DEPARTMENT OF MECHANICAL ENGINEERING

VISVESVARAYA NATIONAL INSTITUTE OF

TECHNOLOGY NAGPUR

MEP 311
Metrology and Quality Assurance
Laboratory Manual

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 LIST OF EXPERIMENTS
Cycle-1

1. To perform Linear Measurements using Vernier caliper, Vernier Depth

gauge, Vernier Height gauge, Micrometer etc.

2. To perform Angle measurements using Bevel Protractor & Sine bar.

3. Testing and calibration of Dial Gauge using Dial Calibration Tester.

4. Testing and calibration of Dial Gauge using Slip Gauges.

5. Calibration of Micrometer and Vernier Calliper using Slip Guages.

6. Circularity Estimation Using Dial Gauge.

Cycle-2

7. Study and use of optical flat for flatness testing.

8. To measure Major Diameter, Minor Diameter, Pitch and Thread Angle

using (a) Tool Makers Microscope and (b) Profile Projector.

9. Evaluation of the Gear Profile and Alignment using Rolling Gear Tester.

10. Measurement of Radial and Axial Runout on Rotating Cylindrical Object

11.Measurement of Straightness using Inclinometer.

12. Statistical Quality Control, Experimentation and Analysis using Minitab.

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 EXPERIMENT NO. 1

Name of Experiment: To perform Linear Measurements using Vernier caliper, Vernier

Depth gauge, Vernier Height gauge, Micrometer etc.

Aim: To perform linear measurement using Vernier Caliper, Vernier Height Gauge,
Outside Micrometer, Depth Micrometer.

Instruments: Vernier Caliper, Vernire Height Gauge, Outside Micrometer, Depth

Micrometer

DESCRIPTION:

1. VERNIER CALIPER

Principle: The Vernier Caliper consists of two scales: (i)MAIN SCALE (ii). VERNIER
SCALE. Utilizing the difference between the two scales or the divisions, which are
slightly different in size, are used to increase the accuracy of measurement.

Description: Vernier Caliper consists of two scales, one is fixed and the other is
movable. The fixed scale is called as the Main Scale, which is calibrated on L - shape
frame and carries a fixed jaw. The movable scale is called as the Vernier Scale, which
slides over the main scale and carries a movable jaw. Both the scales have two
measuring tips. The accuracy of measurement depends on the condition of the
measuring frame w.r.t. main scale. When the two measuring tip surfaces are in contact
with each other, scale shows zero reading. An instrument screw is provided for finer
adjustments for the movable jaw. An arrangement is also provided to lock the sliding
scale on the main scale.

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 Least Count: To increase the accuracy of measurements, vernier instrument make use of
the difference between the two scales, which are slightly different in size. These
instruments have two scales. Main scale is fixed and the Vernier scale slides over the
main scale. When zero on the main scale coincides with the zero on the vernier scale; the
number of division on the vernier scale is one more than the number of division on the
main scale with which it coincides (i.e. 50 divisions on vernier coincides with 49 mm on
main scale) , so the value of the division on the vernier scale (0.98 mm) is smaller than
the value of division on the main scale (1 mm). The difference between the two used for
measurement 1mm – 0.98 mm = 0.02 mm. It can also be calculated as
Value of smallest division on the main scale 1
LEAST COUNT = = = 0.02
Total number of divisions on the vernier scale 50

Errors: The error in the measurement carried out by the vernier instrument are
usually due to the mishandling of the instrument and its jaws on work piece.
1. Errors due to play between sliding jaws on the scale.
2. If the sliding jaw frame becomes worn or warped, it will not slide separately or
snugly on the main scale.
3. Wear and warping of jaws will also cause 0 — 0 point on the main scale and
the vernier scale do not coincide with each other.
4. By misreading of the vernier scale.
5. Error by incorrect feel and touch.

Precaution:
1. The line of measurement must coincide with the line of scale.
2. While measuring outside diameter, the plane of the measuring tip of the caliper must
be perpendicular to the centerline of the work piece.
3. Before reading, try the caliper again for feel and location.

2. VERNIER HEIGHT GAUGE

Principle: This also a sort of vernier caliper, equipped with special Base Block. It has
a main scale and vernier scale mounted on a base casting which is machined perfectly
flat. It is used for Layout Inspection and Marking along with surface plate.

Construction:
(1) BASE: It is provided to ensure rigidity and stability with base machined exactly
flat.
(2) BEAM: The section is chosen such that it ensures rigidity during the use. The
rigidity should be such that the upward force of 1 Kg applied at the tip of
scriber when the measuring jaw is in the highest position in the plane containing the
measuring jaws.
(3) SCRIBER: It is made of hard material with which layout marking is possible

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(4) GRADUATION: All the graduations on the scale should be clearly engraved the
thickness of graduation on both the scales should be identical. For easy reading, it
is recommended that the surface of the beam and vernier should be dull finished.
(5) SLIDER: It has a good sliding fit along the full working length of the beam. A
suitable reading is incorporated to give the fine adjustment.

VERNIER HEIGHT GAUGE

Precautions:
1. The experiment should be performed on a surface plate
2. The zero of the vernier and main scale should coincide by touching the scriber with the
surface plate. If it does not coinciding then with the adjustment screw on main scale for zero
setting it should be set to zero.

3. EXTERNAL MICROMETER

EXTERNAL MICROMETER

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Principle:
The micrometer type instruments are used to measure external and internal diameters as
well as depth and height. The principle of such instruments consists of employment of the
screw and nut, both having accurately cut threads. One complete revolution of the screw
will advance it, in relation to the nut threads, a distance equal to the lead of the thread.

Description :
The micrometer screw gauge essentially consists of an accurate screw having about 10
to 20 threads per cm and revolve in a fixed nut. The other measuring tip consists of a
stationary anvil and base of frame. The screw is threaded for certain length and plain
afterwards. The plain portion is called as Sleeve and its end is the Measuring Surface.
Barrel is a fixed part attached with the frame. The thimble has got 50 divisions around its
periphery on the circular portion. A lock nut is provided for locking the dimensions by
preventing motion of the spindle.

Description of Various Parts:

(1) FRAME: The frame is so shaped as to permit measurement of the cylinder of
diameter equal to the measuring range of the micrometer.
(2) ANVIL and SPINDLE: The fixed anvil of micrometer screw gauge should protrude
at least 3 mm from the frame in order to permit the attachment of measuring wire
support. The anvil should be accurately ground and lapped with its measuring face. The
spindle and screw are initially lubricated with thin, light, non - corrosive oil and in that
condition the spindle should run freely and smoothly throughout the length of its travel.
There should be no perceptible backlash between the spindle screw and the nut.
(3). RATCHET DRIVER: The micrometer should be provided with the ratchet of
friction stop sufficiently diamond knurled to enable satisfactory operation. The
torsional movement of the ratchet drive should be so regulated that the force exerted
between the measuring faces is between 0.5 to 1 Kgf. It should be wear resistant steel.
(4). THIMBLE and BARREL: All the graduation lines on the barrel should be
clearly engraved and for each reading the surface of the thimble and barrel should have
dull finish and the graduation must be blackened.
(5). ADJUSTING NUT: Micrometer screw gauge is generally provided with friction and
adjusting nut to compensate for wear.

Working:
The job whose external diameter is to be measured is placed in between the barrel and
the spindle. The sleeve is first falls loosen slightly and then by light pressure on the
thimble it is moved up to the required end then the dimension are locked by using the lock
nut so that the accurate dimension can be measured.
Precaution:
1. The thimble should be moved gently with little pressure.
2. The exact diameter should be placed in between the barrel and the sleeve
3. Dimension should be accurately measured.
4. Zero error should be eliminated
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4. MICROMETER DEPTH GAUGE
It is used for the measurement of the depths of the holes, slots and recessed area. It has
got one shoulder, which acts as a reference surface and is held firmly and perpendicular
to the centerline of the hole. For the larger ranges of measurements, extension rods are
used. The rods are inserted through the top of the micrometer. The rods are marked after
10 mm so that it can be clamped at any position. The scale calibrated in this instrument
is in the reverse direction, the accuracy depends on touch.

DEPTH MICROMETER

PROCEDURE:

1. Measure the dimensions of the given specimen using linear measuring instruments
discussed above.
2. Draw a proper sketch of the specimen.
3. Mention the dimension on the sketch using variables like D for diameter and L for
length.
4. Write observations in the corresponding observation table.
5. Take 5 observations of each dimension.
6. Find the average value.
7. Mention the unit of dimension.

CONCLUSIONS:
Students are expected to write the findings of the experiment.

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 EXPERIMENT NO. 2
Name of Experiment: To perform Angle measurements using Bevel Protractor & Sine bar.

Aim: To perform angle measurement using Sine Bar and to study Bevel Protractor,
Clinometers, Angle Gauges, and Combination Set.

Instruments :
1. Sine Bar, 2. Slip Gauges, 3. Clinometers, 4. Angle Gauges 5. Combination Set, 6. Bevel
Protractor, 7. Spirit Level, 8. Work Piece

DESCRIPTION :
1. SINE BAR

Principle : Sine Bar is a precision instrument used along with slip gauges for accurate
angle measurement or angle setting. It works of sine principle.

Construction: Sine bar is not itself a complete measuring instrument. Another datum as a
surface plate, slip gauges, and indicating device to make measurement is needed. It consists
of a steel bar and two rollers. The bar is made of high carbon, high corrosion chromium
resistance steel suitably hardened, stabilized and precisely ground. Two rollers are of
accurate and equal diameter. They are attached to the bar at each end. The axes of rollers are
parallel to each other and also to the upper surface of the bar.

Working: For checking angle of component of small size, a sine bar is set at a nominal angle
on the surface plate by suitable combination of slip gauges. The component to be checked is
placed over the plane surface of sine bar as shown in the figure. A dial gauge is carried on
the surface plate and is moved along the upper surface of the component. If there is a variation

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in parallelism of the upper surface of the component and the surface plate, it is indicated by
dial gauge. The combination of slip gauge is so adjusted that the upper surface of the
component is truly parallel with the surface plate.

SINE BAR FOR MEASURING ANGLE OF HEAVY COMPONENTS

In case components are heavy and cannot be mounted on sine bars then above
arrangement is possible. Height over roller is measured using height gauge using dial test
gauge. This is achieved by adjusting vernier height gauge until dial gauge shows same
zero reading each time. The difference between two readings can be used to know the
angle as follows

3. BEVEL PROTRACTOR
For accurate angular measurement, vernier bevel protractor is commonly used. The
main scale is circular and is graduated in degree. The vernier scale mounted on it slides
on it. The vernier scale has a least count of 5 min. The graduation are used to read the
right and left side on the main scale. To measure angle, one straight edge is rotated
relative to another straight edge and the angle is read with the help of main and vernier
scale.

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 Precautions:
1. Sine bar should not be used for the angles greater than 40° because of any possible
error in construction.
2. Accuracy of sine bar should be ensured.
3. As far as possible longer sine bar should be used because the error are
minimized in log sine bar.

Experimental Procedure:
1) Place the sine bar on a plane surface (Surface Plate)
2) Place the taper work piece over the sine bar on a plane surface.
3) Move the dial gauge over the surface of work piece to check parallelism.
4) Put the combination of slip gauges under the roller the sine bar.
5) Repeat step three

Observations :
h  Height of slip gauges ; I Length between roller contact

ALL DIMENSIONS ARE IN …………

Digital Bevel
Test h Slip gauge gauge Protractor
Specimen h I θ o = Sin −1   combination
I

Result :
1. The taper of Specimen 1 is found out to be………… degrees
2. The taper of Specimen 2 is found out to be………… degrees

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 EXPERIMENT NO. 3

NAME OF EXPERIMENT: - CALIBRATION OF DIAL INDICATOR USING DIAL

CALIBRATION TESTER.

NEED FOR CALIBRATION

All measurement involving length and angle are comparative expect for absolute
measurement in wavelength of light. The work to be measured is being compared with
suitable standard. The standard may directly used against the work, as when gauge block are
used to measure a gap or height but most measurement involve the use of an intermediate
instrument, the comparator. The comparator itself is checked for manufacturing error and
calibrated for absolute measurement. During the services, mechanical part get worn out and
faulty reading result and hence the need for recalibration. In our experiment first of all it is
necessary to calibrate the unit with zero deflection of the dial method and various slip
gauges, the dial indicator is than calibrated with the help of dial tester.

THE EQUIPMENT

It consist of a rigid base on which a vertical column is fixed. There are two adjustable
brackets which can slide along the vertical column and can be adjusted to desired position
(height) and locked. Locking is effected by split sleeve (integral with the bracket) and a
knob. The equipment also has micrometer head. To the thimble of the micrometer a
graduated circular disk is fixed. The range of micrometer head is 0-25mm. The circular disc
has being graduated into 500 divisions. The pitch of micrometer is 0.5 mm thereby giving
least count of 0.001 mm (1 micron). The micrometer head has carbide tipped flat anvil so that
wear is minimum. The complete assembly (the micrometer head with the circular head) is
held vertically by bottom bracket. The top brackets received the dial indicator. The dial
indicator usually supplied with the mean for alternative method of fixing namely by means of
a back log or by means of the stem. When the first method is adopted, it is necessary for the
clamp to be quit tight, since slip may otherwise occur and false reading result.
When second method is used, care must be taken not to apply too great a clamping force as
this may cause the plunger to jam in the stem. The hole in the bracket which is to take stem
must be smoothly finished and truly circular and good fit on stem. The stem is purposely
made cylindrical to fine limit of accuracy, and the hole in the fixture should be
correspondingly accurate. Should the hole be not true and smooth then there may be a
tendency to nip the stem across a diameter, thus destroying it and causing the plunger to bind
or even lock. The holes in the fixture are so arranged so that the axis of dial indicator and
axis of micrometer anvil are coaxial.

PROCEDURE

1. The dial indicator is fixed in the hole of the fixture by means of stem. Make sure that
plunger just touches the anvil.
2. The pointer is adjusted to read zero in the 12 o’clock position. This is achieved by
rotating the bezel and clamping it in the desired position.

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3. Next step is to adjust the zero of the circular disc against the crossed wire. There is also
the provision to adjust the cross wire by means of lever so that it is in the field vision.
Thus the set up is ready for calibration
4. Rotate the thimble in the clockwise direction.
5. Note down the readings (read against the cross wire) for each 10 div. (0.10mm)
movement of dial gauge. Repeat the procedure for entire range of dial gauge.

ANALYSIS OF RESULT
A hypothetical set of reading obtained are tabulated for guidance.
TABLE
Division of dial gauge
0 10 20 30 40 50 60 70 80 90
Turn1 - -1 +1 - - - +6 +4 +2 -
Turn2 - - 0 +2 +4 - - - +3 +2
Turn3 - - - - +4 +6 +8 - - -
Turn4 1 -1 - - - - +7 +5 +3 -
Turn5 - - - +2 +4 - - - +5 +3

The graph is plotted similar to one shown in fig.1

OBSERVATION TABLE
Division of dial gauge
0 10 20 30 40 50 60 70 80 90
Turn1
Turn2
Turn3
Turn4
Turn5

CONCLUSIONS:
Students are expected to write the findings of the experiment and draw conclusion based on
those findings.

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 EXPERIMENT NO. 4

NAME OF EXPERIMENT: - TESTING AND CALIBRATION OF DIAL GAUGE

USING SLIP GAUGES.

PURPOSE
Dial gauge or indicator is most common inspection tool on shop floor in metrology
laboratories. Their accuracy over their working range is to be tested.

PRINCIPLE
The testing involves giving the plunger known displacement and correspondingly recording
the gauge reading and thus establishes error; if any in its working range.

The important steps before this are as follows-

1. The plunger stem should be made perpendicular to the surface causing displacement. In
this case it should be mounted perpendicular to surface plate. This is done by checking
with a small engineer’s square in contact with the plunger and viewing against light in
several positions, the gap should be same.
2. The height x should be accurately determined and combination of slips equal to this be
inserted to serve as zero reading base for providing a known displacement.
3. Make a combination slightly more than x and inserted below plunger. Dial gauge would
indicated some reading which is equal to an excess to length in combination over zero
base.
4. Readjust the combination to the changed value and try it. If there is no error in the dial
gauge at this stage, dial should read zero and at the same time be in contact with the slip,
which is indicated line on slip gauge top when moved under the plunger. If any reading
indicated still, readjust the slip and try till dial read zero; and still is in contact with slips
the set up is now ready.

EQUIPMENTS : Slip gauge, dial gauge, surface plate, small engineer’s square, magnetic
base, dial gauge tester.

PROCEDURE
1. Increase slip gauge combination by 1,2,3,…………….mm in steps of 0.1mm till the
complete range is covered.
2. Lift stem for inserting the combinations.
3. Record the dial readings.

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OBSERVATION TABLE:

Ascending order Descending order

Sr True Recorded Difference True Recorded Difference
no. displacement displacement displacement displacement

GRAPH
1. True displacement Vs Recorded displacement
2. Recorded displacement Vs Difference.

CONCLUSION and DISCUSSION

1. Is the dial gauge is suitable for its full range?
2. What are the likely sources of error?

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 EXPERIMENT NO. 5

NAME OF EXPERIMENT: - Calibration of a Micrometer and Vernier Calliper using Slip

Gauges

PURPOSE: A Micrometer can inherit some inaccuracies on account of manufacturing

defects and assembly and thus render it unsuitable for accurate measurement. It is therefore
necessary to identify these error and causes for finally adjusting the reading.

THEORY
Calibration provides these errors over the entire range of micrometer.
The type of error exist are-
1. Zero error
2. Progressive error
3. Periodic error
1. Zero error
When the micrometer anvil faces are brought in contact, the circular scale zero (0) does not
coincide with the reference zero line. This error is easily determined.

2. Progressive error
Some error in the micrometer screw pitch (say the pitch is 0.501 mm instead of 0.5 mm as it
should be) will mean that for every revolution of thimble the screw advanced by 0.001 mm
more than 0.5 mm the needed movement. Thus if we rotate thimble through 20 revolution ,
recorded movement by 20*0.5 mm where as the screw has actually moved by 20*0.501 mm.
Such an error of 0.001 mm gets on adding up and is therefore called as progressive or
cumulative error. Same thing occur if the pitch is less i.e. say 0.498 mm instead of 0.5 mm.
To determine this error slip gauge combination of uniformly increasing thickness one used as
slandered between anvil faces and reading are noted. The internal may be of 1 cm, 2cm, or
2.5 cm. as may be suitable. A graph plotted between error and distance will reveal of a
progressive error exists. The curve will be of nearly uniformly rising or dropping nature.

3. Periodic error

Periodic error is the error caused by eccentric mounting of thimble circular divisions (center
A) with respect to the screw axis 'B' is rotated through 90 degree, circular scale rotate along
with it and not on the axis 'A'. Therefore 25 divisions does not necessarily coincide with O.
This will happen for all position until once again 0.0 match after and full revolution. The
error, therefore is seen to exist only for a revolution period. A check by introducing slip
gauges of uniformly increasing thickness to cover the only 1 pitch length at different position
of anvil can be made for 1 revolution determining periodic error. If it exits, the nature of
curve shall be identical to the one revolution interval. The three errors explained above and
known for a micrometer for all at its position will enable us to compute the correct reading
from the observed one.

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OTHER MEASUREMENT
A micrometer can also be checked for the following by using optical flats.
1. Parallelism of anvil faces
2. Flatness of anvil faces
3. Coaxially

EQUIPMENT
1. Vernier micrometer - least count 0.001 mm, Range 25-50 mm, Pitch 0.5 mm
2. Micrometer stand
3. Slip gauge

PROCEDURE
Read micrometer after introducing 25.000 mm slips increased combination by 2.5 mm (or
1mm or 2 mm) and read the micrometer. keeping the interval some i.e. 2.5 or 1 mm,
increased the combination and read the micrometer till the complete range i.e. 25-50 mm is
covered. At a length say 28 mm introduce combination of following values in order.
28.0, 28.1, 28.2, 28.3, 28.4 and 28.5 and read the micrometer. Repeat measurement at other
any two lengths.

OBSERVATIONS

(A) PROGRESSIVE ERROR

Sr.no. True Distance (mm) Distance Read (mm) Error in (mm)
1
2
3
4
5
6
7
8
9
10

(B) PERIODIC ERROR

Sr.no. True Distance (mm) Distance Read (mm) Error in (mm)
1 28.0
2 28.1
3 28.2
4 28.3
5 28.4
6 28.5
7 28.6
8 28.7
9 28.9
10 29.0
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GRAPHS:
Plot graphs as below

1. Distance Vs Error for both periodic and progressive error ( X axis distance and Y axis
error )

DISCUSSION
1. Have you identified the existence of this error?
2. Do you agree with the likely causes of this error?
3. Can you use the information for accurate computation of an observed reading?
Illustrate by an example?
4. Have the anvil faces influenced the error?

PRECAUTIONS
1. Do not hold slips in hand for a long time to avoid thermal expansion.

2. It is essential that the measuring pressure be some always. Hence use the ratchet for
rotating the thimble and stop at the first click after anvil touch the slips.

3. Do not leave the slip gauges suspended in the anvils. Keep cloth pieces below the anvil
faces to avoid any damage to slips in the event of their slipping through the anvils

4. Use slips with maximum care.

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 EXPERIMENT NO. 6

AIM: Circularity Estimation Using Dial Gauge

Apparatus: Dial gauge, marker, specimen, centers
Theory: Circularity requires the surface of any cross section to meet size requirements and
also be within the circularity tolerance zone.

PROCEDURE: measure the diameter of the specimen using vernier caliper. Fix the
specimen in two centers. Mark 5 sections along the length of the specimen. Divide
circumference into 12 parts. Adjust the dial gauge. Note dial gauge deflection at every part.
Plot the polar graph.
OBSERVATION TABLE:
Point Section 1 Section 2 Section 3 Section 4 Section 5
1
2
3
4
5
6
7
8
9
10
11
12

OBSERVATIONS AND CONCLUSIONS

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 EXPERIMENT NO. 7

AIM :- STUDY AND USE OF OPTICAL FLAT FOR FLATNESS TESTING

APPARATUS: - Optical Flat and Monochromatic Light Source

OPTICAL FLAT
Flatness testing of a work piece is done by observing fringe pattern obtained by interference
of two monochromatic light rays reflected from, lower surface of top optical flat and upper
surface of lower flat surface through the very fine air gap between two flats. The essential
equipment for measurement by light wave interference is a monochromatic light source and a
set of optical flats. An optical flat is a circular piece of optical glass or fused quartz having its
two plane faces flat and parallel and the surfaces are finished to an optical degree of flatness.
Optical flats vary in size from 25 mm diameter to about 300 mm diameters. If an optical flat
is placed upon another flat reflecting surface without applying pressure it will not form an
intimate contact, but it will lie at some angle ‘θ’ making an inclined plane. If the optical flat
is now illuminated by monochromatic source of light, the eye if placed in proper position,
will observe a number of bands. These bands are produced by interference of the light rays
reflected from lower surface of the top flat and the top surface of lower flat through a very
thin layer of air between the flats.

In fig, the angle ‘θ’ between two flats is shown exaggerated too much in order to understand
the principle of interference. If the path lengths of two light rays differ by an odd number of
half wavelengths i.e. λ/2, 3λ/2, 5λ/2 etc, then the complete interference is achieved

PROCEDURE:
A) For a perfectly flat surface
1. Keep optical flat on masterpiece.
2. Apply sufficient pressure by two fingers so that no air gap exists.
3. Observe the fringe pattern.
4. Keep optical flat once again on same surface of the object and apply pressure gently
so that some air gap exists. Observe the fringe pattern.
5. When the fringes are perfectly straight and same fringe width for dark and bright

19
 band we conclude that the surface is perfectly flat.

B) For curved surfaces such as concave and convex.

1. Keep optical flat on a convex surface.
2. Apply light pressure on the flat so that it rocks on the new high spot of the convex
surface.
3. Observe the fringe pattern with the change in the contact point.
4. For convex surface the fringes curve around the point of contact. Keep optical flat on
a concave surface.
5. Apply light pressure on the edge of the flat and at the center.
6. Observe the fringe pattern with the change in the contact point.
7. For concave surface the fringes curve away from the point of contact

PRECAUTION
1) Take care while putting optical flat on surface that finished surface is on w/p
2) Handle the optical flat carefully while observing the curvature
3) Apply on the moderate pressure for proper contact

OBSERVATION TABLE:
Sample Fringe pattern Nature of surface Sketch of pattern
observed obtained

CONCLUSIONS

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 EXPERIMENT NO. 8 (a)

Name of Experiment: Tool Maker's Microscope

Aim: Measurement of major diameter, minor diameter, pitch angle of the thread .

Resources: Tool Maker's Microscope, Threaded Work piece

Theory:
Tool maker's microscope consist of the optical head which can be adjusted vertically along
the ways of a supporting columns. The optical head can be clamped in any position by a
screw. The working table on which the parts to be inspected are placed, is secured on a heavy
hollow base. The table has a compound slide by means of the measured part can have
longitudinal and lateral movements. Accurate micrometer screws having thimble scales
control these movements. At the base is arranged a light source which provides a beam of
light. The beam of light passes through a transparent glass plate on which flat parts to be
checked are placed. A shadow image of the outline of contour of the part passes through the
objective of the optical head. Observations are made through the eyepiece of the optical head.
Cross-lines are engraved on the ground glass which can be rotated through 360 degrees ,and
the measurement are made by these cross lines. The angle of rotation of screen can be read
through an auxiliary eyepiece provided on the optical head. The eyepiece field of view
contains an illuminated circular scale with a division.

PRECAUTION:
1. The position of the thread should not be disturbed .
2. Remove dust and burrs from the work piece .
3. Handle micrometer gently

PROCEDURE:
1. Clean the job with brush, remove all the dust partials, oil stains and burr.
2. Place the job on the co-ordinate glass taking care that it will not scratch the glass.
3. Switch on the rocker you will get an image of the work piece in the eyepiece.
4. Match the cross hair line with one edge of the shadow for major diameter, minor
diameter and pitch and note the reading on the micrometer.
5. The match the same line with other edge of the shadow of the same and note reading on
micrometer.
6. Difference in two reading is the dimension of work piece
7. Measurement of angle of the thread: It is determined by rotating the screen until a
line on the screen coincides with one flank of the thread profile. The angle of screen
rotation is noted and then the screen is further rotated till the same line coincides with

21
 the other flank of thread. The difference in two angular reading gives the actual angle
of thread on the screw.
OBSERVATION:
Initial Final
Specimen Thread Parameter Difference
Reading Reading
Angle of thread
Major Diameter
Minor Diameter
Thread Pitch
Angle of thread
Major Diameter
Minor Diameter
Thread Pitch
Angle of thread
Major Diameter
Minor Diameter
Thread Pitch

RESULT:
1. The major diameter of the thread is found to be ______________________ mm.
2. Minor diameter of the thread is found to be _______________________ mm
3. The pitch of the thread is found to be____________________________mm.
4. The angle of the thread is found to be _____________________.

CONCLUSIONS:
Students are expected to write the findings of the experiment and draw conclusion based on
those findings.

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23
 EXPERIMENT NO. 8(b)

Name of Experiment: Profile Projector

Aim: To measure the various thread parameters with the help of profile projector.

Resources: Profile projector, Threaded work peace

Theory:
Fundamentally projection comparator (projector) is a measuring instrument which project as
enlarge shadow of the part being measured on a screen. By this device complicated shaped
parts can be easily checked. In any projection system there are four essential element, viz.
source of light, collimating or condensing lens, projection lens and screen. The illumination
required for any projector in a parallel beam of light, which is possible if the source of light
is a point source and is placed at the principle focus of the collimating lens. The purpose of
collimating lens is to render the beam of light from point source parallel. The projection lens
consists of a system of lenses which form a real image on the screen of an object placed
between it and collimator. The screen is generally translucent so that the image can be
viewed from the opposite side.

Precautions:
• The position of the thread should not be disturbed,
• The reading should be carefully taken.
• Remove the burrs and dust from threaded sample.
• Do not touch the screen glass, worktable glass, lenses, mirrors and bulb by naked
hand to avoid the finger prints.
• Handle micrometer gently.

Experimental Procedure:
1. Clean the job with brush, remove all the dust partials, oil stains and burr.
2. Place the job on the co-ordinate glass taking care that it will not scratch the
glass.
3. Switch on the illumination light and adjust its intensity to get a image of the work on
screen. Adjust the focal length to get clear image depending upon the Magnification lens
selected (10x or 20x)
4. Match the cross hair line with one edge of the shadow for major diameter, minor
diameter and pitch and note the reading on the micrometer.
5. The match the same line with other edge of the shadow of the same and note reading on
micrometer.
6. Difference in two reading is the dimension of work piece.
7. Measurement of Angle of the thread :It is determined by rotating the screen until a line
on the screen coincides with one flank of the thread profile. The angle of screen rotation
is noted and then the screen is further rotated till the same line coincides with the other
flank of thread. The difference in two angular reading gives the actual angle of thread on
the screw.

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OBSERVATION:
Initial Final
Specimen Thread Parameter Difference
Reading Reading
Angle of thread
Major Diameter
1
Minor Diameter
Thread Pitch
Angle of thread
Major Diameter
2
Minor Diameter
Thread Pitch
Angle of thread
Major Diameter
3
Minor Diameter
Thread Pitch

RESULT: -
1. The major diameter of the thread is found to be __________________ mm.
2. Minor diameter of the thread is found to be ____________________ mm
3. The pitch of the thread is found to be _________________ mm.
4. The angle of the thread is found to be__________________.

CONCLUSIONS:
Students are expected to write the findings of the experiment and draw conclusion based on
those findings.

PROFILE PROJECTOR

25
 EXPERIMENT NO. 9

AIM : Evaluation of the Gear Profile and Alignment using Rolling Gear Tester

APPARATUS: Gear rolling tester, Gear tooth vernier caliper, vernier caliper

THEORY:
Brief description of different characteristics of measuring of tooth thickness by gear truth
vernier is given. It consists of a horizontal and a vertical vernier scale. It is based on the
principle of vernier scale. The thickness of a tooth at pitch line and the addendum is
measured by an independent tongue each of which is adjusted independently by adjusting the
slide screws on graduated beams.

TERMINOLOGY OF GEAR TOOTH

1. Pitch circle diameter (PCD) : It is the diameter of a circle which by pure rolling action
would produce the same motion on the toothed gear wheel. It is equal to D = (T X
OD)/(T+2)OD = outside diameter T = number of teeth

2. MODULE: It is defined as the length of the pitch circle diameter per truth. Module
m=D/T and is expressed in mm.

3. CIRCULAR PITCH (CP) : It is the arc distance measured around the pitch circle from
the flank of one truth to a similar flank in the next 1.00th CP==ΠD/T=Πm.

4. ADDENDUM: This is the radial distance from the pitch circle to the tip of the truth. It is
equal to one module.

5. Clearance: This is the radial distance from the tip of a tooth to the bottom of the mating
tooth space when the teeth are symmetrically engaged. Its standard value is 0.157m or
0.25m.

6. DEDENDUM: This is the radial distance from the pitch circle to the bottom of tooth
space. Dedendum = Addendum +Clearance = m +0.157m =1 .157m.=1.25m (metric
gearing system)

7. TOOTH THICKNESS: This is the arc distance measured along the pitch from the
intercepts with one flank to the intercepts with the other flank of the same tooth.

PROCEDURE:
For finding PCD, module, addendum, dedendum and clearance:
1. First find the blank diameter, OD by a vernier caliper and also count the number of
teeth T of the spur gear.
2. Next calculate pitch circle diameter D=(TxOD)/(T+2)
3. Find addendum, clearance, pitch, module and dedendum as per the formulae given in
the theory.

26
FOR CHORDAL TOOTH THICKNESS (using gear tooth calliper):
1. Set the chordal depth (addendum) on the vertical slide of the gear tooth vernier and then
insert the jaws of the instrument on the tooth to be measured.
2. Adjust the horizontal vernier slide by the fine adjusting screw so that the jaws just touch
the tooth.
3. Read the horizontal vernier slide and note the reading. It gives the chordal thickness of
tooth
4. Repeat the observations for the different teeth.
5. Compare the values of different characteristics with the standard value and set the
percentage error.

OBSERVATION:
1. Least count of caliper
2. Number of teeth

OBSERVATION TABLE FOR SETTING GEAR TOOTH CALLIPER FOR SPUR

GEAR

No of teeth N1 N2 N3
Chordal Thickness
Height of teeth

CHORDAL THICKNESS = (M.S.R+V.S.R*L.C)

HEIGHT OF THE TOOTH= (M.S.R+V.S.R*L.C)

CALCULATIONS:
1. Pitch circle diameter, D=(TxOD)/(T+2)=
2. Module, m =D/T mm =
3. Addendum = m =
4. Dedendum = m+0.157m =

27
Gear Rolling Tester:

CONCLUSION:

28
 EXPERIMENT NO. 10

NAME OF EXPERIMENT: Radial and Axial Runout

AIM: Measurement of Radial and Axial Runout on Rotating Cylindrical Object

29
 EXPERIMENT NO. 11

NAME OF EXPERIMENT: Straightness Measurement

AIM: Measurement of straightness using Inclinometer

30
 EXPERIMENT NO. 12

NAME OF EXPERIMENT: STATISTICAL QUALITY CONTROL USING MINITAB

SOFTWARE

Aim: Plotting of X bar and R Chart using Minitab Software.

Theory:
Statistical process control is an effective method for improving a firm’s quality and
productivity. Many tools may be utilized to gain the desired information on a firm’s quality
and productivity. Some of the more commonly used tools are control charts, which are useful
in determining any changes in process performance. These include a variety of charts such as
p charts, c charts and x bar and R charts.

X bar chart:
An x bar chart is used to monitor the average value, or mean, of a process over time. For each
subgroup, the x bar value is plotted. The upper and lower control limits define the range of
inherent variation in the subgroup means when the process is in control.

R chart:
An R Chart is a control chart that is used to monitor process variation when the variable of
interest is a quantitative measure. Now, what does all this mean? These charts will allow us
to see any deviations from desired limits within the quality process and, in effect, allow the
firm to make necessary adjustments to improve quality.

Construction of Charts:
In order to construct x bar and R charts, we must first find our upper- and lower-control
limits. This is done by utilizing the following formulae:
3σ 3σ
UCL = µ+ ;    LCL = µ− ;
n n
While theoretically possible, since we do not know either the population process mean or
standard deviation, these formulas cannot be used directly and both must be estimated from
the process itself. First, the R chart is constructed. If the R chart validates that the process
variation is in statistical control, the x bar chart is constructed.

Steps in Constructing an R chart

1. Select k successive subgroups where k is at least 20, in which there are n measurements in
each subgroup. Typically n is between 1 and 9. 3, 4, or 5 measurements per subgroup is quite
common.
2. Find the range of each subgroup R(i) where R(i)=biggest value - smallest value for each
subgroup i.
3. Find the centerline for the R chart, denoted by
4. Find the UCL and LCL with the following formulas: UCL= D(4)RBAR and
LCL=D(3)RBAR with D(3) and D(4) can be found in the following table:

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Table of D(3) and D(4)
n 2 3 4 5 6 7 8 9
D3 0 0 0 0 0 0.076 0.136 0.184
D4 3.267 2.574 2.282 2.114 2.004 1.924 1.864 1.816

5. Plot the subgroup data and determine if the process is in statistical control. If not,
determine the reason for the assignable cause, eliminate it, and the subgroup(s) and repeat the
previous 3 steps. Do NOT eliminate subgroups with points out of range for which assignable
causes cannot be found.
6. Once the R chart is in a state of statistical control and the centerline RBAR can be
considered a reliable estimate of the range, the process standard deviation can be estimated
using:

d(2) can be found in the following table:

n 2 3 4 5 6 7 8 9
d2 1.13 1.69 2.06 2.33 2.53 2.7 2.85 2.97

Steps in Constructing the XBAR Chart

1. Find the mean of each subgroup XBAR(1), XBAR(2), XBAR(3)... XBAR(k) and the
grand mean of all subgroups using:
2. Find the UCL and LCL using the following equations:
A(2) can be found in the following table:
n 2 3 4 5 6 7 8 9
A2 1.88 1.02 0.73 0.58 0.48 0.42 0.37 0.34

3. Plot the LCL, UCL, centerline, and subgroup means

4. Interpret the data using the following guidelines to determine if the process is in control:
a. one point outside the 3 sigma control limits
b. eight successive points on the same side of the centerline
c. six successive points that increase or decrease
d. two out of three points that are on the same side of the centerline, both at a distance
exceeding 2 sigma’s from the centerline
e. four out of five points that are on the same side of the centerline, four at a distance
exceeding 1 sigma from the centerline
f. using an average run length (ARL) for determining process anomalies

Example:
The following data consists of 3 sets of measurements of the diameter of an engine Shaft.

Measurement Measurement Measurement

n Range Xbar
#1 #2 #3
1 2.0000 1.9998 2.0002 0.0004 2.0000

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 2 1.9998 2.0003 2.0002 0.0005 2.0001
3 1.9998 2.0001 2.0003 0.0007 2.0001
4 1.9997 2.0000 2.0004 0.0004 2.0000
5 2.0003 2.0003 2.0002 0.0001 2.0003
6 2.0004 2.0003 2.0000 0.0004 2.0002
7 1.9998 1.9998 1.9998 0.0000 1.9998
8 2.0000 2.0001 2.0001 0.0001 2.0001
9 2.0005 2.0000 1.9999 0.0006 2.0001
10 1.9995 1.9998 2.0001 0.0006 1.9998

R CHART LIMITS            

R = 0.0004
UCL= ( R) D=4 *R = 0.001
2.574*0.0004
LCL= ( R) D=3 *R = 0
0*0.0004
X CHART LIMITS
X = 2.0001
UCL ( X ) =X + A2 R =2.0003
LCL ( X ) =X − A2 R =1.999

The graph for the above data can be plotted as below.

EXPERIMENTAL PROCEDURE:
1. Measure the component dimensions and note it down in the table according to group size.
2. Plot the graph using Minitab.

33
 How to operate Minitab?
1. To open the Minitab click on Star>Programmes>Minitab.
2. Click on File>New>Select Minitab Worksheet>Click Ok.
3. Structure your data down a column or across rows, using the following table as a guide.
Multivariate data must be entered down columns, with one column for each variable.

Subgroups are equal size Subgroups are unequal size

Univariate Down columns or across rows Down columns with subgroup
(one variable) indicator column
Multivariate Down columns Down columns with subgroup
(more than indicator column
one variable)
4. Now choose Stat > Control Charts > Variables Charts for Subgroups > Xbar-R.
5. Choose All observations for a chart are in one column.
6. Select the column and then enter the subgroup size.
7. Click OK to get results.
The Xbar-R chart is displayed which also indicates the UCL and LCL values of both the
Xbar and R.

CONCLUSION:

34