the reading
obtained from the vernier caliper.

4. Fix the selected measuring head in the instrument.

5. Now divide the given circular specimens bore into no. of equal parts.

11
TABULATION

s.no Specimen Vernier scale reading in mm Actual

dimensio
n of the
Mainscale Vernier Scale Vernier Scale Total reading =MSR specimen
reading Coincidence reading +VSR

MSR VSC VSR = VSC X LC

mm div mm mm

s.no BORE GAUGE READING (BGR) DIAL GAUGE READING Actual bore
(DGR) diameter
Anvil Washer TOTAL IDR ODR TR*LC =BGR-DGR
size size READING(TR)=Anvil (div) (div) (mm)
(mm) (mm) +washer

12
 6. Measure the diameters of the hole by dial bore gauge at different divisions and note
down the reading of the dial indicator.

7. Subtract the dial indicator readings from the nominal diameter of the bore to get the actual size.

RESULT :

Thus the given bore size is measured by using bore dial gauge.

13
19
 EX.NO: CALIBRATION AND MEASUREMENT OF GIVEN DATE:
SPECIMEN USING LINEAR MEASURING INSTRUMENT
DIAL HEIGHT GAUGE

AIM

To calibrate and measure the dimension of givens specimen using linear measuring instrument dial

height gauge.

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

1. Dial height gauge (L.C=0.01mm, Range: 0 – 300mm)

2. Specimen

3. Surface plate

4. slipgauges

THEORY:
Various types of height gauges are vernier height gauge, Dial height gauge,A digital 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
sliding jaw assembly arrangement is provided to carry a removable clamp.
 The upper and lower surfaces of the measuring jaws are parallel to base, so that it can be used for
measurements over or under surfaces. 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 certain distance above surface with a scribing
attachment in pace of measuring jaw.

 Dial height gauge consists of dial indicator instead of vernier.

 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.

PROCEDURE:

1. Clean the measuring faces of the dial height gauge to ensure accurate readings.

20
CALIBRATION TABULATION

S. SLIP DIAL HEIGHT GAUGE ERROR %

N
GAUG Main scale DIAL DIALGAUGE TOTAL OF
O
reading (Upper GAUGE READING READIN ERROR
E
counter) DIVISION G
DGR=DGD*LC
READI
MSR TR=MSR+DGR
N
G(MM) mm
DGD
mm mm
(DIV)

SPECIMEN MEASUREMENT TABULATION

S.NO SPECIME DIAL HEIGHT GAUGE ACTUA

N L
DIMENSI Main DIALGAUGE DIAL TOTAL HEIGHT
ON scale DIVISION GAUGE READIN
reading READING G
(Upper
DGD DGR=DGD*LC TR=MSR+DGR
counter)
(DIV) mm mm
MSR

mm

21
2. Lower the height gauge gently to touch the surface plate.

3. Reset to zero on counter and dial gauge.

4. Place the object on a flat, stable surface

5. Adjust the height gauge until it stands upright and stable on the object.
6. Take the reading in the upper counter and dial gauge.

22
CALCULATION :

1) TR= [MSR + (DGD X LC)]

2) ERROR= Slip Gauge Reading – Total Reading

3) % OF ERROR=SLIP GAUGE READING-TOTAL READING/SLIP GAUGE READING

4) AH = TR±ERROR
TR- Total Reading
MSR-Main Scale Reading
DGD- DIAL GAUGE DIVITION

LC-Least Count

AH-Actual HEIGHT

23
RESULT:

Thus INSTRUMENT DIAL HEIGHT GAUGE are calibrated and dimension of the given
specimen is measured.

24
25
 EX.NO. MEASUREMENT OF FLATNESS USING DATE
AUTOCOLLIMATOR
AIM
To check the flatness of the surface plate by using Autocollimator

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

1. Autocollimator

THEORY:
Definition of straightness of a line in two planes
A line is said to be straight over a given length, if the variation of the distance of its points from two
planes perpendicular to each other and parallel to the general direction of the line remains within the
specified tolerance limits; the reference planes being so chosen that their intersection is parallel to the
straight line joining two points suitably located on the line to be tested and the two points being close to the
ends of the lengths to be measured.

The tolerance on the straightness of a line is defined as the maximum deviation in relation to the
reference straight line joining the two extremities of the line to be checked shown in Fig.

It is a special form of telescope that is used to measure small angles with a high degree of resolution.
It is used for various applications such as precision alignment, verification of angle standards, and detection
of angular movement, among others. It projects a beam of collimated light onto a reflector, which is
deflected by a small angle about the vertical plane. The light reflected is magnified and focused on to an
eyepiece or a photo detector. The deflection between the beam and the reflected beam is a measure of the
angular tilt of the reflector.
 Figure illustrates the working principle of an autocollimator

The reticle is an illuminated target with a cross-hair pattern, which is positioned in the focal
plane of an objective lens. A plane mirror perpendicular to the optical axis serves the purpose
of reflecting an image of the pattern back on to the observation point. A viewing system is
required to observe the relative position of the image of the cross-wires. This is done in most of the
autocollimators by means of a simple eyepiece.
If rotation of the plane reflector by an angle ϴ results in the displacement of the image by an
amount d, then, d = 2fϴ, where f is the focal length of the objective lens.
It is clear from this relationship that the sensitivity of an autocollimator depends on the focal
length of the objective lens.
Autocollimators may be classified into three types:
1. Visual or conventional autocollimator
2. Digital autocollimator
3. Laser autocollimator
4. Visual Autocollimator
In this type of autocollimator, the displacement of the reflected image is determined visually.A
 pinhole light source is used, whose reflected image is observed by the operator through an eyepiece.
Visualcollimators are typically focused at infinity, making them useful for both short and long-distance
measurements. The plane reflector is one of the vital parts of an autocollimator, because a mirror that is not
flat will defocus the return image, resulting in poor definition of the image. High-quality mirrors with a
flatness tolerance of 1 μm per 100 mm are used. Most visual collimators have a resolution of 3–5" over a
distance of 1.5 m.
The following are some of the typical applications of visual autocollimators:
1. Determination of angular measurements up to 3"
2. Determination of straightness of machine guideways
3. Determination of parallelism of slide movements with respect to guideways
4. Flatness estimation of machine tables, surface plates, etc.
5. Verification of right angle prisms for angular errors
6. Angle comparisons of reflecting surfaces

Auto-collimator is basically a telescope permanently focused for infinity. This is a sensitive extremely
accurate optical instrument which is used in workshops for inspecting straightness, squareness and
parallelism. The instrument uses the basic principle of reflection. A plane parallel beam of light projected on
to a plane reflecting surface placed normal to the beam is reflected back along the same path. When the
surface is slightly tilted the reflected beam returns but in deviated path. The angle of direction is taken as a
measure to check the straightness.
PROCEDURE:
 Set mirror on slide.
 Adjust autocollimator to the mirror.
 Move the slide and observe the autocollimation image.
 Each tilting of the mirror in the guiding direction effects a y-displacement of the autocollimation image from the
zero-position.
 A tilting vertical to the guide can be tested by a rectangular prism instead of a mirror.
 Move the mirror by the base length of the mirror (100 mm or 50 mm) and read out each difference ∆θy or ∆y 0 to
the previously recorded value.
 The local slope m of the slide is determined by: m = ∆y 0 or m = tan ∆θy ≈ ∆θy
2f
TABULATION:
S.no Detail Position

A B C D E

Read out angle by

autocollimator(difference
from the read out angle )

Sl. Position Reading ϴ Difference Rise or Cumulative Adjustment Error

No betweenfirst fall in rise or fall to bring
reading interval bothto zero
mm

sec Radian μ μ μ
Calculation °
: 1 sec = 1
=2.77×10−4 °
3600
π
1 degree = rad
180
1 sec =4.848×10−6 rad

1 micron (1μ) = 1
mm
1000
RESULT :
The flatness of the surface plate checked by using autocollimator
 EX.NO MEASUREMENT OF SPUR GEAR TOOTH PARAMETERS DATE:
: USING GEAR TOOTH VERNIER CALIPER

AIM:
To measure the spur gear parameters using gear tooth vernier caliper.

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

 Gear tooth vernier caliper

 Surface plate

THEORY:

1. Gear tooth vernier caliper having two scales.

2. One scale is located at horizontal direction and another scale is located in vertical direction. Both horizontal
and vertical scales have a fixed mainscale. In the vertical vernier scale the measuring plate is attached.

3. Vernier scales are move with respect to the main scale. The horizontal scale is used to find out thickness of
gear tooth.

4. The vertical scale is used to find out the depth of gear tooth. The vertical vernier scale the measuring plate is
attached and on the horizontal scale
Gear Parameter Measurement

TABULATION:

S.no GEAR Vernier scale reading in mm

PARAMETER
Main Vernier Vernier Scale Total reading
scale Scale reading =MSR +VSR
readi Coincidenc VSR = VSC X
ng e VSC LC
MSR mm
div mm
mm
OUTSIDE
DIAMETER
GEAR TOOTH
THICKNESS
DEPTH OF
GEAR TOOTH
 PROCEDURE :

1. The very first step is to find the blank diameter of this gear using vernier caliper and to calculate its number
of teeth.

2. find out the gear tooth thickness as well as the depth of gear tooth.

3. The measuring plate of vertical vernier scale is perfectly landed, perfectly touches top land of gear tooth and
the horizontal vernier scale with respect to main scale so perfectly touches with its root position. So in one
pass we can calculate its tooth thickness and depth of gear tooth.

4. lock the position with the help of lock nut

5. Calculate the gear tooth thickness by observe the readings on a horizontal main scale and vernier scale and
depth of gear tooth can be measure on a vertical scale.

6. Calculate the other gear parameter using the relation.

GEAR PARAMETERS:

s.no Parameter Measured value

1. Outside Diameter
2. Tooth Thickness
3. Depth Of Gear
4. PCD
5. Module
6. Cicular Pitch
7. Addendum
8. Dedendum
9. Clearance

RESULT:
Thus gear parameter are measured and calculated using gear tooth vernier caliper.
15
15
 EX.NO: ANGULAR MEASUREMENT USING BEVEL DATE:
PROTRACTOR
AIM:
To measure the angle in the given work piece using Bevel Protractor.

TOOLS/EQUIPMENT/APPARATUS/ MATERIALS REQUIRED:

1. Bevel Protractor

2. Work piece
THEORY:

The universal bevel protractor with a 5' accuracy is commonly found in all tool rooms and
metrology laboratories. It has a base plate or stock whose surface has a high degree of flatness and surface
finish. The stock is placed on the workpiece whose angle is to be measured.An adjustable blade attached to a
circular dial is made to coincide with the angular surface. It can be swiveled to the required angle and locked into
position to facilitate accurate reading of the circular scale that is mounted on the dial. The main scale on the dial
is graduated in degrees and rotates with the rotation of the adjustable blade. An acute angle attachment is
provided for the measurement of acute angles.The main scale on the dial is divided into four quadrants, each
measuring 90°.Each division on this scale reads 1°. The degrees are numbered from 0 to 90 on either side of the
zeroth division. The vernier scale has 24 divisions, which correspond to 46 divisions on the main scale.
Least count calculation

1 main scale division = 1°

24 vernier divisions correspond to 46 main scale divisions.

There is 24 equal division in verniear scale.

0-24 division in verniear scale is coinside with 46th division in mainscale

24 verniear scale division = 46 main scale division = 46 °

∴ 1 vernier scale division = 46° = 23°

24 12
Least count of vernier caliper = 2 main scale division -1 vernier scale division
1°
=2 °- 23° = = 5´
12 12

1°
∴ least count of Bevel Protractor= = 5´
12

16
SPECIMEN MEASUREMENT TABULATION:
Least count = 5 mins

S.no Workspiece Bevel protractor

Main Vernier Scale Vernier Scale Total reading

scale Coincidence reading =MSR +VSR
reading VSC VSR = VSC X
MSR LC
‘deg’
degree div min

17
 PROCEDURE :

1. The appropriate size blade to suit the given job was fixed and locked.
2. The job / component were 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.
5. the procedure was repeated to find out all the required angles.

RESULT:
The angle of the given work piece was measured using Bevel protractor Angle of the given work piece

= degree
18
 EX.NO. MEASUREMENT OF ANGLE USING SINE BAR DATE:

AIM:

To measurethetaper angleofthegiven specimen using bevelprotractor/sine bar.

TOOLS/EQUIPMENT/APPARATUS/MATERIALSREQUIRED:

1. BevelProtractor

2. Sine bar

3. Slipgauge set

4. Surface plate

5. Dialgaugewithstand

THEORY:

SURFACE PLATE

The foundation of all geometric accuracy and indeed of all dimensional measurement in workshop
is surface plate. It is a flat smooth surface sometimes with leveling screws at the bottom.
SINEBAR

A sine bar consists of a hardened, precision ground body with two precision ground
cylinders fixed at the ends. The distance between the centers of the cylinders is precisely controlled,
and thetopofthe bar is parallel to a line throughthe centersof the two rollers. The dimension between
the two rollers is chosen to be a whole number (for ease of later calculations) and forms the hypotenuse
ofa trianglewhen in use. Whena sine bar is placedona level surfacethe top edge will be parallelto that
surface. Ifone roller is raised bya knowndistance, usuallyusinggauge blocks, thenthetopedgeofthe bar
will be tilted bythe same amount forming an angle that may be calculated by theapplication of the sine
rule.
SLIP GAUGES

Theyarerectangular blockshardenedandcarefullystabilized. Thesurfaces arehighly

polished to enhancewringing. It is usedas a referencestandard for transferring the dimensions of
unit of length from primary standard. It is generally made up of high carbon, high chromium
hardened steel.

SINE BAR

1. Preparation:

Ensurethat thesine barandtheworkpiecearecleanandingoodworkingcondition. Check for any

signs of damage or wear.

2. Mounting: Securelymountthe sine bar ona flat andstable surface, such as a surface plate or
worktable.

3. Setting the reference angle: Determine the reference angle you want to set on the sine bar. This is
typically specified in the experiment or application. It could be a specific angle or the complementary
angle of the desired angle.

4. Calculation: Calculate the distance between the two parallel surfaces of the sine bar that
corresponds to the desired reference angle. This can be done using trigonometric functions or by
referring to tables or formulas specific to the sine bar.

5. Levelling: Use a spirit level or other leveling tool to ensure that the sine bar is parallel to the
horizontal plane. Make any necessary adjustments to achieve a level position.

6. Placing the workpiece: Position the workpiece on the sine bar, ensuring that it makes proper
contact with both parallel surfaces. The workpiece should be securely clamped or held in place.
7. Measurement: Use a height gauge or other precision measuring instrument to measure the height
difference between the workpiece and the reference surface of the sine bar. This height difference
corresponds to the angle set on the sine bar.

8. Calculation of the angle: Calculate the angle of the workpiece based on the height difference
measured andtheknown referenceangle. Usetrigonometricfunctionsortables specific to the sine
bar to determine the angle.

9. Repeatability: Repeat the measurement process multiple times at different positions along the
workpiece to ensure consistency and accuracy. Check the measurements against each other
to verify the angle or make necessary adjustments.

10. Recordingandreporting: Recordthemeasured angle, alongwiththeappropriateunit of

measurement (e.g., degrees), and anyother relevant information for documentation or reporting
purposes. 24

11. Maintenance: After use, cleanthe sine barand theworkpiece, andstorethemproperly in a

protective case or box to prevent damage and maintain their accuracy
TABULATION:

S Slip GaugeSetting Slip Gauge Angle2θ Semi- taperangle

. for h1 Settingforh2 (Radian)
N
O Θ Radian

AVERAGE

FORMULA USED:

Sin 2Θ = h1-h2/l

Where
h1 =heightofslipgaugesetting 1
h₂ = height of slip gauge setting 2
Θ= Required angle
L= lengthof thesine bar betweensupport points
RESULT:

Thetaper angle ofthe given specimen is measured using sine bar.

 Ex.No. NON CONTACT MEASUREMENT USING Date:
PROFILE PROJECTOR

AIM:

To measure the fundamental dimensionso f gear by non-contact measurement using profile projector.

TOOLS/EQUIPMENT/APPARATUS/MATERIALSREQUIRED:

1. Profile Projector.

2. Gear.

SPECIFICATIONS:

Type : Floor type with vertical optical axis

Screen: Screen inclination, Screensize, and Lens magnification. Contour

projector magnification accuracy = ±0.1%

Micrometer Head= 0-25 mm L.C=0.1

mm

Colourilluminator= 150/250 W

Halogen Magnification= 10x, 20x, 50xlenses Theory:

By using lenses and beams of light, profiles of small shapes can be magnified. The enlarged
image can be compared with accurate drawing made to the scale of magnification. Such a
comparison can reveal any deviations in the sizes and contours of the objects and to get a numerical
assessment of such deviations, measurements can be made on the enlarged shadow. The measured
dimensions on the shadow will then have to be divided bythe multiplication factor. The projection
apparatusused forthis purpose is termed as anopticalprofile projector. The essential featuresofa
profile projector arethat, it should be accuratelyas stated and that there should be maximumlatitudein
holdingand adjusting the work piece and examining the projected shadow.
Sequenceof Operations:

1. Preparation: Ensure that the profile projector is clean and free from any dust or debris. Check that
the projector's light source is functioning properly and adjust the intensity of illumination as needed.
Set up the profile projector on a stable surface or mount it on a stand if necessary.

2. Calibration:Calibratetheprofileprojectorbyusinga knowncalibrationartifactor standard

gauge block to verify the accuracy of the measurements. Adjust the magnification and
focus settings to ensure clear and sharp images.

3. Workpiece Setup: Securely mount theworkpieceor object to be measuredonthe stage ofthe

profile projector using clamps, holders, or fixtures. Positiontheworkpiece so that the featureor
profile to be measured is aligned with the projection path of the profile projector.

4. Alignment and Focus: Adjust thepositionandorientationoftheworkpiece, ifnecessary, to align

the feature of interest with the center of the projection screen. Use the focus adjustment controls to
obtain a clear and sharp image of the profile on the projection screen.

5. Measurement and Inspection: Observe the magnified profile image on the projection screen
and compare it with the desired specifications or reference templates. Use the reticle or graticule
lines on the projection screen to measure dimensions, angles, odeviations from the desired
profile. Adjust the workpiece position and orientation as needed to measure various sections or
features of the object.

6. Documentation: Record the obtained measurements, observations, or deviations in a suitable

data sheet or documentation system. Take photographs or capture images of the profile projector
screen if necessary for further analysis or documentation.

7. Post-Measurement or Inspection: Carefully remove the workpiece from the profile

projector stage, taking care not to damage the object or the instrument. Clean the projection
screenand anyother componentsthat mayhave come into contact withthe workpiece. Storethe
profile projectorin a safeandproper location to prevent damageor contamination.

PROCEDURE:

1. Therequired Magnificationadapterisfixed inthe centerprojector.

2. Thespecimen gear is placed on theglassplateand perfectly focused on the

screen.

3. Theprofileofspecimengear istraced ona tracing paper is fixed onthe

screen using pencil.

4. Then the angle between the two reference surface and dimension are measured
usingtable micrometer and the Rotatethe table screen circular scaleand are tabulated.

5. Thentheotherparameterslike geartooththickness, depthand pitchwill be measured

by adjusting the micrometer in X-axis and Z-axis direction respectively.
TABULATION:

S.N Dimensionto be Initial Point (mm) Final Point Difference

O measured (mm)
RESULT:

Thusthe fundamentaldimensions of gearare measured by non-contact

measurement using profile projector.
 EX.NO: MEASUREMENT OF SURFACE FINISH IN MANUFACTURED DATE:
COMPONENTS

AIM:
To study of surface finish tester and roughness & texture of specimen to be measured by mitutoyo
surftest SJ-210

SURFACE TEXTURE:
Surface texture is a term used to describe the physical characteristics of a surface, including its small-
scale irregularities and patterns, which affect how the surface interacts with other materials and its
overall quality[1]. Surface texture is composed of two main elements: waviness and roughness, as
illustrated in your image.
Components of Surface Texture
Roughness: These are the finer irregularities present on the surface, usually formed during
manufacturing processes such as machining or grinding. Roughness is defined by parameters like
roughness height and width, indicating the amplitude and spacing of the microscopic peaks and
valleys
Waviness: These are larger, more widely spaced irregularities, caused by factors like vibration,
deflection, or wear during manufacturing. Waviness has its own height and width, which are greater
than those of roughness
Lay direction: This refers to the predominant direction of the surface pattern, often resulting from the
movement of the tool during machining processes.

Surface Texture Parameters

Roughness height: The vertical distance from the highest peak to the lowest valley within the
roughness.
Roughness width:The horizontal spacing between adjacent peaks or valleys in the roughness profile.
Waviness height:The vertical distance from the highest peak to the lowest valley in the waviness
profile, which is usually much greater than roughness height.
Waviness width:The horizontal spacing between adjacent peaks or valleys in the waviness profile.
Roughness-width cutoff: The point that separates roughness from waviness, used for analysis and
measurement[1].
FORMULA
The texture of a surface is given by:
Texture = Waviness + Roughness

Both waviness and roughness contribute to the overall surface texture, which is essential in
determining functional properties such as friction, lubrication, and wear resistance[1]. The presence of
flaws (such as scratches or pits) also affects the texture, and accurate measurement is key for quality
control in engineering applications.

SURFACE TEXTURE SYMBOLS:

The image explains the standard surface texture symbol as defined by ASME Y14.36 (1996). This
symbol is used in engineering drawings to specify surface finish requirements.

Surface Texture Symbol Structure

The symbol consists of two legs joined at a 60-degree angle.
The height parameters, such as 1.5H and 3H,refer to proportionate dimensions, where H is the
lettering height in the drawing.
The basic symbol is placed on the edge view of the surface to indicate where the surface finish
specification applies.
Additional text or symbols may be added above or below to provide further instructions about
acceptable finishing processes or required roughness value.

KEY DETAILS:
Angle: Both arms are at 60 degrees from the baseline.
Height: H is defined as the standard height for lettering on drawings.
Application: Indicates required surface texture (like machining, grinding, etc.), and special
instructions may be included above this symbol.
The symbol may be used with additional lines or marks (as shown below in the image) to specify
further details about the finish.

This symbol standardizes how surface finish instructions are communicated on technical drawings,
ensuring clarity and uniformity in manufacturing[1].The image shows the standard surface texture
symbol per ASME Y14.36–1996[1].

The symbol is formed by two lines at a 60° angle, joined above the surface's edge view.
Lettering height (H) is a reference for sizing the symbol elements in technical drawings.
The symbol may include extra features (like added lines or numbers) beneath or beside it to specify
finish details, such as process or roughness value.
Dimensions like 1.5H and 3H in the diagram indicate standardized proportions for clarity and
consistency on engineering documents.

This symbol is widely used to indicate surface finish requirements on manufactured parts

Surface finish symbols define the required texture, roughness, and machining process for a part.

Ra (Roughness Average) – Indicates the required surface smoothness.

Machining Symbols (◻, ◻, ◻) – Defines milling, grinding, or turning processes.
Coating and Plating Indicators – Specifies anodizing, galvanizing, or painting requirements.
Lay Symbols (↔, ◻, ◻) – Show the direction of machining marks.

Proper surface finish ensures optimal performance, durability, and appearance in custom CNC
machining applications.
 MILLING AND LATHE:

This image compares the surface texture directions created by two different machining processes.

Milling:The tool moves in a straight line, producing parallel creases on the workpiece's surface. The
symbol in the drawing indicates these parallel marks, illustrating the milling process.
Turned on a lathe:The workpiece spins while a tool shapes it, producing circular or spiral marks. The
associated symbol shows these concentric creases, typical of lathe turning.
Each symbol visually communicates the dominant direction of tool marks, helping machinists and
quality inspectors identify the process used and understand the surface finish requirements on
engineering drawings

SURFACE ROUGHNESS PARAMETERS:

The most important parameters are:

Ra (Average Roughness): The arithmetical mean of absolute values of the surface deviations. Widely
used parameter that provides a general measure of surface texture.

Rz (Mean Roughness Depth): The value of the mean level of roughness accepted in measurement
units.
Rt (Total Roughness): The measured distance from the highest peak to the deepest valley throughout
the length of the measurement.
Rq (Root Mean Square Roughness): The standard deviation of the mean level of squares of the
surface deviations.

Depending on the accuracy needed for a particular application, these measurements are often done in
micrometers (µm) or nanometers (nm).

SURFACE FINISH TESTER:

A surface finish tester is an instrument used to measure the roughness and texture of a surface, critical
for quality control in manufacturing and engineering applications
Working principle of Tracing the surface: A precision stylus, often with a very fine tip, is traced
across the surface of the material being tested.
Recording vertical movement: As the stylus moves, its vertical movement up and down the surface
is detected by a sensor.
Signal generation: Different types of sensors convert this mechanical movement into an electrical
signal
Inductance-type: A stylus-driven armature causes the air gap in an inductor to change, which varies
the inductance and creates a signal proportional to the vertical displacement.
Piezoelectric pickup: A piezoelectric sensor converts the stylus's vertical motion directly into an
electrical signal.
Amplification and processing: The electrical signal is amplified to a measurable level.
Calculation of roughness parameters: The amplified signal is then processed by a microprocessor,
which uses standardized algorithms to calculate surface roughness parameters such as \(R_{a}\)
(average roughness).
Display: The final results, sometimes with a visual profile of the surface, are displayed on a screen or
recorded for analysis.
PROCEDURE:
The procedure to measure surface roughness with the Mitutoyo Surftest SJ-210 is as follows:

1. Power on the Surftest SJ-210 device.

2. Press the menu button and select "Measurement condition."
3. Go to "Setting" and define the standard for measurement. Choose the applicable industrial standard
such as ISO.
4. Select the measurement profile to measure surface roughness parameters.
5. Define the roughness parameters. The SJ-210 supports various parameters; use a Gauss filter for
measurement.

6. Set the filter value (Lambda C, the cutoff value) according to the tolerance specified in the
technical drawing or as per ISO 4288 guideline. For example, use 0.25.
7. The SJ-210 automatically selects Lambda S according to the cutoff value.
8. Set the number of sampling lengths (default is 5 in ISO standard, which can be adjusted).
9. Optionally, enable or disable detector travel before and after measurement, and adjust measuring
speed or range based on measurement position.
10. Press the start button. The drive unit traces the surface, and the device shows the roughness profile
on the display.
11. Use the page button to view detailed roughness profile and other measurement data.
12. For subsequent measurements, settings are remembered, so you do not need to repeat
configuration.

This procedure is designed to be quick and easy to follow for on-site surface roughness measurement
with the portable Surftest SJ-210 instrument
RESULT:
Thus the study of surface finish tester and roughness & texture of specimen to be measured
successfully by mitutoyo surftest SJ-210