DEPARTMENT OF MECHANICAL ENGINEERING METROLOGY AND SURFACE ENGINEERING LABORATORY MANUAL MARRI LAXMAN REDDY INSTITUTE OF TECHNOLOGY & MANAGEMENT Dundigal, Quthbullapur (M), Hyderabad – 500 043, R.R.Dist. A.P Date of Issue: 29-06-2013 Compiled by Mr. CH. VAMSHIKRISHNA Document No: MLRITM / ME / LAB / SOP Version : Authorized by Date of Revision: 10-07-2013 Verified by Dr. R. Kotaiah HOD ME LIST OF EXPERIMENT.(METEROLOGY LAB) S.NO Name of the experiment. 1. VERNIER CALIPERS 2. MICROMETER(OUTSIDE) 3. MICROMETER(INSIDE) 4. GEAR TOOTH MICROMETER 5. BORE GUAGE 6. SPIRIT LEVEL 7. OPTICAL BEVEL PROTRACTOR 8. TOOL MAKERS MICROSCOPE 9. SCREW THREAD MICROMETER 10. VERNIER HEIGHT GAUGE 11. MICROMETER DEPTH GAUGE 12. ALIGNMENT TEST ON DRILLING MACHINE 13. ALIGNMENT TEST ON MILLING MACHINE 14. ALIGNMENT TEST ON LATHEMACHINE VERNIERCALIPERS-EXP(1) Aim:To measure the length and diameter using vernier calipers Apparatus:Linearmeasurement applies to measure the length, diameter, height and thickness including external and internal measurements. These are designed for linear and end measurement. Construction:Vernier consists of 2 scales one fixed and other movable. The fixed scale known as the main scale is calibratyed on “L” shaped frame and carriers a fixed jaw. The movable vernier scale slides over the main scale and carriers a measuring tip when the jaws are closed the zero of vernier and main scale coincide.An adjustment is provided to liock the sliding scale. Use:These are used for both – internal and external measurement, its generate used for measuring by closing the jaws on work surface and taking readings from main scale is examined to as certain which of its division coincide and added to the main scale reading. Least count= One division of main scale reading/ No. division on scale .mm 49 MSD=50 VSD 1 MSD=1mm 1 VSD= 49 MSD/50 VSD L.C= 1MSD- 1VSD = 1- 49/50 =0.02 mm Precautions:1.Line of measurements and scale must coincide 2.Measurement tips of caliber should parallel to the work place center line 3. Do not apply pressure on place. Calculations: Lengthofthespecimen S.NO MSR(mm) VSR VSR X LC TR= MSR + (VSR X LC) mm VSR VSR X LC TR= MSR + (VSR X LC) mm VSR VSR X LC TR= MSR + (VSR X LC) mm 1 2 3 4 Diameterofthespicemen S.NO MSR(mm) 1 2 3 4 Depthofthespicemen S.NO 1 2 3 4 MSR(mm) Thicknessofthespicemen S.NO MSR(mm) VSR VSR X LC TR= MSR + (VSR X LC) mm VSR X LC TR= MSR + (VSR X LC) mm 1 2 3 4 InsideDiameterofthespicemen S.NO MSR(mm) VSR 1 2 3 4 Result:The experiment is conducted on the vernier calipers for measuring for the physical quantities of the given spicemen. Conclusion:1. 2. 3. 4. 5. Length of the spicemen ----------- mm Diameter of spicemen----------- mm Inner diameter of the hollow cylinder- ----------- mm Outer diameter of the spicemen- ---------- mm Thickness of the spicemen----------- mm MICROMETER(Outside)--------EXP(2) Aim:To measure the length, height and diameter of the given spicemen Apparatus:Micrometer, spicemen Micrometer:It is one of the most common and most popular form of measuring instrument for previse measurement with 0.001 mm accuracy micrometer with 0.001 mm are available. Principle:Micrometer works on the principle of screw and most when is turned through pitch distance i.e., one revolution. It advances by one pitch distance i.e., on revolutions of screw corresponds to a linear movement of a distance equal to the pitch of the thread. Least count (L.C) = 1 Division of MSR/ No of Divisions of the PSR Procedure:1. 2. 3. 4. 5. 6. Select the micrometer with a desired range depending upon the fire of the work piece to be measured. The next step is to check it for zero error incase of 0.25 mm micrometer, the zero error is checked by contracting the faces of the fixed anvil andf the spindle. The barrel has graduation, in interval, of 1mm above this reference line. These are also graduation below reference line OLH the middle of 2 successive upper graduation so as to read 0.5mm For measuring the dimension, hod work below faces of the anvil and spindle and then move the spindle by rotating the thimble limit and spindle by rotating then touches the work piece. Take the thimble reading which coincides with the reference line on the sleeve Total reading=MSR + (LC X PSR) mm Calculations:Lengthofthespicemen S.NO MSR(mm) VSR VSR X LC TR= MSR + (VSR X LC) mm VSR X LC TR= MSR + (VSR X LC) mm 1 2 3 4 OuterDiameterofthespicemen S.NO 1 2 3 4 MSR(mm) VSR Thicknessofthespicemen S.NO MSR(mm) VSR VSR X LC TR= MSR + (VSR X LC) mm 1 2 3 4 Precautions:1. 2. 3. First clean the micrometer by wipping off dirt. Set zero readings on instrument before measuring Hold the point whose dimensions is to be measured properly turn thimble. Result:The experiment is conducted on micrometer to find out the length, diameter and thickness of the given spicemen. Conclusion:1. 2. 3. Length of the spicemen -----------mm Outer Diameter of the spicemen -----------mm Tjhickness of the spicemen -----------mm INSIDEMICROMETER(3) Aim:To determine inside diameter is a given hollow spicemen Apparatus:Inside micrometer, hollow spicemen Micrometer:It is one of the most common and most popular form of measuring instrument for precious measurement with 0.001mm accuracy are also available. Principle:Micrometer 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 corresoonds 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:1. 2. 3. 4. 5. Select the micrometer with a desired range depending upon the size of the work piece to be measured. The next step is to check it for zero error. In case of 0.25mm micrometer, the zero error is checked by contracting the faces of fixed anvil and the spindle. The barrel has graduation , in travels of 1mm above the reference line For measuring the dimension, hold work b/w faces of the anvil the spindle by rotating then touches the work piece Take the thimble reading with coincides with the reference line on the sleeve. Total reading = MSR + (PSR X LC )mm Precautions:1. 2. 3. first clean the micrometer by wiping off dirt, fit, dust grit off it. Clean them with a piece of cloth or paper Set zero readings on instrument before measuring. Innerdiameterofthespicemen-1 S.NO MSR(mm) PSR PSR X LC TR= MSR + (PSR X LC) mm PSR X LC TR= MSR + (PSR X LC) mm 1 2 3 4 Innerdiameterofthespicemen-2 S.NO MSR(mm) PSR 1 2 3 4 Result:The experiment is used to find the inner diameter of the hollow spicemen of given spicemem Conclusion:The inner diameter of the hallow spicemen is ---------------- mm GEARTOOTHMICROMETER–EXP(4) Aim:To determine the thickness of given gear tooth. Apparatus:Gear tooth micriometer, gear Theory:Gear tooth micrometer is used to measure the thickness of gear tooth at pitch line. It is similar to simple micrometer but gear tooth micrometer having flanks at the end of anvil and spindle. The flanks of the micrometer. Gives the thickness of gear tooth at pitch line. Principle:Gear tooth micrometer works on the principle of screw and when screw is turned through nut for one revolution 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 thread. Least Count(LC)= Pitch of the spindle screw/ No of divisions of the spindle(mm) Procedure:1. 2. 3. 4. 5. Select the micrometer with a desired range depending upon the thickness of the work piece to be measured. The next is to check it for zero error in case of 0.25mm micrometer, the zero error, is surfaces of anvil and spindle. The barrel has graduations, in interval of 1mm above the subsequent line. For measuring, hold the work piece b/w faces of anvil and spindle and move the spindle by rotating the thimble unit it just touches the work piece. Take the thimble reading which coincides with reference line on the sleeve. Total reading = MSR+(PSR X LC)mm Simplecalculations:MSR = 3mm PSR= 6mm LC = 0.01mm Error = 27mm PSR X LC = (6+27)X0.01=0.33mm TR=MSR+(PSRXLC)=3+0.33mm Precautions:1. 2. 3. Clean the micrometer by wiping off dirt Clean the micrometer thoroughly with paper or cloth Set zero readings on instrument before measuring Pitchcirclediameter S.NO MSR(mm) PSR PSR X LC TR= MSR + (PSR X LC) mm PSR PSR X LC TR= MSR + (PSR X LC) mm 1 2 3 4 5 Diameterofgear S.NO MSR(mm) 1 2 3 4 5 Result:The experiment is conducted on gear tooth micrometer and the thickness is diameter Conclusion:The thickness of the given spicemen gear tooth is found to be mm BOREGAUGE-EXP(5) Aim:To determine the bore diameter (int. dice) of the given spicemen Apparatus:Bore gauge, Anvils, Washers, Specimens Theory:Bore gauge, is generally used to determine the bore diameter of components. Bore gauge consists of following parts. 1. 2. 3. 4. Dial gauge Vertical column Arrangement of anvil and washer Movabale spindle Dialindicator:This is used for measuring and checking linear measurement. These require less skills in their use than other instruments such as micrometer. Gauges etc., when dial indicator is used as essential part in mechanism of any set up for measure purpose. It is referred as dial gauge. This dial gauge consists of graduated circular dial. Pointer. Point. Pointer gear train arrangement vessel clamp, revolution counter. It activates a pionion which is attached to the pointer shaft. A gear train is used b/w plunger rack and pinion, to magnify the movement of the plunger to the pointer. A revolution counter is used to count the number of revolutions of the pointer Least count = 0.01mm Procedure:1. 2. 3. 4. Select the suitable anvil and washer to measure the dimension of given spicemen. Insert anvil and washer at the bottom of vertical column of bore gauge Subtract the dial indicator value from the sum of anvil and washer value. Which gives the bore diameter of given spicemen Repeat same procedure to get the bore diameter at different positions of spicemen Samplecalculations:Least count (LC)=0.01mm Anvil size = 45mm Washer size = 45mm Total indicator Reading = 14 X 0.01= 0.145mm Total Reading=(Anvil size + Wasjher size)-(Dial indicator for Reading) = (45+4.5)-(0.145)=49.355mm CalculationTotalreading:- Bore diameter = (Anvil size + Washer Size)- (Dial indicator Reading). InnerDiameter ofthespecimen-1 S.NO Anvil Size Washer size Dial indicator reading TR= Anvil size+ Washer size – Dial indicator reading (mm) Dial indicator reading TR= Anvil size+ Washer size – Dial indicator reading (mm) 1 2 3 4 5 InnerDiameter ofthespecimen-2 S.NO Anvil Size Washer size 1 2 3 4 5 Result:The experiment has been conducted on bore gauge to determine the bore diameter of given spicemen. Conclusion:The bore diameter of the given spicemen is mm SPIRITLEVEL–EXP(6) Aim:To check the flatness of given surface plate Apparatus:Spirit level, surface plate Theory:Generally spirit level is used for leveling the machinery and other instruments. But spirit levels are also used to measure the angles. It is also called precision level. It consists of glass tube and of the tube. If the tube is fitted through a small angle if R- radius of tuibe Ldistance of bubble moved when spirit level is fitted to same angle The angle is calculated as fallows L=R8, 8=L/R Procedure:1. 2. 3. 4. 5. Keep the spirit level on the surface plate Observe the bubble in the spirit level If bubble is in the middle of spirit level than surface is flat. If bubble is not in the middle of spirit level than surface is not flat Repeat the same procedure at different places of surface plate Flatnessofthespecimen S.NO 1 2 3 4 5 Horizontal Vertical Result Result:The experiment has been conducted on spirit level to check the flatness of given surface plate Conclusion:The given surface plate is flat/not flat--------------------- OPTICALBEVELPROTRACTOR—EXP(7) Aim:To determine angle of given specimen Apparatus:Bevel protractor, spicemen Theory:It is the simplest for measuiring the angle below the two faces of the component Their consists of protractor which is used to measure the angles 1) Vernier 2) Optical Vernierbevelprotractor:It consists of a base plate to the main body and adjustable blade which is attached to the circular plate. A vernier scale is provided on the main scale the adjustable scale is capable of rotating freely about the center of the main scale and it can be locked at position by lock nut. It is capable of measuring 0 to 360 deg. The main scale on the disc is graduiated in degrees of arc. The vernier scale has 12 divisions on each side of centre zero. Each division on the vernier scale = 5pow1 of arc which is the least count of vernier scale The reading of vernier bevel protractor = MSR+(VSR X LC)mm Opticalbevelprotractor:A recent development of vernier bevel protractor is optical bevel protractor. In this instrument a glass ole is divided at 10pow1 of arc intervels through out 360deg and this glass ole is fitted inside the main body. A lens is fitted through which measurements are taken from the glass ole. With the help of the optical bevel protractor it is possible to read 5pow1 of arc 1.e., LC of this instrument is 5pow-1 Procedure:1. 2. 3. 4. Place the adjustable blade on the component Tight the blade using lock nut Take the main scale reading Take the vernier scale reading from vernier scale which is fixed on the main sxcale through lens Angleofthespecimen-1 S.NO 1 2 3 4 5 MSR0(mm) VSR’ VPSR X LC TR= MSR + (VSR X LC) mm Angleofthespecimen-2 S.NO MSR0(mm) VSR’ VPSR X LC TR= MSR + (VSR X LC) mm 1 2 3 4 5 Result:The experiment is conducted an optical bevel protractor and angle of given specimen is determined Conclusion:The angle of given specimen is TOOLMAKERSMICROSCOPE-EXP(8) Aim:To determine the angle and pitch of given external screw thread Apparatus:Tool makers microscope, specimen Theory:The tool maker microscope is designed for measurement of components of difficults forms. Ex:- profile of external threads, tools , guage. It can be used for measuring center to center distance of holes in any plane it consists of optical head which can be adjusted vertically along inspection the table can be moved in longitudinal direction and lateral direction by micrometer screws, which arte having barrel and thimble at back of base light is arranged which provides on the optical head. The image of component passes through optical head and observations. The reading of longitudinal micrometer is noted. The difference gives the pitch of the thread. Calculations: Table:1. s.no MSR PSR TR MSR PSR TR MSR PSR TR MSR PSR TR Table:2. s.no Result:The experiment is conducted on tool makers microscope , the angle, pitch of thread determined. Conclusion:The pitch of the screw thread = 1.155mm Angle of external screw thread = 35deg.17’ SCREWTHREADMICROSCOPE-EXP(9) Aim:To determine the diameter of the thread Apparatus:Screw thread micrometer, specimen Principle:Micrometer work on the principle of screw. When screw is turned through nut one revolution it advances by one pitch distances by one pitch distance i.e., one revolution of screw corresponds ta a linear movement of a distance equal to the pitch of the thread LC= Pitch of the spindle screw / No . of divisions on the spindle. Procedure:1. 2. 3. 4. 5. Select the micrometer with a desired range depending upon the size of the work piece to be measured The next step is to check it for zero error in lost of 0.25mm Micrometer. The zero error is checked by contracting the faces of the fixed axial. The spindle. The barrel has graduation in internal of 1mm above the reference line. There are also graduation below the reference line out the middle of two successive upper graduation so as the read 0.5mm For measuring the dimension, hold work below faces of axial and spindle. Take the thimble reading while consider with the reference line on the sleeve TR=MSR+(lc X PSR) Precautions:1. 2. 3. 4. Clean the micrometer by whipping off dirts, oil, dust, grit off it. Clean them with a piece of cloth or paper Clean measuring faces of anvil and spindle Hold the part whose dimension is to be measured. Pitchdiameterofthespecimen S.NO 1 2 3 4 5 MSR(mm) PSR PSR X LC TR= MSR + (PSR X LC) mm Outerdiameterofthespecimen S.NO MSR(mm) PSR PSR X LC TR= MSR + (PSR X LC) mm 1 2 3 4 5 Result:The experiment is conducted on screw thread micrometer and the diameter of the screw thread is determined Conclusion:The diameter of screw thread is obtained as mm VERNIERHEIGHTGAUGE-EXP(10) Aim:To measure the height of the given specimen by vernier height gauge Apparatus:It is similar to vernier calipers, but in this graduated is held in a vertical position and it is used in conjunction with a surface plate Construction:A vernier height gauge consists of :1. 2. 3. A finely grouped and lapped base. The base as massive and robust in construction to ensure rigidity and stability. A vertical graduated beam (or) column is supported on a massive base. Attached to the beam is sliding vernier head carrying the vertical scale and a clamping screw. Features:1. 2. 3. 4. 5. 6. All the parts are made of good quality steel or stainkless steel The beam should be sufficiently rigid and square wit base. The measuring jaws should have a clear projection from the edge of the beam. Atleast equal to the projection of the base from the beam The upper and lower gauging surface of the measuring jaws shall be flat and parallel to the base Scruber should also be of the same nominal depth as the measuring jaws so that it may be resolved Projection of the jaws should be atleast 25mm Precautions:1. 2. When not in use .vernier height guage should be kept in to case It should be tested for the straightness, squareness and parallelism of the working focus of the beam. Lengthofthespecimen-1 S.NO 1 2 3 4 MSR(mm) VSR VSR X LC TR= MSR + (VSR X LC) mm Lengthofthespecimen-1 S.NO MSR(mm) VSR VSR X LC 1 2 3 4 5 Result:The height of given specimen is found using vernier height gauge Conclusion:The height of the specimen and obtained as mm TR= MSR + (VSR X LC) mm MICROMETER DEPTHGAUGEEXP(11) Aim: It is used for measuring the depth of holes , slots and recessed area. Apparatus: Micrometer , specimen. Theory: It has got one shoulder which act as reference surface and is held firmly and perpendicularly to the center line of the hole. Here also for larger ranges of measurement , extension rod are used. The screw micrometer depth gauge has range of 20mm or 25mm. the length of the micrometer depth gauge varies from 0 to 225mm. the rod is inserted through the top of the micrometer. The rod is marked after every 10mm so that it could be clamped at any position in using this instrument . Procedure: 1. 2. 3. 4. 5. To measure the depth of any material, use the micrometer depth gauge. Take the sample piece, the length of the rod varies from 0 to 225mm. Various rods are used as per requirement at the certain limit that gauge will move as it is by rotating screw in clock wise direction. Tight the screw and measure the main scale and circular scale also adding the initial value of the rod this gives MSR, VSR, TSR by adding LC. Note down readings by following procedure. Observation Table: Sr .No 1 2 3 4 5 MSR VSR LC TSR Result: The depth of the given specimen is found using MICROMETER DEPTH GAUGE. Conclusion: 1. 2. Depth of the hole Depth of the slot mm. mm ALIGNMENTTESTONDRILLINGMACHINE-EXP(12) Aim:To perform alignment tests on drilling machine Apparatus:Gauge blocks, dial gauge, straight edges FlatnessofclampingsurfaceofBase:This test is performed by placing a straight edge on same dimension of two gauge blocks on the plate in the various dimensions. The error is noted by inserting the feeler gauge between gauge block and straight edge if clearance is noted than it is said that the base plate is not flat otherwise it is flat. FlatnessofclampingSurfaceofTable:This test is performed by placing a straight edge on same dimension of 2 gauge blocks on the table in the various dimensions. The error is noted by inserting the feeler gauge between gauge blocks and straight edge otherwise it is running in proper way PerpendicularityofDrillHeadGuideWithBaser:Perpendicularity (squareness) of drill head guide with the base plate is performed by placing the frame levels on drill head guide and base plate. Th3e error is noted by nothing the difference of two frame levels. If the difference is 0 then it is said that sleeve is parallel to base plate. TotalDeflection:For this test in dial indicator is fioxed on table and its feeler touches the surface of the spindle.The dynamometer or load is applied to the spindle and spindle is rotated. In this position observe the diviation of dial gauge if any devitation is noted then it is said that the spindle is deflected under load otherwise under load otherwise no deflection of spindle under load. ALIGNMENTTESTONMILLINGMACHINE-EXP(13) Aim:To Perform the alignment test on milling. Apparatus:Spirit level, gauge blocks, dial gauge Theory:Following are the tests on milling machine Testforlevelingofmillingmachine: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. TrueRunningofspindle:A mandrel placed in the spindle and tedt 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. TrueRunningofspindle:For this test the mandrel is p[laced in the spindle and dial indicator is fixed on the table. The feeler of dial gauge is made to touch the surface of manderal. ParallelismofspindleAxiswithitsverticalmoment: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 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. Parllelism(or)TableSurfacewithlongitudinalsurface: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. ParallelismofTableSurfacewithmainspindle: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 machione to the table. ParallelismofTableSurfacewithArbor:Arbor is placed in the spindle and test is conducted on the surface of order. If any degration is noted than it is saidf that arbor is not parallel to the table ALIGNMENTTESTONLATHEMACHINE---EXP(14) Aim:To perform alignment test on table Apparatus:Spirit level, gauge blocks, dial gauge Theory:The following are the alignment tests on lathe. Levelingofmachine:It is essential that a machine tool should be installed truly horizontal and vertical plane and this accuracy must be mainted . The level of machine base in longitudinal and transverse direction is tested by spirit level or precision level. The spirit level is placed at a to measure the level. Truerunningofmainspindle: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. Parallelismofmainspindletosaddlemovement:If the axis of the spindle is not parallel to the saddle movement then it is not possible to get req. dimension of work piece while doing the operation on lathe. The spindle is moved and the deviation in the reading of dial gauge are noted. ParallelismofTailstockguidewaystosaddlemovement: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 oftailstockguidewaystocarriagemovement: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 Parallelismofmainspindletocarriagemovement: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. TrueRunningofheadstockcenter:The test mandrel is placed in the head stock and test is conducted on the surface of carriage. The dial gauge shows any diviations in the reading then the head stock is not running in proper.