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METROLOGY LAB EXPERIMENTS

Exp1. VERNIER CALIPERS & EXTERNAL MICROMETER

AIM : To measure the height, length, diameter of the given specimens using (A) Vernier Callipers
and (B) Outside Micrometer.
Learning Objectives:
1. To understand the use of instruments and to learn the measurements with and calibration of
instruments.
2. To understand the concept of how to use the instruments and take the measurements.
Apparatus required :
1. Vernier calipers
2. Outside Micrometer
3. Specimens
a. Cylindrical Piner
b. Metal Plate

Specification :
1. Vernier Caliper: Range : 0 - 150 mm, Least Count = 0.02 mm
2. Outside Micrometer: Range : 0 – 25 mm, 25 – 50 mm, Least Count = 0.01 mm

A. VERNIER CALIPERS
Description of Vernier Caliper : The vernier caliper consists of L-shaped frame on which
two scales are calibrated. One scale is fixed and the other scale is movable. The fixed scale is
called the main scale and carries a fixed jaw. The movable jaw slides over the main scale and
carries a movable jaw. Both the jaws has measuring tips. When the two jaws are closed, the zero
on the vernier scale coincides with the zero of the main scale. For precise setting of the movable
jaw, an adjustment screw is provided. Also there is a clamping screw to lock the vernier sliding
scale as shown in the fig below. The main scale and the vernier scale is calibrated both in MKS
(Metric Kilogram Second) System & FPS (Foot Pound Second) System. The Metric system is
shown in millimeters (mm) and FPS system is shown in inches. Presently metric system is being
used. Vernier calipers are available in different sizes depending upon the measuring range. They
are i) 0 to 150 mm ii) 0 to 300 mm iii) 0 to 500 mm and iv) 0 to 1000 mm. On the main scale,
inches are calibrated on the top and mm are calibrated on the bottom of the scale. Similarly on
the vernier scale, inches are calibrated on the top and mm are calibrated on the bottom. On the

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main scale, divisions are marked in mm from 1 to 150 mm and further. Each division on the main
scale represents 1 mm.

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2
Inches on main scale & vernier scale
Clamping Screw to lock main scale

Clamping Screw to lock vernier sliding scale

Millimeters on main scale & vernier scale Fine Adjusting Screw for vernier scale

Fig: Schematic diagram of Vernier Caliper

Principle : The principle of the vernier is that when two scales or divisions slightly different in size
are used, the difference between them can be utilized to enhance the accuracy of measurement.
OR
The principle of vernier is based on the difference between two scales or divisions which are
nearly, but not quite alike for obtaining small difference. It enables to improve / enhance the
accuracy of measurement.
Least Count of Vernier Instrument : Vernier instruments have two scales, main scale and the
vernier scale.
The main scale is fixed and the vernier scale slides over the main scale. When both the jaws of
the vernier caliper are touching each other, then the zero on the vernier scale coincides with the
zero on the main scale. But , the vernier scale has one more division less than that of the main
scale with which it coincides. So, the value of a division on vernier scale is slightly smaller than
the value of a division on the main scale. The difference is called the Least Count. It is shown on
the instrument.
Least Count (L.C.) is the difference between the value of main scale division and vernier scale
division.
Thus Least Count of a vernier instrument = Value of the smallest division on the main scale –
The value of the smallest division on the vernier scale.

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49 divisions on the main scale Least Count (L.C.) = 0.001 inch

50 divisions on vernier scale is made equal to 49 divisions on the main

Least Count (L.C.) = 0.02 mm

Fig: Working principle of Vernier Caliper

Figure above shows, 50 divisions on the vernier scale coincides with 49 divisions on the main
scale
Therefore, The value of the smallest division on vernier scale = 49/50 mm.
Thus, Least Count = value of smallest division on main scale – value of smallest division on
vernier scale
i.e. Least Count = 1 – 49 = 0.02 mm
50
Least count can also be calculated as :
The ratio of the value of minimum division on the main scale to the number of divisions on the
vernier scale.
i.e. minimum division on the main scale = 1, and number of divisions on the vernier scale = 50

Least Count = 1 = 0.02 mm

50
The value of minimum division on the main scale is 1 mm. Here 1 division on the main scale is
being divided by 50 divisions on the vernier scale.
Initially when both the ends of the jaws touch together, the zero on the vernier scale coincides
with the zero of the main scale. Whenever you take some dimension, zero on the vernier scale
moves away towards right as

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B. OUTSIDE MICROMETER
Principle of Micrometer : Micrometer works on the principle of screw and nut. We know that
when a screw is turned through nut through one revolution, it advances by one pitch distance.
i.e., one rotation of screw corresponds to a linear movement of a distance equal to pitch of the
thread.
If the circumference of the screw is divided into number of equal parts ‘n’, its rotation through
one division will cause the screw to advance through [ Pitch/n ] length.
Thus, the minimum length that can be measured by such arrangement will be [ Pitch/n ].
Bu reducing the pitch of the screw, the length value on one circumferential division can be
reduced and accuracy of measurement can be increased considerably.

Description : Micrometer is one of the most common and most popular forms of measuring
instrument for precise measurement with 0.01 mm accuracy.
Micrometers are available with 0.01 mm, 0.001 mm accuracy.
Micrometers are used to measure the outside diameters and lengths of small parts to an
accuracy of 0.01 mm.
Also it can measure the thickness id small plates sheets etc.
The main pares of an outside micrometer are :

1. U-shaped steel frame : The outside micrometer has ‘U’ shaped or ‘C’ shaped frame. It
hold all the micrometer parts together. The gap of the frame permits the maximum
diameter or length of the jog to be measured. The frame is generally made of steel, cast
steel, malleable Cat Iron or light alloy. The micrometer frame is constructed such that to
conveniently place fingers to for grip and should be heat insulating material.
2. Anvil and Spindle : The micrometer has a fixed anvil protruding 3 mm from the left hand
side of the frame. The diameter if the anvil is same as that of the spindle. Another
movable anvil is provided on the front of the spindle. The anvils are accurately ground
and lapped with its measuring faces flat and parallel to the spindle. The anvils are made
up of tungsten carbide faces.
The spindle is the movable measuring face with the anvil on the front side. The spindle
engages with the nut. It should run freely and smoothly throughout its length of travel.
There should be no backlash between the spindle screw and nut. There should be full
engagement of nut and screw when the micrometer is at its full reading.
3. Lock nut : A lock nut is provided on the micrometer spindle to lock it. When the
micrometer is at its correct reading. The lock effectively locks the spindle without altering
the distance between the measuring faces.
4. Sleeve or Barrel : The sleeve or barrel is accurately divided and clearly marked in 1 mm
division on the datum line along its length which, serves as the main scale. It is chrome
plated and adjustable for zero setting.

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5. Thimble : The thimble can be moved over the barrel. It has 50 equal divisions around its
circumference. Each division having a value of 0.01 mm as which serves as vernier scale
shown below.

Fig: Working of Micrometer

5
U- Frame Fixed anvil Movable anvil or spindle
Sleeve scale thimble ratchet

Tungsten carbide faces

Thimble scale
spindle lock Sleeve or barrel

Datum line

Least count 0.01 mm

Measuring range 0 - 25 mm ANALOUGE OUTSIDE MICROMETER

Fig: Schematic diagram of Micrometer

Micrometers are available in the measuring ranges of 0 to 25 mm, 25 to 50 mm, 50 to 75 mm,

75 mm to 100 mm, 100 to 125 mm, 125 to 150 mm and so on up to 600 mm. They have accuracy
up to 0.01 mm and 0.001 mm

1. The Vernier principle may also be applied to an outside micrometer, increasing its
accuracy. It gives readings with an accuracy of 0.01mm.

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2. The Vernier scale is engraved on the micrometer barrel. There are 50 divisions on the
Vernier scale and they are equal to 1 division on the thimble. Hence one division on the
barrel is equal to 0.5/50 that of thimble.
3. Hence, least count (LC) of the micrometer is equal to 0.01mm.

PROCEDURE

1. Take the given work pieces to be measured.

2. Place the work piece between the two jaws of vernier calliper or between two anvils of
micrometer.
3. Measure the Main Scale Reading [ MSR ], note the readings on the main scale up to zero
of the Vernier scale.
4. Measure Vernier Scale Reading [ VSR ], note the graduations on the Main Scale.
5. Consider the least count of Vernier Calipers and Micrometer and also the zero error, if
any.
6. Calculate the Total Reading, TR = MSR + [(VSR) x LC]
7. Repeat the above procedure and take different readings.

CALCULATIONS

A. USING VERNIER CALIPERS: (L.C = 0.02 mm)

1st Specimen : Cylindrical Pin Dimension : Length
Error : 0

S. No. MSR VSR VSR x LC Total = Error Adjusted Total

MSR + VSR x LC = Total – Zero Error
1
2
3
4 Average = (Total 1 + Total 2 + Total 3) / 3=

2nd Specimen : Cylindrical Pin Dimension : Diameter

Error : 0

S. No. MSR VSR VSR x LC Total = Error Adjusted Total

MSR + VSR x LC = Total – Zero Error
1
2
3
4 Average = (Total 1 + Total 2 + Total 3) / 3=

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3rd Specimen : M.S.Plate Dimension: Thickness

Error: 0

S. No. MSR VSR VSR x LC Total = Zero Adjusted Total

MSR + VSR x LC = Total – Zero Error
1
2
3
4 Average = (Total 1 + Total 2 + Total 3) / 3

Where, MSR – Main Scale Reading

VSR – Vernier Scale Reading
LC – Least Count

B .USING MICROMETER: (L.C = 0.01 mm)

1st Specimen : Cylindrical Pin Dimension : Diameter

Error : 0

S. No. MSR VSR VSR x LC Total = Error Adjusted Total

MSR + VSR x LC = Total – Zero Error
1
2
3
Average = (Total 1 + Total 2 + Total 3) / 3=

2nd Specimen : M.S. Plate Dimension : Thickness

Error : 0

S. No. MSR VSR VSR x LC Total = Error Adjusted Total

MSR + VSR x LC = Total – Zero Error
1
2
3
Average = (Total 1 + Total 2 + Total 3) / 3=

Where, MSR – Main Scale Reading

PSR – Pitch / Circular Scale Reading
LC – Least Count

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PRECAUTIONS
1. The line of measurement should coincide with that of line of scale.
2. Set the instrument to zero reading before measuring.
3. The calipers / micrometer should not be dropped or tossed aside.
4. They must be kept free of grit, chips and oil.
5. When using the calipers for inside diameter measurements, the instrument must be
rocked on one of the jaws to make sure the other jaw or blade falls on the
diametrically opposite point.
6. No play should be there between the sliding jaws on scale otherwise the accuracy of
the venire Calipers will be lost.
7. Do not drop the vernier caliper on the ground, otherwise the measuring edges will get
damaged.
8. Do not tighten the clamping screws too tightly.
9. Care should be taken for the depth bar not to be damaged or bent.
10. Clean the vernier calipers with a soft and clean cloth before and after use.

RESULT : The height, length, diameter, thickness of the given specimens are measured.

A. USING VERNIER CALIPERS

 Length of cylindrical pin is

 Diameter of cylindrical pin is

 Thickness of M.S. Plate is

B. USING MICROMETER

 Diameter of cylindrical pin is

 Thickness of M.S. Plate is

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Exp2. INTERNAL MICROMETER & BORE DIAL INDICATORS

AIM : To measure the internal diameter of the given specimens by (1) Internal Micrometer

and (2) Bore Dial Gauge.

Learning Objectives:
1. To understand the use of instruments and to learn the measurements with and calibration of
instruments.
2. To understand the concept of how to use the instruments and take the measurements.

1. INTERNAL MICROMETER
Specification :
1. Internal Micrometer Range : 5 - 30 mm, Least Count = 0.01 mm
2. Stick Micrometer Range : 25 – 38 mm, Least Count = 0.01 mm

APPARATUS :

1. Internal Micrometer; 2. Surface Plate; 3. Extension rods; 4. Specimen

THEORY : It is one of the most common and most popular form of measuring instrument for
precious measurement with 0.001mm accuracy are also available.
It is used for measuring the diameter of holes and other internal dimensions to an accuracy of
0.01mm.
It consists of four parts:
(i) Measuring head (micrometer unit),
(ii) number of interchangeable extension rods,
(iii) Spacing collars,
(iv) Handle.

The measuring unit has a barrel and thimble graduated and the same turned in the barrel. A
basic internal micrometer covers a measuring range of 50 – 200 mm by using extension rods.

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INTERNAL MICROMETER

Fig: Schematic diagram of Internal Micrometer

The extension rods are commonly arranged in 25 mm ranges. The measurement is read in the
same manner as that of an outside micrometer. Using one range of extension rods, distance
between the contacting surfaces is varied by rotating the thimble up to the extent of the screw
length. Greater distances are obtainable by the use of different extension rods and spacing
collars. The range of measurement for which an extension rod is applicable is always marked on
it. Spacing collars are used when those dimensions are needed which cannot be obtained by the
use of extension rod and micrometer unit. Detachable handles are provided to lower the
micrometer into deep holes.

PRINCIPLE :-

Micro meter works on the principle of screw and nut. When screw is turned through nut one
revolutions it advances by one pitch distance i.e., one revolution of screw corresponds to a linear
moment of a distance equal to the pitch of the thread.

L.C= Pitch of the spindle/ No of divisions on the spindle

PROCEDURE for (i) INTERNAL MICROMETER :-

1. Select the micro meter with a desired range depending upon the size of the work piece to
be measured.

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2. The next step is to check it for zero error. In case of 0.25mm micrometre, the zero error is
checked by contracting the faces of fixed anvil and the spindle.
3. The barrel has graduation, in travels of 1mm above the reference line.
4. For measuring the dimension, hold work b/w faces of the anvil the spindle by rotating
then touches the work piece.
5. Take the thimble reading with coincides with the reference line on the sleeve.
6. Repeat the experiment and calculate average value.

CALCULATIONS FOR (i) INTERNAL MICROMETER Range ( 5 – 30mm)

Least count, L.C = Pitch of the screw / no. of divisions on pitch scale.

Specimen S. No. MSR VSR VSR x LC Total = ER +

MSR + (VSR x LC)
BUSH - 1

AVERAGE READING = TR1 + TR2 + TR3

3
BUSH - 2

AVERAGE READING = TR1 + TR2 + TR3

3
BUSH - 3

AVERAGE READING = TR1 + TR2 + TR3

3

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PRECAUTIONS:

a) Use of a reference surface like a surface plate is advisable in order to avoid measurement
errors like tilting of the bore while taking a reading. The bore axis must be perpendicular
to the axis of the micrometer.
b) After placing the micrometer unit inside the bore, ensure that the diameter is being
measured and not the chord by moving one contact surface of the micrometer up and
down as well as sideways.
c) Take readings without parallax error.
d) Handle the equipment with care.

RESULT:

The internal diameters of the given specimens are measured by using internal micrometer.

a) The internal diameter of Bush 1. with internal micrometer is

b) The internal diameter of Bush 2. with internal micrometer is

c) The internal diameter of Bush 3. with internal micrometer is

2. BORE DIAL GAUGE

THEORY AND DESCRIPTION:
Bore gauge, is generally used to determine the bore diameter of components. Dial Bore Indicator /
gauge consists of following parts.
1. Dial gauge or Dial Indicator
2. Vertical column
3. Arrangement of anvil and washer
4. Movable spindle
Dial bore indicator consists of measuring head and guide is attached with extension rod & collars
for specific dimension chosen from the table in the instrument box. Holder is assembled to the
measuring head and dial indicator is fixed inside the holder during tightening. The condition is
initially 1 kgf is applied to the dial indicator for getting exact reading.

PRINCIPLE: Dial bore indicator works on comparator principle.

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PROCEDURE:

1) Once approximate bore is find out by using vernier caliper or inside micro meter.
2) Chose the same little more size extension rod & collar if necessary select and fit the
assembly of the bore dial indicator.
3) Now set the external micrometer to the required dimension and lock it.
4) Set the bore dial indicator with the micrometer and set the dial of the dial gauge to zero.
5) Keep the dial bore indicator into the specimen bore and not the readings.
6) Repeat same procedure to get the bore diameter at different positions of specimen and
take the average reading.

Least count = 0.01mm

Inner Diameter of the specimen-1 : RING

S.No Anvil Size Washer Size Dial Indicator Reading Total Reading = Anvil Size +
Washer size - Dial Indicator
Reading (mm)
1
2
3
AVERAGE = TR1 + TR2 + TR3 =
3

Fig: Schematic diagram of Bore Gauge

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Inner Diameter of the specimen-2 : BUSH

S.No Anvil Size Washer Size Dial Indicator Total Reading = Anvil
Reading Size + Washer size – (LC X
Dial Indicator Reading)
(mm)
1
2
3
Average = TR1 + TR2 + TR3 = 61.69/3 =
3
PRECAUTIONS:

a) Use of a reference surface like a surface plate is advisable in order to avoid measurement
errors like tilting of the bore while taking a reading. The bore axis must be perpendicular
to the axis of the bore dial indicator.
b) After placing the bore gauge unit inside the bore, ensure that the diameter is being
measured and not the chord by moving one contact surface of the bore gauge up and
down as well as sideways.
c) Take readings without parallax error.
d) Handle the equipment with care.

Result:-

The experiment is used to find the inner diameter/bore diameter of the hollow specimen.

1. The inner diameter of the given Specimen 1. Ring is

2. The bore diameter of the given Specimen 2. Bush is .

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Exp3. GEAR TOOTH VERNIER CALIPERS

AIM : To measure the Chordal Addendum, Chordal Tooth Thickness of a Spur Gear using a Gear
Tooth Vernier Calipers.

Learning Objectives:
1. To understand the use of instruments and to learn the measurements with and calibration of
instruments.
2. To understand the concept of how to use the instruments and take the measurements.
APPARATUS :

1. Gear Tooth Vernier; 2. Vernier calipers; 3.Surface Plate; 4. Spur Gears

THEORY :

Gears are mainly used for transmission of power and motion. For close control over the accuracy
of manufacture, precision measurement of gears plays a vital role.
Various types of gears commonly used are.

Description :

Fig: Schematic diagram of gear tooth caliper

The gear tooth Vernier consists of two Vernier callipers fixed at right angles to each other as a
one unit for the measurement. The vertical vernier scale measures the chordal addendum or the

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chordal depth of the gear teeth. Similarly the horizontal vernier scale measures the chordal
width or chordal thickness of the gear teeth.

Tooth thickness is defined as the length of the arc on the pitch circle between opposite faces at
the same tooth, Arc ADC.

Chordal tooth thickness is defined as the segment AEC. While PD is the tooth addendum, PE is
the chordal tooth addendum and tooth height is defined as PQ.

Terminology Of Gear Tooth :-

Base Circle :- It is circle from which involutes form is generated. Only the hare on a gear is fixed
and unalterance.
Pitch Circle :- It is an imaginary
Pitch Circle Diameter :- It is the diameter of a circle which by pure rolling action would produce
the same motion as the tooth gear wheel. This is more important diameter of gear.
Module :- It is defined as length of pith circle diameter per tooth.
(M)=D
N
Where D = Outside diameter / Addendum circle diameter of the spur gear
N = No. of teeth of spur gear
Addendum : This the radial distance from the pitch circles to the tooth.

Clearance : This is the radial distance from the tip of tooth to the bottom of a mating tooth
space, when the teeth are symmetrically engaged. Its STD value is 0.157 M .

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Fig: Nomenclature of Gear

Dedundum : This is radial distance from the pith circle to the bottom of tooth space.
Blank Diameter : This is the diameter of blank from which gear is out
Blank Diameter = P.C.D + 2M
Tooth Thickness : This is the arc distance measured along the pitch circle from it’s intercept
with one flank to it’s intercept with the flank of same tooth. The teeth thickness measurement is
the more important measurement. Most of gear manufacturer may not undergo checking of all
other parameter but thickness measurement is must.
Gear tooth thickness is measured by using gear tooth vernier caliper. It is applicable for gears
where tooth traces are straight line.

15
Formulas

Chordal Addendum (d) = NM/2 [ 1 + 2/N – Cos(90/N) ]

Theoretical Chordal Tooth Thickness or Chordal Width (w) = NM Sin (90/N)

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PROCEDURE

1. Place the gear to be measured on the surface plate carefully. Fix the positions at which
measurements are to be taken.
2. Take the spur gear to be measured and measure the outer diameter of the gear using an
ordinary Vernier Callipers . Take three measurements at three different places and
calculate the average diameter for the spur gears 1,2 and 3 and note down in the
observation table.
3. Count the no. of teeth (N) for spur gears 1,2 and 3 and not down in the observation
table.
4. Now calculate the module of the spur gear using the formule m = D/N
5. After getting the values of Diameter, No. of teeth and Module, calculate the theoretical
value of the Chordal Addendum / Chordal depth (d) by the formula
d = NM/2 [ 1 + 2/N – Cos(90/N) ]
And note the value in the table for the gears 1,2 and 3.
6. Similarly calculate the Chordal Width w = NM Sin (90/N)
And note the value in the table for the gears 1, 2 and 3.
7. Set the theoretical value of the Chordal Andedum (d) on the vertical vernier scale of the
gear tooth vernier callipers and tighten the screws.
8. Set the blade (which is fixed) of the vertical vernier on the top of the gear teeth and
measure the width of that gear tooth with the horizontal vernier. This value what you get
is the Actual value of the chordal width (w) and note it down.
9. Similarly set the horizontal vernier scale to the theoretical value of the chordal width (w).
10. With the horizontal vernier (w) scale fixed, put this vernier on the tooth of the gear and
measure the depth with the vertical vernier and note it down.
11. Like this take the actual readings for gears 2 and 3 respectively.

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CALCULATIONS

1. Least Count of Gear Tooth Vernier scales = LC = 0.02 mm

Gear Dia of No of Module Chordal Width (w) Chordal Addendum or
No Gear (D) Teeth M = D/N+2* Chordal Depth (d)
(N)
Theoretical Actual Theoretical Actual
1
2
3

*Note : +2 is added to take care of any discrepancies, wear etc.

PRECAUTIONS
a) Take readings without parallax error.

b) Handle the equipment with care.

RESULT

Hence, the Actual Chordal Addendum or Chordal Depth (d) , Chordal Tooth Width (w) are
measured using Gear Tooth Vernier. The values are as under : -

a) Actual Chordal Addendum of gear 1)

b) Actual Chordal Addendum of gear 2)

c) Actual Chordal Addendum of gear 3)

d) Actual Chordal Width / Thickness of the gear 1)

e) Actual Chordal Width / Thickness of the gear 2)

f) Actual Chordal Width / Thickness of the gear 3)

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Exp4. MACHINE TOOL “ALIGNMENT TEST ON THE LATHE”

AIM : To perform machine tool alignment tests on lathe machine.

Learning Objectives:
1. To understand to perform machine tool alignment tests on lathe machine with use of
instruments and to learn the take measurements.
2. To understand the concept of how to perform machine tool alignment tests and take the
measurements.
APPARATUS :

1. Spirit Level 2. Straight Edges 3. Test Mandrels 4. Slip Gauges.

5. Dial Indicators with magnetic dial stands 6. Lathe Machine

1. Test for level of installation:

(a) In a longitudinal b) In transverse direction
Measuring instruments: Spirit level, gauge block to suit the guide ways of the lathe bed.

Theory:- The following are the alignment tests on lathe.

Levelling of machine:- It is essential that a machine tool should be installed truly horizontal and
vertical plane and this accuracy must be maintained. The level of machine base in longitudinal
and transverse direction is tested by spirit level or precision level. The spirit level is placed at to
measure the level.

True running of main spindle:- The true mandrel is placed in the main spindle and test is
conducted on the surface of material if dial gauge shows any deviation in the reading then it is
said that the main spindle is running in the proper way.

Parallelism of main spindle to saddle movement:- If the axis of the spindle is not parallel to the
saddle movement then it is not possible to get required dimension of work piece while doing the

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operation on lathe. The spindle is moved and the deviation in the reading of dial gauge are
noted.
Parallelism of Tailstock guide ways to saddle movement:- To check the parallelism of guide
ways with the saddle movement in the both vertical and horizontal directions. The dial indicator
is held on the spindle and block is moved simultaneously any deviation in reading of dial gauge is
noted if no deviation in the reading then tail stock guide ways is parallel to saddle movement
otherwise it is not parallel to saddle movement.

Parallelism of tail stock guide ways to carriage movement:- To check the parallelism of guide
ways with the carriage in both vertical and horizontal objections. A block is placed on the guide
ways of tail stock. The dial indicator is held on the carriage and block is moved simultaneously
any deviation in reading of dial gauge is noted

Parallelism of main spindle to carriage movement:- To check the parallelism of main spindle to
carriage in both vertical and horizontal. The deviation is observed the spindle is not parallel to
the carriage.

True Running of head stock centre:- The test mandrel is placed in the head stock and test is
conducted on the surface of carriage. The dial gauge shows any deviations in the reading then
the head stock is not running in proper.

Procedure: - The gauge block with the spirit level is placed on the bed ways on the front position,
back position and in the cross wise direction. The position of the bubble in the spirit level is
checked and the readings are taken.

Permissible error: Front guide ways. 0.02 mm/meter convex only. Rear guide ways, 0.01 mm to
mm convexity. Bed level in cross-wise direction ±0.02/meters. Straightness of slide
ways(for machines more than 3 mm turning length only, measurement taken by
measuring tight wire and microscope or long straight edge). Tailstock guide ways parallel
with movement of carriage 0.02

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mm/m. No twist is permitted. The error in level may be corrected by setting wedges at suitable
points under the support feel or pads of the machine.

Result : Parallelism of the table is checked and errors are noted as follows :-
a) Error in Longitudinal direction ‘a’ =
b) Error in Traverse direction ‘b’ =

2. Straightness of saddle in horizontal plane:-

Measuring instruments: Cylindrical test mandrel (600mm long), dial indicator.

Procedure: - The mandrel is held between centres. The dial indicator is mounted on the saddle.
The spindle of the dial indicator is allowed to touch the mandrel. The saddle is then moved
longitudinally along the length of the mandrel. Readings are taken at different places.

Permissible error: 0.02 mm over length of mandrel.

Result : Errors in Straightness of Saddle in horizontal movement are noted.:-

a) Position A =
b) Position B =

3. Alignment of both the centres in the vertical plane:

Measuring instruments: Cylindrical mandrel 600 mm long, dial gauge.

Procedure: The test mandrel is held between centres. The dial indicator is mounted on the
saddle in vertical plane as shown in figure. Then the saddle along with the dial gauge is travelled
longitudinally along the bed ways, over the entire length of the mandrel and the readings are
taken at different places.
Permissible error: 0.02 mm over 600 mm length of mandrel (Tail stock centre is to lie higher
only).

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Result : - Error of 0.11 mm over 600 mm length of mandrel.

Fig: Positioning of shaft between centres (for measuring in vertical Plane)

4. True running of taper socket in main spindle

Instruments required: Test mandrel with taper shank and 300 mm long cylindrical measuring
part, dial gauge.

Procedure: The test mandrel is held with its taper shank in a head stock spindle socket. The dial
gauge is mounted on the saddle. The dial gauge spindle is made to touch with the mandrel. The
saddle is then travelled longitudinally along the bed ways and readings are taken at the points A
and B as shown in figure.

Permissible error: Position A 0.01 mm, position B 0.02 mm.

Result : - Error in Position ‘A’ is 0.41 mm and ‘B’ is 0.35 mm.

Fig: Positioning of shaft for true running of taper socket

5. Parallelism of main spindle to movement:

(a) In a vertical plane (b) In a horizontal plane

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Measuring instruments: Test mandrel with taper shank and 300 mm long cylindrical measuring
part, dial gauge.

Procedure: The dial gauge is mounted on the saddle. The dial gauge spindle is made to touch the
mandrel and the saddle is moved to and fro. It is checked in vertical as well as in horizontal
plane.

Permissible error: (a) 0.02/300 mm mandrel rising towards free end only.
(b) 0.02/300 mm mandrel inclined at free end towards tool pressure only.

Result : - Error obtained at position ‘a’ and ‘b’ are

6. Movement of upper slide parallel with main spindle in vertical plane:

Measuring instruments: Test mandrel with taper shank and 300 mm long cylindrical measuring
part, dial gauge.
Procedure: The test mandrel is fitted into the spindle and a dial gauge clamped to the upper
slide. The slide is transversed along with the dial gauge plunger on the top of the stationary
mandrel.

Permissible error: 0.02 mm over the total movement of the slide.

Result : - Error obtained is

7. True running of locating cylinder of main spindle:

Measuring instrument: Dial gauge.

Procedure: The dial gauge is mounted on the bed, touching at a point on main spindle. The main
spindle is rotated by hand and readings of dial gauge are taken.

Permissible error: 0.01 mm.

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Result : - Error obtained is .

8. True running of head stock centre:

Measuring instruments: Dial gauge.

Procedure: The live centre is held in the tail stock spindle and it is rotated. Its trueness is checked
by means of a dial gauge.

Permissible error: 0.01 mm.

Result : - Error obtained is 0.02 mm & 0.15 mm.

9. Parallelism of tailstock sleeve to saddle movement:

Measuring instruments: Dial indicator

Procedure: Tailstock sleeve is fed towards. The dial gauge is mounted on the saddle. Its spindle is
touched to the sleeve at one end and the saddle is moved to and fro, it is checked in H.P. and
V.P. also.

Permissible error: (a) 0.0 1/100 mm (Tailstock sleeve inclined towards tool pressure only).
(b) 0.0 1/100 mm (Tailstock sleeve rising towards free end only).

Result : - Error obtained is

(a)

(b)

10. Paralle1ism of tail stock sleeve taper socket to saddle movement

(a) In V.P.
(b) In H.P.

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Measuring instruments: - The mandrel with taper shank and a cylindrical measuring part of
300mm length, dial gauge.
Procedure: - Test mandrel is held with its taper shank in tail-stock sleeve taper socket. The dial
gauge is mounted on spindle. The dial gauge spindle is made to touch with the mandrel. The
saddle is then transverse longitudinally along the bed way and readings are taken.
Permissible error:-
(a) 0.03/300 mm (mandrel rising towards free end only).
(b) 0.03/300 mm (Mandrel inclined towards tool pressure only).

Result : - Error obtained is

(a)

(b)

PRECAUTIONS:

i) The mandrel must be so proportioned that its overhang does not produce appreciable sag, else
the sag must be calculated and accounted for.
ii) The indicator set up must be rigid, otherwise variations in readings as recorded by point may
be solely due to deflection of the indicator.

REVIEW QUESTIONS
a) What is the necessity of conducting various alignment tests on lathe?
b) What are the various alignment tests to be conducted on the lathe?
c) What is straightness?
d) What is flatness?
e) What is square ness?
f) What is parallelism?
g) What do you mean by axial slip of main spindle?
h) It is necessary to conduct alignment tests on other machine tools? If so why? Not, why not?

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Exp5. MACHINE TOOL “ALIGNMENT TEST ON THE MILLING MACHINE

AIM : To perform machine tool alignment tests on milling machine.

Learning Objectives:
1. To understand to perform machine tool alignment tests on milling machine with use of
instruments and to learn the take measurements.
2. To understand the concept of how to perform machine tool alignment tests and take the
measurements.
APPARATUS :

1. Spirit Level 2. Straight Edges 3. Test Mandrels 4. Slip Gauges.

5. Dial Indicators with magnetic dial stands 6. Vertical Milling Machine

Theory : - Following are the tests on milling machine.

Test for levelling of milling machine :- It is essential that a machine tool should be installed truly
horizontal and vertical plane and this accuracy must be maintained. If milling base is not installed
truly horizontal then bed will undergo a deflection and produce a simple bend.

True Running of spindle :- A mandrel placed in the spindle and test is conducted on the surface
of mandrel. A dial gauge is fixed on the machine table and feeler of the dial gauge is made to
touch the lower surface of it clearance is noted then it is said that the table is not flat otherwise
it is flat.

True Running of spindle :- For this test the mandrel is placed in the spindle and dial indicator is
fixed on the table. The feeler of dial gauge is made to touch the surface of manderal.

Parallelism of spindle Axis with its vertical moment :- For this test the manderal is placed in the
spindle and dial indicator is fixed on the table. The feeler of dial gauge is made to touch the
surface of mandrel also moved up and down, the mandrel also moved up and down observe any

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direction in the reading of dial gauge is noted then that is said that it is not running in proper way
mandrel. Axis slip of main spindle is developed due to the error in bearing support for this test
feeler of the dial gauge is placed on the face of main spindle and the dial gauge.

Parallelism (or) Table Surface with longitudinal surface :- A machine is placed in the spindle and
test is conducted on the surface of mandrel. If any degration is noted then it is noted then it is
said that spindle is not parallel to the table.
Parallelism of Table Surface with main spindle :- A mandrel is placed in the spindle and test is
conducted on the surface of mandrel. A dial gauge is fixed on the table and feeler is touched to
the spindle. If any deviation takes place the spindle is not machine to the table.

Parallelism of Table Surface with Arbor :- Arbor is placed in the spindle and test is conducted on
the surface of order. If any degration is noted than it is said that arbor is not parallel to the table.

Procedure:

(1) Flatness of work table

(a) In longitudinal direction.
(b) In transverse direction.

Measuring instruments: - Spirit level.

Procedure: - A spirit level is placed directly on the table at points about 25 to 30 cm apart, at A,
B, C for longitudinal tests and D, E and F for the transverse test. The readings are noted.

Permissible error:

Direction A-B-C, ± 0.04 mm

Direction D-E-F, ± 0.04 mm

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Fig: Error finding

Result : Error obtained is

Direction A-B-C, ± 0.06 mm

Direction D-E-F, ± 0.08 mm

(2) Parallelism of the work table surface to the main spindle

Measuring instruments :- Dial indicator, test mandrel 300 mm long, spirit level.

Procedure :- The table is adjusted in the horizontal plane by spirit level and is then set in its
mean position longitudinally. The mandrel is fixed in the spindle taper. The dial gauge is set on
the machine table, and the feeder adjusted to touch the lower surface of the mandrel. The dial
gauge readings at (A) and (B) are observed, the stand of the dial gauge being moved while the
machine table remains stationary.
Permissible error: 0.02 / 300 mm.

Result : Error obtained is .

(3) Parallelism of the clamping surface of the work table in its longitudinal

motion: Instruments :- Dial gauge, straight edge.

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Procedure :- A dial gauge is fixed to the spindle. The dial gauge spindle is adjusted to touch the
table surface. The table is then moved in longitudinal direction and readings are noted. If the
table surface is uneven it is necessary to place a straight edge on its surface and the dial gauge
feeder is made to rest on the top surface of the straight edge.

Permissible error :- 0.02 up to 500 mm length of transverse, 0.03 up to 1000 mm and 0.04
above1000 mm length of transverse.

Result : Error obtained is :-

(4) Parallelism of the cross (transverse) movement of the worktable to the main spindle :
- ( a) In vertical plane
(b) In horizontal plane

Instruments :- Dial gauge, test mandrel with taper shank.

Procedure :- The work table is set in its mean position. The mandrel is held in the spindle. A dial
gauge fixed to the table is adjusted so that its spindle touches the surface of the mandrel. The
table is moved cross-wise and the error is measured in the vertical plane and also in the
horizontal plane.

Permissible error :- 0.02 for the overall transverse movement of the work table.

Result : -Error obtained is 0.04 for the overall transverse movement of the work table.

(5) True running of internal taper of the spindle :-

Instruments :- 300 mm long test mandrel, dial

gauge.

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Procedure: The test mandrel with its taper shank is held in the main spindle. Dial gauge is kept
scanning the periphery of the mandrel. Spindle is rotated and dial gauge readings are noted at
different points say A and B as shown.

Permissible error: Position A :- 0.01 mm, Position B: 0.02 mm.

Result :- Error obtained in Position ‘A’ = 0.04 mm and in Position ‘B’ =0.05 mm.

(6) Square nests of the centre T-slot of worktable with main spindle

:- Instruments :- Dial gauge, special bracket.

Procedure :- To check the perpendicularity of the locating slot and the axis of the main spindle.
The table should be arranged in the middle position of its longitudinal movement, and a bracket
with a tenon at least 150 mm long inserted in the locating slot as shown in figure. A dial gauge
should be fixed in the taper, the feeder being adjusted to touch the vertical face of the bracket.
Observe the reading on the dial gauge when the bracket is near one end of the table, the swing
over the dial gauge and move the bracket so that the corresponding readings can be taken near
the other end of the table.

Permissible error :- 0.025 mm in 300 mm.

Result :- Error obtained is.

(7) Parallelism of the T-slot with the longitudinal movement of the

table :- Instruments :- Dial gauge, special bracket.

Procedure :- The general parallelism of the T-slot with the longitudinal movement of the table is
checked by using 150 mm long braked having a tenon which enters the slot, the dial gauge is
fixed to the spindle taper and adjusted so that its feeder touches the upper surface of the

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bracket. The table is then moved longitudinally while the bracket is held stationary by the hand
of the operator and dial gauge deviations from parallelism are note down.

Permissible error :- 0.0 125 mm in 300 mm.

Result :- Error obtained is

(8) Parallelism between the main spindle and guiding surface of the overhanging arm :-

Instruments :- Dial gauge, mandrel.

Procedure :- The overhanging arm is clamped in its extreme extended position. The dial gauge is
fixed to the arbor support. The feeder of the dial gauge is adjusted to touch the top or ride of the
test mandrel. The arbor can then be moved along the overhanging arm and the deviations from
parallelism observed on the dial gauge.
RESULTS :

PRECAUTIONS:
i) All moving parts of the machine must be locked while reading the dial gauge,
ii) If the table surface is uneven, straight edges must be used.

Fig: Schematicdiagram of positioning

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REVIEW QUESTIONS:
i) Distinguish between geometric tests and practical tests.
ii) How will you measure the flatness of the table surface?
iii) What are the various alignment tests conducted on vertical milling machine?
iv) What are the various measuring instruments used in alignment test of a milling machine
v) What are the dimensions of a test piece used in practical test?

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Exp6. ANGULAR AND TAPER MEASUREMENTS

AIM : To find out the taper angle of given specimens using (1) Sine Bar & slip gauges and
(2) Bevel Protractor.

Learning Objectives:
1. To understand the use of instruments and to learn to take the measurements with and
calibration of instruments.
2. To understand the concept of how to use the instruments and take the measurements for
taper or angle jobs and work pieces.
APPARATUS :

1. Sine Bar 2. Surface Plate 3. Spirit Level 4. Slip Gauges.

5. Dial Indicators with magnetic dial stands 6. Bevel Protractor 7. Taper Block

8. Taper Mandrel

THEORY : (1) SINE BAR

Fig: Working diagram of Sine bar

The higher degree of precision available for linear measurement in the form of slip gauges can be
utilized for measurement of angles with the aid of a simple but elegant piece of apparatus known
as Sine bar. The Sine bar can take several forms according to the purpose of its use and method
of application. The simplest one consists of a lapped steel bar at each and of which is attached on

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accurate cylinder. The axis of the cylinders being mutually parallel and also parallel to the upper
surface of the bar. The Sine bar is designed principally for the precise setting of angles and is
generally used in conjunction with slip gauges. The principle of operation of Sine bar relies upon
the applications of trigonometry.

(2) BEVEL PROTRACTOR

Fig: Schematic diagram of bevel protractor

A protractor is a device for measuring the angle between two intersecting lines. Protractors are
generally used for measuring existing lines, but they can also be constructed to help draw them.
The universal bevel protractor is designed for precision measuring and layout of angles. The
universal bevel protractor is capable of measuring obtuse angles as well as acute angles when
accompanied with the correct attachments. The main component of the bevel protractor is the
main scale. The main scale is graduated into four 90-degree components. The main scale is
numbered to read from 0 to 90 degrees and then back from 90 degrees to 0. Any angle can be
measured with the Vernier bevel protractor, but you have to be careful to note which part of a
full circle you are measuring. For every position of the bevel protractor, four angles are formed.
Two of the angles can be read directly on the main scale and the Vernier scale while the other
two are supplemental angles. Keep track of the obtuse and acute angles and try to read from
zero whenever possible.

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PROCEDURE

1. Place the spirit level on the 4 sides of the surface plate. Ensure that the surface plate is
horizontal by centering the spirit level’s bubble in all the 4 positions.
2. Now place the sine bar on the surface plate.
3. Place the template with taper face on the flat face of the sine bar or place the sine bar
on the template.
4. If the template is too small to hold the sine bar, place the template on the sine bar and
increase the height from one end roller of sine bar by adding slip gauges.
5. Check the template for parallelism of the surface with the help of spirit level
(i.e., the level of the outer surface of template is equal to the surface plate
level)

6. The flatness of the template surface can be known by the position of the bubble in the
spirit level.
7. By using slip gauges (added at one end) increase the height so as to make the template
level with the surface plate.
8. Measure the total value of slip gauges (H).
9. Note down the centre distance between the rollers of sine bar (L).
10. Calculate angle Ɵ of the specimen by using the formula , sin-1 (H/L)
CALCULATIONS :-

1. WITH SINE BAR & SLIP GAUGES :

SPECIMEN : (i) TAPER BLOCK (ii) TAPER MANDREL

S.No SLIP GAUGES Distance Between H/L Sin-1(H/L)

HEIGHT (H) mm Rollers (L) mm
(i)

Average =
(ii)

Average =

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2. WITH BEVEL PROTRACTOR ( LC = 5̕)

(i) SPECIMEN : TAPER BLOCK

S.No. Main scale reading Vernier scale reading Total Reading

MSR(degrees) VSR (divisions) x LC MSR + VSR x L.C
(degrees, minutes)
1

3
Total1 + Total 2 + Total3
Average = =
3

(ii) SPECIMEN : TAPER MANDREL

S.NO Main scale reading Vernier scale reading Total Reading

MSR PSR MSR + VSR x L.C
1

2
3

Total1 + Total 2 + Total3

Average = 3 =

PRECAUTIONS:

a) While measuring with the bevel protractor, ensure that a surface plate is used. Also
ensure that the blades touch the surface plate and the specimen completely for an error
free measurement.
b) Sine bar should be used only when slip gauges are used for accurate measurement.
c) Wringing should be done to avoid errors due air films between 2 slip gauges.
d) Levelling of the surface plate must be done prior to the start of the experiment so as to
avoid any errors due to wrong levels across the surface plate.
e) Do not touch or apply any kind of pressure or place any weights on the surface plate
during the experiment, as it can affect the position of the bubble of the spirit level and
hence cause an error in the no. of slip gauges placed under the sine bar.

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RESULT

The taper angles of given specimen by using Sine Bar & Slip Gauges are :-

Taper Block
Taper Mandrel

The taper angles of given specimen by using the Bevel Protractor are :-
Taper Block
Taper Mandrel

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Exp7. STRAIGHTNESS OF SURFACE PLATE

AIM : To check the straightness of a surface plate along a given direction.

Learning Objectives:
1. To understand the use of instruments and to learn to take the measurements with and
calibration of instruments.
2. To understand the concept of how to use the instruments and take the measurements for
taper or angle jobs and work pieces.
APPARATUS Required :

1. Spirit Level; 2. Sine Bar; 3. Slip Gauges; 4. Surface Plate; 5. Polishing Cloth; 7. Scale / Steel
Rule
Description :

SURFACE PLATE – A surface plate is the most widely used reference surface. They are used as a
reference surface for testing other flat surfaces for marking out and measurements. A surface
plate is a geometrically true flat, level plane.

The material used for surface plate is of good quality close grained plain or alloy cast iron with
proper heat treatment. The Indian Standards categorises the surface plates into 2 grades “Grade
I” and “Grade II” but the industries classify them into 3 grades – “Grade AA”, “Grade A” and
“Grade B”.

“Grade AA” and “Grade A” are used for high class precision and inspection work. “Grade B” is
used for general workshop purposes. Although cast iron surface plates are highly popular, the
iron surface plates have the advantage of allowing a certain amount of wringing and holes are
not readily chipped out of its surface or edges from something dropped on it.

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THEORY :

A straight line is defined as the shortest length between 2 points. But a line is said to be straight
over a given length, if the variation of the distance of its points from 2 planes perpendicular to
each other and parallel to the
general direction of the line
remains within specified
tolerance limits.
Reference
Straight Line Straightness
Error
PROCEDURE :

1. The surface to be tested is cleaned. The spirit level is placed along the 4 edges of the surface
plate as shown in Fig. to check whether the plate is levelled approximately. If not, the plate can
be levelled.

Fig: Surface Plate

2. A straight line is drawn on the surface plate along the required orientation. It is divided
into a number of equal sections such that the length of each section is equal to the length
of the sine bar, say, AB, BC, CD and DE.
3. The sine bar is placed on the first section AB, so that the 2 rollers are placed on each end of
the 1st section A and B. The spirit level is placed on the sine bar and the bubble movement is
checked. The bubble movement indicates whether A is higher or lower than B.

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E
B C D
A

4. Now to bring back the bubble to the centre of the level, slip gauges are placed under the
rollers of the sine bar. In order to correct minute bubble movements, a combination of slip
gauges can be used under both the rollers, in such a way that the difference between the slip
gauges can elevate A or B.

5. Calculate the total net height of the slip gauges. This is equal to rise or fall of point B
relative to A. Record this value as –ve (with a minus sign) if point B is below A and as +ve if
point B is above A (with a plus sign).

6. Move the sine bar and the spirit level to the next section BC. Take another reading as in
steps 4 & 5. Continue this until all the sections CD and DE are completed.

7. Repeat the readings as the sine bar and spirit level is moved in the reverse direction
towards A. Take the average of the readings at each position / section as the
measurement result.

E
B C D
A

CALCULATIONS

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S. No. Section Rise or Fall over 50mm section Average rise or fall Cumulative

over 50mm section rise or fall

Forward (δf) Backward (δb) (δf + δb) / 2 (μm)

(mm) (mm) (mm)

1 OA

2 AB

3 BC

4 CD

5 DE

Now plot a graph between cumulative rise or fall of each section end and the position of the Sine
Bar. This graph is the contour of the given line AE drawn on the surface plate.

Next, a straight line is drawn connecting A and E. This is called the datum line AE.

Measure the ordinates of each points B, C and D from this straight datum line. Draw 2 lines
parallel to the datum line in such a way that each line passes through the highest and the lowest
points on the contour drawn.

The straightness error is the ordinate distance between the parallel lines measured parallel to
the Y-Axis. The tolerance on the straightness of the line is equal to the maximum deviation in
relation to the reference straight line through the 2 end points considered.

PRECAUTIONS

1. Ensure that the surface plate is at first levelled on all 4 sides, before beginning the
experiment.
2. After the surface plate has been levelled, do not place any other object or apply any
other force by leaning on the surface plate.
3. The slip gauges must be wringed in order to avoid any air gaps.
4. Clean the surface plate with petrol before starting the experiment so that the surface
plate is free of any grit, chips or dirt.

RESULT
a) The error in straightness of the given line is over a length of

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Exp8. THREAD MEASUREMENT

AIM : To measure the effective diameter of the given screw thread.

Learning Objectives:
1. To understand the use of instruments and to learn to take the measurements with and
calibration of instruments.
2. To understand the concept of how to use the instruments and take the measurements for
taper or angle jobs and work pieces.
APPARATUS :

1. Micrometer 2. Thread wire 3. Surface Plate 4.

Specimen

THEORY :

Fig: Screw thread terminology

A parallel screw thread is a continuous helical groove of uniform cross section and uniform axial
spacing formed on the exterior of a circular cylinder or on the interior of a circular hole so that
the axial displacement of a point travelling along the helix connecting corresponding points is
proportional to the angular displacement about the axis.

Pitch P of the screw is the distance measured parallel to the axis between the 2 corresponding
points on adjacent thread forms in the same axial plane. Major diameter D of the screw thread,
is the diameter of an imaginary cylinder, coaxial with the screw, and envelops the crest of
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the

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screw or root of the nut. Minor diameter d of the screw thread, is the diameter of an imaginary
cylinder coaxial with the screw or the nut, which makes a continuous contact at the roots of the
thread on the screw or the crest of the thread on the nut.

Effective diameter E is the diameter of the imaginary coaxial cylinder intersecting the thread in
such a manner that the intercept on the surface of the cylinder between the points where it
meets the opposite flanks of the thread groove, is equal to half the pitch (= P/2)

(M-D)/2
C P/2

W/2 W/2
O
A
θ

K E D M

M D W
BC = = OB  OC =
  – OC
 2  2
W
=  (KC  OK
)2
W
= ( cot  cos ec )
2 – 2P 2
W P
= (1 + cos ec )  cot
2 2

D = M  W (1 + cos ec ) + P cot 

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E = D  2  AC = D  CK
P
= [M  W (1 + cos ec ) + P cot ] (
2 cot )
P
= M  W (1 + cos ec ) + cot
2

Where,

M - Maximum length θ - Thread angle

W - Wire diameter E - Effective diameter
P - Pitch of the screw

For Metric threads with a thread angle of 60o, wire diameters suitable for measurement are as
follows:

a) Minimum diameter = 0.505P

b) Maximum diameter = 1.01P
c) Best diameter `= 0.577P

Three Wire Method :In this method three wires of equal and precise diameter are placed in the
thread grooves at opposite sides of the screw and by measuring the distance between the outer
surfaces of the wires with the Micrometer. Out of the three wires in the set two wires are placed
on one side and the third on the other side. The wires are either held in the hand are screwed in
the grooves by applying grease on the threads or by sticking the ends of the wires in wax or
Vaseline on a stand. Anyhow in such methods, we must ensure freedom to the wires to adjust
themselves under the micrometer pressure.
PROCEDURE:

1. Take the screw thread with a given pitch P. Select wires of diameter ranges given above,
i.e., with a minimum diameter of 0.505P
2. Measure the diameter of the wire with micrometer carefully. Let the wire diameter be W.
3. Place the wires on grooves of the thread such that one side of wire is on top of screw and
the two are below/ bottom side of the screw by applying grease.
4. Now place one anvil of the micrometer on top of the wire when placed on the screw and
the other anvil of micrometer on top of the two wires when placed below the screw.
5. Now measure the distance of the anvil length, say M.
6. Calculate the effective diameter of the screw using the equation.

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7. Repeat the experiment and calculate the average values.

CALCULATIONS

Least count, LC = Pitch of the screw / no. of divisions on pitch scale.

Pitch scale reading, PSR = Main scale reading / no. of turns.
Total measurement = MSR + VSR x LC

WIRE DIAMETER (W) : M16

S. MSR VSR VSR x LC Total = MSR + VSR x LC Error Adjusted Total

No = Total – Zero Error

4 Average Wire Diameter (W) = (Total 1 + Total 2 + Total 3) / 3

= mm

Where, MSR – Main Scale Reading

VSR – Vernier Scale Reading
LC – Least Count

WIRE DIAMETER (W) : M18

S. MSR VSR VSR x LC Total = MSR + VSR x LC Error Adjusted Total

No = Total – Zero Error

4 Average Wire Diameter (W) = (Total 1 + Total 2 + Total 3) / 3

mm

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WIRE DIAMETER (W) : M20

S. MSR VSR VSR x LC Total = MSR + VSR x LC Error Adjusted Total

No = Total – Zero Error

4 Average Wire Diameter (W) = (Total 1 + Total 2 + Total 3) / 3

= mm

MAXIMUM LENGTH (M) : M 16

S. MSR VSR VSR x LC Total = MSR + VSR x LC Error Adjusted Total

No. = Total – Zero Error

4 Average Max. Length (M ) = (Total 1 + Total 2 + Total 3) / 3 =

mm

MAXIMUM LENGTH (M) : M 18

S. MSR VSR VSR x LC Total = MSR + VSR x LC Error Adjusted Total

No. = Total – Zero Error

4 Average Max. Length (M ) = (Total 1 + Total 2 + Total 3) / 3 =

mm

Machine Tools Lab Department of Mechanical Engineering

 Raghu Engineering College (Autonomous)

MAXIMUM LENGTH (M) : M 20

S. MSR VSR VSR x LC Total = MSR + VSR x LC Error Adjusted Total

No. = Total – Zero Error

4 Average Max. Length (M ) = (Total 1 + Total 2 + Total 3) / 3 =

mm

CALCULATIONS FOR EFFECTIVE DIAMETER

Fig: Working Position

Where M = Max. Length of the micrometer reading
W = Wire Diameter
E = Effective Diameter

EFFECTIVE DIAMETER (E)

P
E = M  W (1 + cos ec ) + cot 
2
where P = Pitch of the thread.

(1) For M 16 Thread

M = 16.38 mm
W = 1.37 mm
P = 2.0 mm
θ = 600 (Metric threads with a thread angle of 60o )

Machine Tools Lab Department of Mechanical Engineering

 Raghu Engineering College (Autonomous)

E = 16.38 – 1.37 (1+Cosec 600) + 2 x Cot 60o

2
= 16.38 – 1.37 (1+1.1547) + 0.57735
= 16.38 – 1.37 (2.1547) + 0.57735 = 14.005 mm

(2) For M 18 Thread

M = 18.14 mm
W = 1.40 mm
P = 2.5 mm
θ = 600 (Metric threads with a thread angle of 60o
) E = 18.14 – 1.40 (1+Cosec 600) + 2.5 x Cot 60o
2
= 18.14 – 1.40 (1+1.1547) + 1.25 x 0.57735
= 18.14 – 1.40(2.1547) + 0.87466 = 15.998 mm

(3) For M 20 Thread

M = 21.08 mm
W = 1.18 mm
P = 2.5 mm
θ = 600 (Metric threads with a thread angle of 60o
) E = 21.08 – 1.18 (1+Cosec 600) + 2.5 x Cot 60o
2
= 21.08 – 1.18 (1+1.1547) + 1.25 x 0.57735
= 21.08 – 1.18(2.1547) + 0.87466
= 19.412 mm

PRECAUTIONS
1) Take readings without parallax error.
2) Handle the equipment with care.

RESULT
1. The effective diameter of wire for M16 thread is mm.

2. The effective diameter of wire for M18 thread is mm.

3. The effective diameter of wire for M20 thread is mm.

Machine Tools Lab Department of Mechanical Engineering