SRR ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

V SEMESTER

LAB MANUAL

ME6513 METROLOGY & MEASUREMENT LAB

NAME :

ROLL NO :

YEAR / SEM :

Signature
S.No DATE Name of the Experiment Mark
With Date
 1

10

11

12

Average Mark =

Expt No : Date:

EXPERIMENT ON TOOL MAKER’S MICROSCOPE.

Aim :-
To determine the thread parameters by using tool maker’s microscope.

Apparatus :-
Tool maker’s microscope & specimen
Theory :-
Introduction:- The tool maker’s microscope is a versatile instrument that measure by optical
means with no pressure being involved, thus very useful for measurement on small and delicate
parts. It is designed for:

a) Measurement on parts of complex form e.g. - profile of external thread, tool,

templates, gauges, etc.
b) Measuring centre to centre distance of holes in any plane.
c) A variety of linear measurements.
d) Accurate angular measurements.

Tool maker’s microscope is shown in fig. The optical head can be moved up or down the
vertical column and can be clamped at any height by means of clamping screw. The table which
is mounted on the base of the instrument can be moved in two mutually perpendicular
horizontal directions (longitudinal and
lateral) by means of accurate micrometer
screw having thimble scale and venires.

Principle of measurement
 Fig. Terminology Fig Principle of operation.

A ray of light from a light source fig. b is reflected by a mirror through 90’ It then passes
through a transparent glass plate (on which flat parts may be placed ). A shadow image of the
outline or counter of the workspaces passes through the objective of the optical head and is
projected by a system of three prisms to a ground glass screen. Observations are made through
an eyepiece. Measurements are made by means of cross lines engraved on the ground glass
screen. The screen can be rotated through 360’; the angle of rotation is read through an auxiliary
eyepiece
Procedure: -
A) Pitch Measurement: -

1) Take the hacksaw blade and mount on the moving blade of tool maker’s
Microscope in horizontal position.
2) Focus the microscope on the blade.
3) Make the cross line in the microscope coincided with one of the edge of the
blade.
4) Take a reading on ground glass screen, this is the initial reading.
5) The table is again moved until the next edge of the blade coincides with the
cross-line on the screen and the final reading takes.
6) The difference between initial and final reading gives pitch of the blade.

B) Teeth Angle :-

1) Place the blade on the table in same position.

2) Rotate the screen until a line on the angle of screen rotation is noted.
3) Take the angular reading, the initial one.
 4) Again rotate the screen until the same line coincides with the other flank of the
tooth.
5) Take the final angular reading.
6) The teeth angle of blade in the difference between the two angular
readings.
Observation Table:
I.R or F.R = MSR + (VSR x L.C)

Initial Final Difference

Parameters S.No Reading reading (F.R) (I.R – F.R) Mean
(I.R)
1
Pitch 2
3
1
Teeth Angle 2
3
1
Teeth Height 2
3

Result:-
A) Pitch = B) Teeth angle = C) Teeth Height =

Expt No : Date:

EXPERIMENT ON MECHANICAL COMPARATOR

Aim:-

Experiment on mechanical comparator and study of optical and pneumatic

comparator.

Apparatus:-
Dial indicator, slip gauges, surface plate etc.

Theory:-
Definition- A comparator is a device used to get dimensional variation between unknown
dimensions of a part and same standard or master setting (slip gauge).
Classification-
Based on principle used for magnification.
1. Mechanical comparators.
a. Dial-indicator.
b. Johnson ‘mikrokator’.
c. Read-type mech. comparators.
d. Sigma comparators.
2. Mechanical-Optical comparators.
3. Electrical and Electronic comparators.
4. Pneumatic comparators.
5. Fluid displacement comparators

Characteristic:-
1. The instrument must be of robust design and construction.
2. Must be free from backlash, wear effects and inertia should be minimum.
3. The maximum compensation for temperature effects should be provided.
4. The scale must be linear and must have straight line characteristic.
5. Indicator should be constant in its return to zero.
6. Vary sensitive as well as withstand reasonable ill usages
7. Maximum versatility i.e. wide operation range.
8. Measuring pressure should be low and constant.

Application of the comparator:-

1. In mass production where component are to be checked at a very fast rate.
2. A laboratory standard.
3. For inspection of newly purchased gauges.
4. attached with machines to maintain required tolerance in machining.
5. In selective assembly of parts.

Mechanical comparators:-

A] Dial Gauge (Dial indicator):-

 Figure. Dial Gauge

It is one of the most widely used mechanical comparator. It consists of a dial connected to
plunger projecting at its bottom. The plunger moves upward when a very slight upward pressure
as applied. The mechanism has a system connected to the toothed rack. A compound gear is
provided to connect toothed rack to pointer. A helical spring is used to bring back the plunger to
its original position. When pressure is released the pointer moves. The indicator is adjusted to
zero by rotating dial rim. The minimum reading of dial is 0.01mm. A revolution counter in form
of a small dial is provided to indicate the total travel by stem.

Advantages of Mechanical Comparator:-

1. Cheaper.
2. Do not require any external supply.
3. Linear scale for easy understanding.
4. Robust, compact, easy to handle.
5. Portable and suitable for ordinary workshop condition.

Disadvantages of Mechanical Comparator:-

1. More moving parts so friction is more.
2. Slackness in moving reduces their accuracy considerably.
 3. The mechanism has more inertia and this may cause the instrument to be sensitive to
variation.
4. Range limited as pointer moves over a fixed scale.

A] To compare against standard.

1. First decide the dimension of specimen to be compared against the standard.

2. Get the std.(desired) value of that dimension from design manual.
3. Build up a slip gauge bar of standard value by wringing.
4. Place the slip gauge bar, specimen and dial indicator on the surface plate as shown in
figure.(a).
5. The pointer of dial indicator is made to touch the top surface of slip gauge bar.
6. Adjust the dial indicator to zero reading.
7. Then pointer is made to touch the top surface of specimen as shown in figure.(a).
8. Note the dial reading, it gives the deviation of specimen dimension from standard
value.
9. Take minimum 3 reading for one dimension at different position as shown in figure.
(b).
10. Repeat the same procedure for different workpieces.
B] To determine dimension of a standard.

1. First measure particular dimension of specimen with steel rule.

2. Build up a slip gauge bar of height equals to measured dimension.
3. Place the slip gauge bar, specimen and dial indicator on the surface plate as shown in
figure.(a).
4. Make the dial indicator pointer to touch the top surface of slip gauge bar.
5. Adjust the dial indicator to zero reading.
6. Then make the pointer to touch the top surface of specimen as shown.
7. Note the dial reading at different point.
8. Repeat the same procedure for different dimensions.

Observation Table:-

S.No Nominal Slip Forward Reverse Error

 gauge Value mm mm Forward Reverse
mm mm
1
2
3
4
5

Result:-

A) Mean Forward Error =

B) Mean Reverse Error =

Expt No : Date:
MEASUREMENT OF TAPER ANGLE USING SINE BAR

Aim:-
To determine unknown angle using sine bar.

Apparatus:-

Sine bar, surface plate, dial indicator, slip gauges.

Introduction: - Sine bar is used in conjunction with slip gauges for precise angular
measurement. Sine bar is used either to measure angle very accurately or face locating any
work to a given angle. Sine bars are made from high chromium, corrosion resistant steel,
hardened, ground and stabilized.

Figure: Sine Bar

Two cylinders of equal dia. are attached at ends. The axes of these two cylinders are
mutually parallel to each other and also parallel to and at equal distance from the upper
surfaces of the sine bar. Accuracy up to 0.01mm /m length of sine bar can be obtain.

Precaution in use of sine bar :-

a) The sine bar should not be used for angle greater than 60o.
b) A compound angle should not be formed by mis-aligning the component with sine
bar.
c) Accuracy of sine bar should be ensured.
d) As far as possible longer sine bar should be used since many errors are reduced by
using longer sine bars.
Application of sine bar :-

A] Checking of unknown angles of small workpiece.

Figure. Checking of unknown angles of small workpiece.

B] Checking of unknown angles of heavy component.

H2
H1

Figure. Checking of unknown angles of heavy component.

Slip Gauges:-
Introduction:-

Slip gauges are rectangular blocks of steel having a cross-

section of about 30 by 10mm. These gauges are used to provide
end standard of specific length by temporarily combining a
number of individual gauge by ‘wringing’, each representing a
dimension (standard) into a single gauge bar. Here the basic
requirements are formation of a bar in reasonable cohesion
between individual element and its dimension truly within specific
limits representing the desired nominal dimensions.
Accuracy:-

Accuracy up to 10 millionth of an inch for flatness and

parallelism can be obtained in slip gauges.
Grading:-
Grading according to accuracy and application.
AA - for master slip gauges.
A - for reference purpose.
B - for working slip gauges.
Grade 2 - Workshop grade
Grade 1 - Tool-room grade (More precise
work)
Grade 0 - Inspection grade
Grade 00 - Standard-room grade
Calibration grade - Special grade (Prepared on chart)

Slip Gauge Table:-

Step
Sr. No. Slip gauge value or range Nos.
(mm)
1 1.005 - 01
2 1.01 to 1.49 0.01 49
3 0.5 to 9.5 0.5 19
4 10 to 40 10 04
5 50 to 100 25 03
Total
= 76
Wringing:-

Figure. wringing

The term ‘wringing’ refers to condition of intimate and

complete contact and of permanent adhesion between measuring
faces. Wringing is done by hand though sliding and twisting
motions. One gauge is placed perpendicular to other using
standard gauging pressure and rotary motion is then applied until
the blocks are lined up. In this way air is expelled from between
the gauge faces causing the blocks to adhere. This adherence is
caused partly by molecular attraction and partly by atmospheric
pressure. Similarly, for separating two wring slip gauges,
combined sliding and twisting motion should be used.
Procedure:-

1. Place the work piece/wedge above the sine bar

and make it horizontal with the base.
2. The dial gauge is then set at one end of the work
moved along the upper surface of the component.
3. If there is any variation in parallelism of the upper
surface of the component and the surface plate, it
is indicated by the dial gauge.
4. The combination of the slip gauges is so adjusted
that the upper surface is truly parallel with the
surface plate.
5. Note down the values of the slip gauges.
6. Calculate the angle using the formula.
θ=Sin-1(h/l)
7. Repeat the procedure 3 or 4 times and take the
average.

OBSERVATIONS:

S.No. HEIGHT(h) LENGTH(l) ANGLE

Calculations:-
A] Sin θ = h/L
 θ = Sin-1 ( h/L )

θ=

Results:-
The unknown angle of component is ___________
Expt No :
Date:

MEASUREMENT WITH VERNIER HEIGHT GAUGE

AIM:

To calibrate vernier height gauge.

INSTRUMENTS USED:

1. Surface 2. Vernier height gauge 3. Specimens

THEORY: Vernier Height Gauge: Vernier height gauge is a sort of Vernier

calipers equipped with a special with a base and other attachment, which
make the instrument suitable for height measurement. Along with sliding jaw
assembly arrangement is provided to carry a removable clamp. The upper
and lower surfaces of the measuring jaws are parallel to base, so that it can
be used for measurements over or under surfaces. The vernier height gauge
is mainly used in the inspection of parts and layout work. The vernier height
gauge can be used to scribe lines at certain distance above surface with a
scribing attachment in pace of measuring jaw. Dial indicators can also be
attached in the clamp and many exact measurements can be made as it
exactly gives the indication when the dial tip is touching the surface. Surface
plates as datum surface are used for the above measurements.
PROCEDURE:
1. Place the object and the vernier height gauge on the surface plate.
2. Note the value on the scale when the moving jaw is touching the bottom
of the object.
3. Take the moving /sliding jaw to the top of the object and note down the
value on the scale.
4. The difference between 3&2 will give the height of the object.

S.No Silp Gauge Value mm MSR mm VSR mm T.R. mm Error %

PRECAUTIONS:

1. The height gauges should be kept in their case when not in use.
2. Measuring jaws should be handled carefully.
3. While using the Dept gauge, it should be ensured that the
reference surface, on which the depth gauge is rested, is
satisfactorily true, flat and square.
 RESULT:

The given Vernier Height Gauge is calibrated.

Expt No :
Date:

Gear Tooth Measurement

Aim
1. Understand working and use of Gear tooth Vernier caliper,
2. Understand the importance of gear measuremen
Apparatus:
(a) Spur Gear (b) Gear tooth Vernier Caliper

Theory: The main parameters determining the profile of a spur gears are
pressure angle, circular pitch, tooth thickness, crest circle diameter and root
circle diameter. Here we describe the method for measuring of tooth
thickness by means of a gear tooth vernier caliper. The measuring principle
is based upon the determination of the exact depth from the crest of the tooth
at which the chordal thickness should be measured. The correct depth must
ensure that the chordal tooth thickness is measured at the pitch circle. For
spur gears, it can be shown that:

Where m = module, dp = pitch circle diameter, z = no. of teeth

Procedure
(1) Count number of teeth (z) on the gear.
(2) Measure outside diameter (do) of the gear.
(3) Calculate module m = do/(z+2)
(4) Calculate pitch circle diameter dp = mz.
(5) Calculate value of hm from equation (1).
(6) Set the gear tooth vernier caliper from depth and measure width w of
gear teeth
(7) Repeat the measurements on other teeth and determine the average value.

Observation Table:
Number of teeth on gear, z = __________ and outside gear dia do =
_____________

Sr. No Height (h) Width (w)

1
2
3
4
5
Result

1. Height =

2. Width =

Expt No :
Date:
TORQUE MEASUREMENT

AIM:

To measure the torque and find the error in measurement.

APPARATUS REQUIRED:

1. Torque sensor set up.

2. Weight.

THEORY: Torque represents the amount of twisting effort and numerically it

equals the product and perpendicular distance from the point of rotation to
the point of application of the force. This instrument is having a long
flexible bar. The steel part with a spring is attached to one end of the bar.
This end is known as a fixed end.
 The force or weight to be measured is applied to the other end
known as the free end. Two strain gauges are pasted on the top of the strain
gauge where the maximum strain is occurred due to the weight. As the
applied force is increased the bar will bend the resistance of the strain gauge
will change. The amount of the bar bent is directly proportional to the
applied force, so that the change in resistance will be directly proportional to
the force applied.

If a current is passed through the strain gauge, then the change in

voltage across the strain gauge will be proportional to the force. The
resistance of the strain gauge elements also changes with temperature. To
compensate for this problem two strain gauge elements are mounted at right
angles. These two strain gauges are connected in wheatstone bridge circuit.

So any change in resistance of the strain gauge due to temperature

will have effect on the differential output in the bridge. Is typically 2 to 3
mv/volt of applied voltage. For eg. If 10V is applied to the bridge, the full
load output voltage will be only 20 or 30 mV, this small signal can be
amplified with a differential amplifier or an instrumentation amplifier. The
torque value will be indicated directly on the digital reader.

Description : The torque measuring set up consists of Torque indicator and

torque cell with loading system. Torque indicator is a strain gauge signal
conditioner and amplifier used to measure torque due to load applied on the
Torque cell.

The digital indicator consists of

1) Power supply 2) signal conditioner

3) Amplifier and 4) ADC.

PROCEDURE:
1. Apply known weight in the free end of the bar.
2. Connect the transducer to the signal conditioning circuit.
3. Read the digital indicator reading (Torque)
4. Increase the weight in ascending order and read the output.
5. Decrease the weight in the decreasing order and read the output.
6. Repeat the process keeping the load at different points on the
fulcrum arm
TABLE:

Length =0.5 m.
 Calculated Indicator Calculated
S.no Actual load Indicator
reading error error

Length = 1 m.

Calculated Indicator Calculated

S.no Actual load Indicator
reading error error

GRAPH:
Plot graphs:

ACTUAL READING Vs INDICATOR READING

Result

Thus the torque is measured and the error is measured for the given
dimension.

Expt No :
Date:

FORCE MEASUREMENT USING LOAD CELL

Aim:

To measure force (Load) using load cell and study the instrument
characteristics.

Experimental set up:

The digital load measuring setup consists of a load indicator and load
cell with loading system Load indicator is a strain gauge signal conditioner
amplifier used to measure load due to load applied to load cell. Starin gauge
with Wheatstone bridge circuit is used for measuring load.
The load indicator is provided with ZERO balancing facility through
adjustable potentiometer.

Theory: The transducer is an elastic member that converts the quantity

measured through deflection/strain. The strain of specimen depends on
material and modulus. This strain is transferred to strain gauge bonded on
the material resulting in change in resistance of gauge. The starin gauges are
connected in the form of Wheatstone bridge whose imbalance gives output
proportional to change in resistance.

Procedure:

1. Check the connections and switch on the rocker switch in the front panel.

2. Allow 10 mins for warm up of instrument.

3. Adjust the potentiometer in the front panel till display reads ZERO.

4. Apply load on sensor.

5. The instrument reads the load on sensor and displays the value. Tabulate
the Readings.
TABLE:

Sl.No (1) Actual Load (2) Indicated 4 Error (2-3) %Error

Reading (3)

% Error =Col 4/load x100

Graph: Actual loading VS Indicated Loading

Result:

Thus the Force is measured using load cell and the instrument characteristics
are studied.

Expt No :
Date:
 TEMPERATURE MEASUREMENT

Aim:

To measure the temperature using copper constantan thermo couple.

Apparatus Required:

1. Thermo couple
2. Temperature measuring setup.
Procedure:

1. Connect the thermocouple supplied at the impute terminal if copper

constantan Thermocouple is used. Copper wire must be connected to the

terminal and constantan wire to –ve terminal.

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

3. Immerse the junction of thermocouple in boiling at 98° C by using

potentiometer marked max.

4. Repeat the procedure for 2 to 3 times.

Sl.no Actual Indicated

temperature C° temperature C°

10
Graph:

Result:

Thus the temperature is measured using thermocouple.

Graph:

Indicated Temperature Vs Actual Temperature

Expt No :
 Date:
MEASUREMENT OF STRAIGHTNESS AND FLATNESS USING
TWO AXIS AUTO COLLIMATOR

Aim:

To measure the straightness and Flatness given specimen using two

axis auto collimator.

Apparatus required:

Collimator unit, Base, plain reflector, optical Scanner

Procedure:

1. Testing square with auto collimator.

2. Level auto collimator unit on a stand a table.
3. Straighten the light.
4. Observe measuring graphical through the eye below.
5. The smallest discussion of linear scale is measured.
6. Bring plain reflector in front of the auto collimator to get
reflector.
7. Depending upon the verification in surface.
8. Using micrometer provided for eye piece we can measure
the frequency up in lose.
Formulae:

Deviation = Sin θ (A-B)

Where angle θ in rad & Distance A-B in mm

Parallel to the Axis:

Sl.no Distance from MSR Micrometer Result - θ Deviations

ref A-B ( mm)
(Min) (Sec) degree (mm)

2
 3

Perpendicular to the Axis:

Sl.no Distance from MSR Micrometer Result - θ Deviations

ref A-B ( mm)
(Min) (Sec) Degree (mm)

Result:

Thus the straightness and Flatness are determined using

autocollimator.

Graph: Deviation Vs Distance from reference

 E

M
A
T

P
1
2
3
4
5
6

Specimen MSR VSR

S.No T.R. mm
No mm mm

T
 E
M
A
T

P
1
2
3
4
5

Specimen MSR
S.No PSR mm T.R. mm
No mm

R
R