1.

CALIBRATION OF PRECISION MEASURING INSTRUMENTS

Aim: To study and calibrate the precision measuring instruments like Vernier caliper, Micrometer, and Dial gauge. Apparatus Required: Surface plate, Vernier caliper, Micrometer, Dial gauge, and Slip gauges. Specification: Vernier caliper Micrometer Dial gauge Study: 1.) Vernier caliper: Range: Range: Range: L. C: L. C: L. C:

LEAST COUNT = 1 Main scale division 1 Vernier scale division It is used to measure the external diameter, the internal diameter and the length of the given specimen. 2.) Micrometer: The micrometer has an accurate screw having about 10 to 20 threads/cm and revolves in a fixed nut. The end of the screw is one tip and the other is constructed by a stationary anvil.

Uses: Outside micrometer is used to measure the diameter of solid cylinder. Inside micrometer is used to measure the internal diameters of hollow cylinders and spheres. 3.) Dial gauge:

LEAST COUNT = Pitch scale division / Number of threads Pitch scale division = Distance moved / number of rotation

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Uses:

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The Vernier caliper has one L shaped frame with a fixed jaw on which Vernier scale is attached. The principle of Vernier is that when two scale divisions slightly different in sizes can be used to measure the length very accurately. Least Count is the smallest length that can be measured accurately and is equal to the difference between a main scale division and a Vernier scale division.

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The dial gauge has got 2 hands. The short hand reads in mm. One complete revolution of long hand reads one mm. The plunger of the dial gauge has to be placed on the surface whose dimension has to be read. Least Count = One division of the circular scale with long hand. Uses: It is used as a mechanical comparator. 4.) Slip gauges: They are rectangular blocks hardened and carefully stabilized. The surfaces are highly polished to enhance wringing. It is used as a reference standard for transferring the dimensions of unit of length from primary standard. It is generally made up of high carbon, high chromium hardened steel. Uses: These are accurate and used as comparator. 5.) 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. It is used as a base in all measurements.

S.No

Slip Gauge Reading (Actual) In mm

MSR (mm )

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Procedure For Calibration: 1.) The range of the instruments is noted down. 2.) Within that range, slip gauges are selected. 3.) The measuring instrument is placed on the surface plate and set for zero and the slip gauges are placed one by one between the measuring points (jaws of the instruments.) 4.) The slip gauge (actual) readings and the corresponding (observed) readings in the measuring instruments are noted down and tabulated.
Precision Measuring Instruments Reading (Observedl) in mm Vernier Caliper Micro Meter Dial Gauge VSR (div) TR (mm ) Error (mm ) PSR (mm ) HSR (div) TR (mm ) Error (mm ) SHR (mm ) LHR (div) TR (mm ) Error (mm)

1 2 . . 10 Result:

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Uses:

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The precision measuring instruments are studied and calibrated. Calibration graphs are then drawn for all measuring instruments between 1.) Actual value and Observed value. 2.) Actual value and Absolute error. 2(a). MEASUREMENT OF DIMENSIONS OF A GIVEN SPECIMEN USING SLIP GAUGE Aim: To Check the Various Dimensions of a Part Using Slip Gauge Apparatus Required: . Surface Plate, Dial Gauge With Stand, Slip Gauge, Part(Specimen) : Range:_______ L.C. :________mm

Procedure:

1. The part whose dimensions are to be measured is placed on the surface plate. 2. The spindle of the dial gauge is placed over the part and dial gauge is fixed on the stand such that the short and long handoff the dial gauge sows zero readings. 3. Then the part is removed and the slip gauges are placed one over another on the surface plate below the spindle of the dial gauge until the hands of the dial gauge deflect from zero reading.

6. Trial readings are noted down for various initial setup levels of the dial gauge On the stand. Result: The various dimensions of the given Part measured are: A B C : __________mm : __________mm : __________mm

5. The required dimensions of the part is measured by finding out the total Height (Thickness) of the slip gauges.

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4. This ensures that the dimensions achieved by slip gauges and the part is same.

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Specification: Dial Gauge

2(b). CHECKING THE SQUAREESS OF TRY SQUARE USING SLIP GAUGE Aim: To test the square ness of the given try- square. Instruments Required: Surface plate, Angle plate, Try Square, Slip Gauge, Vernier Height Gauge Specification: Try square : Vernier Height Gauge : Least Count Formula: Deviated angle from square ness : 0-15 Cm 0-30 Cm 0.02 mm

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= tan-1 T2- T1 --------H2- H1

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in

Procedure:

1. The given try square and angle plate are placed on the surface as shown. 2. At both ends of angle plate, slip gauge are rung so that they project to equal thickness. 3. If try square is with square ness, then its vertical limp with co-line with both sets of slip gauges. 4. If there is any error in square ness, then vertical limp will not touch any one set of the slip gauge. 5. If so, then thickness of set slip gauges is increased/ decreased so that try square is perfectly aligned. 6. Then thickness of slip gauge is measured t1 and t2. 7. The height level of the set of slip gauge are measured using Vernier height gauges h1 and h2. 4

Where, T1 & T2 are thickness of the slip gauges and bottom and top levels resp.in mm H1 & H2 are the height level of the slip gauges and bottom and top levels resp.in mm

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Degree

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8. This procedure is repeated for different height level of the set of slip gauge.

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Thickness Thickness at top t1 at Bottom t2 (mm) (mm)

Differenc e t2 - t1 (mm)

Height of Bottom h1 (mm)

Height of toph2 (mm)

Differenc e h2 - h1 (mm)

in Deg

1 2 3

Result:

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Thus square ness of try square is tested.

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3(a). MEASUREMENT OF GEAR PARAMETERS USING GEAR TOOTH VERNIER Aim: To measure gear parameter by gear tooth Vernier. Apparatus required: Gear tooth Vernier, Gear specimen.

Formula: 1. 2. W d = =

NM sin (90/N) NM --------2

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1 + 2 / N cos( 90 / N )

3.

D = Chordal addendum of gear in mm M = Module of gear in mm N = NO. Of teeth D = out side Dia in gear in mm Procedure: 1. The N, D of the given gear block are measured. 2. The module m it then calculated.

Where W = Chordal width of tooth in mm

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D ------------(N+2)

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L.C

= 0.02 mm

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Vertical = 0-20 mm

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Gear tooth Vernier: Range = Horizontal =0-40 mm

Specification:

3. Theoretical values of W andd are computed. 4. Theoretical values of W is set in horizontal Vernier scale of gear tooth Vernier and corresponding actual d value scale. 5. Theoretical values of c is set and W is measured along Horizontal scale. 6. This procedure is repeated for 5 teeth and value tabulated. Outside Diameter of Gear TRIAL 1 2 3 4 5 OUT SIDE DIAMETER D mm

Trial 1 2 3 4 5 6 7

Result: Thus the chordal thickness and addendum of gear are measured using gear tooth Vernier.

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Chordal addendum d mm Actual . Theoretical

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Measurement of Addendum and Chordal Width

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Actual Chordal width w mm Theoretical

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The actual values are W = D= 3(b). MEASUREMENT OF FUNDAMENTAL DIMENSIONS OF A GEAR SPECIMEN USING CONTOUR PROJECTOR Aim: To measure the fundamental dimensions of a gear using contour (profile) projector. Apparatus Required: Contour projector Gear specimen Vernier caliper. Specifications: Contour projector:

Vernier caliper: Formulae: m = D/ (N+2) in mm Where,

procedure: 1. The required magnification adapter is fixed in the contour projector. 2. The gear (specimen) is placed on the glass plate perfectly perpendicular to the lens tube and perfectly focused on the screen. 3. The illumination can be improved by adjusting the height of the condenser lens by shifting the knurled knob with provided at the lamp assembly with a helical cut. 4. The profile (contour) of the gear specimen is traced on a tracing paper fixed on the screen using pencil. 5. Then the addendum and the pitch circle are marked on the image using the theoretical values. 6. Again, the image is fixed on the screen and the other dimensions are measured using the table micrometers fixed on the table on the contour projector. Result:

m = module of fear in mm. D = outside diameter in mm. N = No. of teeth. dp = pitch circle diameter. Addendum = 1m. Dp = (D/2) Addendum.

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Magnification accuracy for contour = 0.1 % Micrometer head: 0 25 mm. L.C: 0.01mm. Contour illuminator: 150/250 W Halogen. Magnification: 10X, 20X, 50X lenses. Range: L.C:

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The measured gear parameters using contour projector are: Addendum = ______ mm Pitch = ________mm Dedendum = ______ mm Major Dia = _______mm Chordal width = ______mm Minor Dia = ________mm Pitch circle Dia = ______mm. 4. MEASURMENT OF TAPER ANGLE USING PROFILE PROJECTOR Aim: To measure taper angle and other dimension of a given flat specimen using profile projector. Apparatus required: Contour projector and flat specimen. Specification: Contour projector magnification accuracy Micrometer Head Colour illuminator Magnification Procedure: = = = = 0.1%

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Side A B C

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0-25 mm

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L.C=0.1 mm Table Micrometer reading Initial Final Dimension mm

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150/250 W Halogen 10x, 20x, 50x lenses

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Angle

1. The required Magnification adapter is fixed in the center projector. 2. The flat specimen is placed on the glass plate and perfectly focused on the screen. 3. The profile of specimen is traced on a tracing paper is fixed on the screen using pencil. 4. Then the angle between the two reference surface and dimension are measured using table micrometer and the Rota table screen circular scale and are tabulated

Circular Scale reading Initial Final

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1 2 3

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Taper Angle Deg

Result: Thus the taper angle and other dimension of the given flat specimen is measured 5(a). MEASUREMENT OF BORE DIAMETER BY TWO SPHERES METHOD Aim: To measure the bore diameter using two spheres. Apparatus Required: Spheres Height gauge Specifications: Height gauge: Range:______mm

Procedure: 1. Here we use two spheres of same or different diameter d1 and d2. 2. The two spheres are placed inside the given bore so that one sphere stands above the other and the contact between the bore and the sphere are also ensured. 3. The height h from the surface plate level to the top point of higher sphere is measured by using height gauge. 4. The bore diameter is calculated by using the above formula. 5. Do a model calculation for the calculation for bore diameter. Diameter of sphere 1:-Diameter of sphere 2:-Sl.no Vernier caliper Reading 1 2 3 Sl.no Vernier caliper Reading 1 2 3 Measurement of Bore diameter: Sl.no 1 2 10 Vernier Height Gauge reading (mm) Bore diameter

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Where d1= diameter of sphere 1 d2= diameter of sphere 2 h = height from the surface plate to top point of the upper sphere.

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Formula: Bore diameter db = (d1+d2)/2 + {h (d1+d2)-h2}1/2

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L.C:______mm

3 Result: Thus the bore diameter is measured by using two spheres. The bore diameter of the given specimen is __________mm.

5(b). MEASUREMENT OF RADIUS OF CURVATURE OF CURVED SPECIMEN Aim: To determine radius of curvature of curved specimen cylindrical bars, depth gauge and vernier height gauge. Apparatus Required: Vernier Caliper, circular surface, concave surface, blunt corner, Supporting press, Height gauge, Depth gauge, Depth Micrometer, Circular rod.

Where,

d l

= =

diameter of circular rod

1 2

Length

2. For blunt surface: Where, R H d H = Radius of curvature of blunt surface. = height of blunt surface plate = diameter of circular rod = height of blunt surface with rod.

Radius of curvature of blunt surface:

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Dimension Diameter (d) (l)

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Radius of curvature of circular surface: Vernier Caliper Reading (mm)

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length of disc between 2 rods.

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(l - d)2 ----------8d

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1. for circular surface:

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Formula:

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Sl.no 1 2 3

Dimension Height (H) Height (h) Dia of circular rod

MSR mm

VSR mm

Total Reading(mm)

3.For curved surface: Where, R d h = Radius of curvature of concave surface = diameter of circular rod

Radius of curvature of concave surface: Sl.no 1 2 Dimension Height (H) MSR mm VSR

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mm

Result: The radius of curvature for the following specimen is found.

1. For circular surface is taken and required setup in the arranged. 2. The diameter of roller is measured using Vernier caliper and length l measured 3. Similarly, the blunt surface is also setup as show and required valve of height of the blunt surface h height Hand the radius of blunt surface Ris also noted. 4. The curved surface is arranged as show and diametrerd is measured using Vernier caliper and the height h measured using micrometer

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Procedure:

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Dimension (d)

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Total Reading(mm)

depth micrometer reading.

6(a). TAPER ANGLE MEASUREMENT USING SINE BAR AND SLIP GAUGE Aim: To measure the taper angle of the given specimen using sine bar Apparatus Required: Surface plate, Dial gauge with stand, Sine bar, Slip gauge, Bevel protractor & specimen. : Range:

Formula: Taper angle Where, Procedure: h l

1. The taper angle of the specimen is first found out approximately with the help of a bevel protractor. 2. The sine bar is set at this angle on the surface plate with the help of the slip gauges as shown in the figure. 3. The specimen is placed on the sine bar so that its top taper surface is parallel to the surface plate. 4. The parallelism is checked and adjusted by increasing or decreasing the height level of the slip gauges, so that there should be no deflection in the long hand of the digital gauge when the spindle of the dial gauge is moved over the specimen surface. 5. The total height (thickness) of the slip gauges is noted down. 6. Trial readings are taken by placing the specimen at different points of the sine bar surface. For Small Specimen: Trial 1

Total height of the slip gauge Reading (mm)

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= Sin-1 (h/l) in degrees = the total height (thickness) of the slip gauges in mm = the standard length of the sine bar in mm = 200mm

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Specification: Sine bar

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For Large Specimen: Trial 1 2 3 Result: The taper angle of the given specimen is a. Using bevel protractor =_________________________ degrees b. Using sine bar =_________________________ degrees h1 (mm) h2 (mm) h 2- h 1 (mm)

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6(b). MEASUREMENT OF ANGLE USING VERNIER BEVEL PROTRACTOR Aim: To measure the angles of given specimen using bevel protractor. Apparatus Required: Surface Plate, Dial Gauge, Slip Gauge, Bevel protractor, specimen Procedure: 1. 2. 3. 4.

Result:

Thus angle of given specimens was determined.

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Initially bevel protractor is adjusted as per requirements. Specimen is placed between the blades. Reading noted directly from main scale and Vernier scale For measuring, taper angle of sine bar, protractor is fixed to height gauge. 5. The protractor is corresponding adjusted. 6. Noted reading is tabulated.

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7. MEASUREMENT OF VIBRATION PARAMETERS USING VIBRATION SET UP

Aim: To study the various parameters involved in the vibrations of a given system. To plot the characteristic curves of the given specimen Apparatus Required: Vibration exciter Vibration pick-up Vibration analyzer Power amplifier Oscillator Description:

When an electrical current is passed through the exciter coil, a magnetic field is created around the coil resulting in the upward or downward movement of the suspended coil depending upon the direction of the current flow in the coil. Thus controlling the frequency of the coil current, the frequency of vibration is controlled. Power amplifier is the control unit for the exciter. Piezo electric crystals produce an emf when they are deformed. This output emf may be measured to know the value of applied force and hence the pressure. A piezo electric material is one in which an electric potential appears across certain surfaces of a crystal of the dimensions of the crystal are charged by the application of a mechanical force. The effect is reversible.

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Vibration exciter is an electrodynamic device. It consists of a powerful magnet placed centrally surrounding which is suspended the exciter coil. This assembly is enclosed by a high permeability magnetic circuit.

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The mechanical vibration, if not within limits may cause damage to the materials, structures associated with it.

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Common piezo electric materials include quartz, Rochelle salt, lithium sulphate etc., Caution: Do not remove the fuse cap while power chord is connected to 230V AC mains Procedure: 1. Connect power amplifier output to vibration exciter. 2. Place the vibration pick up on vibration exciter spindle. 3. Connect vibration pick up cable to vibration analyzer sensor socket. 4. select the range 0-100 by two way switch. 5. Note down the displacement, velocity and acceleration from vibration analyzer. 6. Similarly noted above parameters in frequency range of 0-1000 Hz.

Result: Various parameters of vibration such as displacement, velocity and acceleration are studied and the following characteristic curves were plotted. 1. Displacement Vs Frequency 2. Velocity Vs Frequency 3. Acceleration Vs Frequency

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1 2 3 4 5 6 7 8 9 10

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S.No

Frequency (Hz)

Displacement (mm)

Velocity (cm/sec)

Acceleration (m/sec2)

8. MEASUREMENT OF DISPLACEMENT USING LVDT Aim: To measure the displacement using LVDT.

Procedure:

Sl.no 1 2 3 4 5

Push side Micrometer Indicated Reading Reading (mm) (mm)

1. Plug the power chard to AC main 230v/50Hx & Switch on the instrument. 2. Plate RED/CAL switch at read position. 3. Balance the amplifier with the help of zero knobs. Without connecting LVDT to instruments. 4. Replace the RED/CAL switch at CAL position. 5. Adjust the calibration point by rotating CAL knob so display should read 10.00 (i.e.) maximum ranges. 6. Again keep the RED/CAL switch at read position and connect the LVDT cable to instruments. 7. Mechanical zero by rotating the micrometer. Display will read zero this is full balancing. 8. Give displacement with micrometer and observe the digital reading. 9. Plot the graph of micrometer reading.

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Pull Side Micrometer Indicated Reading (mm) Reading (mm)

1. LVDT 2. Micrometer

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Apparatus Required:

Result: Thus displacement has been measured using LVDT. Graph: Indicated reading Vs Micrometer reading

9. MEASUREMENT OF DIMENTION OF GIVEN SPECIMEN USING TOOL MAKERS MICROSCOPE Aim:

1. To find the Major and Minor diameter:

2. Measurement of pitch:

3. Measurement of thread angle: The screw is rotated till linear cross wire coincides with flank of thread profile. The angle of screw rotation and than the same line coincides with flank thread.

The contour is get so that the same it an screen. The reading of micrometer is noted. The reading of are subtracted & different is noted.

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One end of screw thread in made to coincide with cross wire & fixed. Reading is taken. The different between readings given linear measurement.

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Procedure:

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Tool makers microscope, Specimen, Eyepiece.

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Apparatus Required:

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To measure various dimension of a given specimen using Tool makers microscope.

Result: The various parameters of the given specimen are measured.

10. MEASUREMENT OF STRAIGHTNESS AND FLATNESS USING TWO AXIS AUTO COLLIMATOR Aim:

Apparatus required: Procedure: 1. 2. 3. 4. 5. 6. 7. 8. Formulae:

Collimator unit, Base, plain reflector, optical Scanner Testing square with auto collimator. Level auto collimator unit on a stand a table. Straighten the light. Observe measuring graphical through the eye below. The smallest discussion of linear scale is measured. Bring plain reflector in front of the auto collimator to get reflector. Depending upon the verification in surface. Using micrometer provided for eye piece we can measure the frequency up in lose.

Parallel to the Axis: Sl.no 1 2 3 4 20 Distance from ref A-B ( mm) MSR (Min) Micrometer (Sec) Result - degree Deviations (mm)

Deviation = Sin (A-B) Where angle in rad & Distance A-B in mm

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To measure the straightness and Flatness given specimen using two axis auto collimator.

5 6

Perpendicular to the Axis: Sl.no 1 2 3 4 5 6 Distance from ref A-B ( mm) MSR (Min) Micrometer (Sec) Result - Degree Deviations (mm)

Result: Thus the straightness and Flatness are determined using autocollimator.

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Graph: Deviation Vs Distance from reference

11. MEASUREMENT OF THREAD PARAMETERS BY USING FLOATING CARRIAGE MICROMETER

Aim: To measure the major diameter, minor diameter & Effective diameter by using floating carriage micrometer.

(A) Major Diameter Measurement:

(B) Minor Diameter Measurement: ID = D- (R ~ RO) Where D = Diameter of setting master. C = Core or minor diameter of work piece.

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Where D = Diameter of setting master. RS = Micro meter reading over setting master. R = = Micro meter reading over threaded W/P or gauges. + Or is determined by relative size of master & work piece.

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OD = D+ (RS ~ R)

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Formula:

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1. 2. 3. 4. 5.

Floating carriage micrometer. Specimen Prism Wire Cylinder.

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Apparatus Required:

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RP = Reading over master & prism R = Reading over master & prism. (E) Measurement of effective diameter by using 2 wire method: E = T+P T= D+ (RW ~ ROW) Where E = Effective or pitch diameter. T = Measured dimension using cylinder. RW= Reading measured over setting master with wire.

P = (0.86603 * p) W

W =Mean diameter of cylinder wire used = 1.35 mm

Procedure:

Result: Thus, the thread parameters of a screw thread are measured using floating carriage micrometer.

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1. The setting master is held b/w center and taken the reading at the diameter say RS 2. The master cylinder is then replaced by a threaded work piece and R is taken. 3. Take the reading on micrometer and indicator in such a way that radius portion of prism touches master. 4. The cylinder or wire should be chosen so that when placed b/w the threads, they should contact about halfway down the flanks.

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p = Pitch of thread = 2 mm

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ROW= Reading measured over work piece over wire.

12. TORQUE MEASUREMENT

Aim: To measure the torque using shear type load cell.

Calculated Torque = Load x Distance (kg-m)

Thus torque is the essential tensional twisting about its axis of rotation. In this setup shear type load is used to measure the torque a inverse method of measuring the load with the output immune to side load and bending moment is based on measurement of shear components. The load cell is balancing a beam supported on both ends. Procedure: 1. 2. 3. 4. 5. 6. Fix the main frame of transducers rigidity. Connect the cantilever beam with weight pan. Connect transducer wire socket to rear side of indicator. Connect digital indicator at 230V, AC supply. Set zero on indicator, by zero adjust pan provides indicator. Now apply the load gradually and note down reading in upward & downward trend. 24

Torque is the tangential force to set a body in rotation. It is represented as a vector of a force for a rigged body undergoing force rotation about a single axis. Torque = DX, D = Moment of inertia of body about the axis. X = Angular acceleration.

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Description:

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Formula Used:

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1. 2. 3. 4. 5.

Torque measurement equipment Stand lever stain gauge Weight.

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Apparatus Required:

Distance: 1 meter Sl.no 1 2 3 4 5 6 7 8 9 10 Distance: 0.5 meter Sl.no 1 2 3 4 5 6 7 8 9 10 Weight added (Kg) Weight added (Kg) Observed torque (Kg-m) Calculated Torque (Kg-m)

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Model Calculation: Calculated Torque =Load x Distance (kg-m) Result: Thus measurement of torque using shear type load cell has been carried out.

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Observed torque (Kg-m)

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Calculated Torque (Kg-m) 25

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Graph: Observed torque Vs Calculated torque

13. FORCE MEASUREMENT

Aim: To measure the force using load cell.

* Check and ensure that the axis of screw jacks perfectly aligned with load cell. * Ensure that load cell with socket is connected to the rear side of the load indicator. * Apply a small load without any slip in the system. * Note down the reading of dial gauge of force indicator. Sl.no 1 2 3 4 5 Actual load applied (kg) Deflection (div)

* Ensure that proving ring along with load all is perfectly in vertical position.

Procedure:

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Force is one of the major derived parameter having fundamental dimension of mass length and time. It is a vector quantity which, when applied result in a change of momentum in a body. Basically mechanical force is created due to variation of started potential energy. This is different types of load cell like column type, shear type, s-type, and compression type. In this setup, s-type load cell is provided.

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Description:

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1. Proving Ring 2. Load cell 3. Force indicator 4. screw jack 5. Dial gauge. Capacity of proving Ring =2.5 KN.

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Apparatus Required:

6 7 8 9 10 1 division = 0.002mm Result: Thus the force measurement has been measured using load cell. Graph: Deflection Vs Applied load

14. TEMPERATURE MEASUREMENT

Aim: To measure the temperature using copper constantan thermo couple. Apparatus Required: 1. Thermo couple 2. Temperature measuring setup. 3. Ice cubes. Procedure:

Sl.no 1 2 3 4 5 6 7 8 9 10

Actual temperature C

3. Immerse the junction of thermocouple in boiling at 98 C by using potentiometer marked max. 4. Repeat the procedure for 2 to 3 times.

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2. Immerse the junction of thermocouple in ice and adjust the meter reading at 0 C using potentiometer.

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1. Connect the thermocouple supplied at the impute terminal if copper constantan Thermocouple is used. Copper wire must be connected to the terminal and constantan wire to ve terminal.

Indicated temperature C

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Result: Thus the temperature is measured using thermocouple. Graph: Indicated Temperature Vs Actual Temperature

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