||Jai Sri Gurudev||

Sri Adichunchanagiri Shikshana Trust ®

S. J. C Institute of Technology,
Chickballapur – 562 101

Department Mechanical Engineering

Mechanical Measurements & Metrology Lab Manual

Subject Code[BME404]
 ||Jai Sri Gurudev||
S. J. C Institute of Technology, Chickballapur
Department of Mechanical Engineering

INSTITUTE

VISION
“Preparing Competent Engineering and Management Professionals to
Serve the Society”

MISSION
 Providing Students with a Sound Knowledge in Fundamentals of their branch of Study.
 Promoting Excellence in Teaching, Training, Research and Consultancy.
 Exposing Students of Emerging Frontiers in various domains enabling Continuous Learning.
 Developing Entrepreneurial acumen to venture into Innovative areas.
 Imparting value based Professional Education with a sense of Social Responsibility.

DEPARTMENT

VISION
“To Be a Centre of Academic and Research Excellence in Mechanical Engineering to Fulfill Societal
Needs”
MISSION
M1: Imparting Knowledge and Need Based Training in the Field of Mechanical Engineering
M2: Providing State of The Art Facilities to Carryout Research Activities Related to Societal Needs
M3: Promoting Industry-Institute Interactions to Enhance Advances in Latest Technologies

PEO’s [Program Educational Objectives]

PEO 1: Graduates Will Apply Their Engineering Knowledge and Problem Solving Abilities to Lead
Successful Career in Various Technical Organizations or As Entrepreneurs

PEO 2: Graduates Will Be Engaged In Life-Long Learning Activities and Professional Development
through Continuing Education in Mechanical Engineering Stream or In Any Other Allied Streams

PEO 3: Graduates Will Exhibit Effective Communication Skills, Teamwork Abilities, Leadership Qualities
and Ethical Attitude

Program Specific Outcomes (PSOs)

1. Graduates will be able to apply engineering skills in design, manufacturing and analysis
of mechanical systems
2. Graduates will be able to utilize modern technical tools to provide solutions for various
complex mechanical engineering problems
 Program Outcomes (PO’s)
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals,
and an engineering specialization to the solution of complex engineering problems.
2. Problem analysis: Identify, formulate, research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences,
and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and design
system components or processes that meet the specified needs with appropriate consideration for the
public health and safety, and the cultural, societal, and environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of the
information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modeling to complex engineering activities with
an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the
professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering solutions
in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of
the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader in
diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the engineering
community and with society at large, such as, being able to comprehend and write effective reports
and design documentation, make effective presentations, and give and receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the engineering
and management principles and apply these to one’s own work, as a member and leader in a team, to
manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in
independent and life-long learning in the broadest context of technological change.
 MECHANICAL MEASUREMENTS AND METROLOGY LAB
[AS PER CHOICE BASED CREDIT SYSTEM (CBCS) SCHEME]
SEMESTER –IV
Subject Code BME404 IA Marks 50
Number of Lecture Hrs / Week 02 Exam Marks 50
No of Practical Hours / Week 02 Exam Hours 03
CREDITS – 01

COURSE OBJECTIVES:
1. To illustrate the theoretical concepts taught in Mechanical Measurements & Metrology
through experiments.
2. To illustrate the use of various measuring tools measuring techniques.
3. To understand calibration techniques of various measuring devices.

COURSE OUTCOMES
At the end of the course, the students will be able to

Description CL POs
CO1 To calibrate pressure gauge, thermocouple, LVDT, load cell, U PO1, PO6
Micrometer.
CO2 To measure angle using Sine Center/ Sine Bar/ Bevel U PO1, PO6
Protractor, alignment using Autocollimator/ Roller set.
CO3 To demonstrate measurements using Optical Projector/Tool U PO1, PO6
maker microscope, Optical flats.
CO4 To measure cutting tool forces using Lathe/Drill tool
U PO1, PO6
Dynamometer.
CO5 To measure Screw thread parameters using 2-Wire or 3-Wire
method, gear tooth profile using gear tooth vernier/Gear tooth U PO1, PO6
micrometer.
CO6 To measure surface roughness using Tally Surf/ Mechanical U PO1, PO6
Comparator.

PART-A: MECHANICAL MEASUREMENTS

1. Calibration of Pressure Gauge
2. Calibration of Thermocouple
3. Calibration of LVDT
4. Calibration of Load cell
5. Determination of modulus of elasticity of a mild steel specimen using strain gauges.

PART-B: METROLOGY
6. Measurements using Optical Projector / Toolmaker Microscope.
7. Measurement of angle using Sine Center / Sine bar / bevel protractor
8. Measurement of alignment using Autocollimator / Roller set

Demonstration Experiments ( For CIE )

9. Measurement of cutting tool forces using

• Lathe tool Dynamometer OR
• Drill tool Dynamometer.
 10. Measurements of Screw thread Parameters using two wire or Three-wire methods.
11. Measurements of Surface roughness, Using Tally Surf/Mechanical Comparator
12. Measurement of gear tooth profile using gear tooth Vernier /Gear tooth micrometer

Scheme of Examination:

ONE question from part –A or part –B

Write up: 10Marks
Conduction, procedure and result: 30Marks
Viva -Voice:10Marks
Total: 50 Marks

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 INDEX

MECHANICAL MEASUREMENTS

Sl. No. EXPERIMENTS

1. Calibration of Pressure Gauge
2. Calibration of Thermocouple
3. Calibration of LVDT
4. Calibration of Load cell
5. Determination of modulus of elasticity of a mild steel specimen

METROLOGY

Sl. No. EXPERIMENTS

1. Measurement of Screw thread profiles by using
a) Tool Maker’s Microscope b) Optical Profile Projector
2
Measurement of Angle by Using
a. Sine Bar
b. Sine Center
c. Bevel Protector
3. Measurement of alignment using Autocollimator

4. Measurement of cutting forces using lathe tool dynamometer

5. Measurement of effective diameter

a) 2 wire method b) 3 wire method

6. Measurement of Surface roughness by using Mechanical Comparator

7. Measurement of gear tooth profile using gear tooth Vernier

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 MECHANICAL
MEASUREMENTS

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 1
CALIBRATION OF PRESSURE GAUGE
AIM: To calibrate the pressure gauge for its performance using a calibrated standard
bourdon pressure gauge.

APPARATUS: Strain gauge transducers, digital pressure indicator, bourdon pressure gauge,
air compressor, set of cables.

PROCEDURE:

1. The bourdon pressure gauge and strain gauge pressure transducer is mounted on the
compressor.
2. Turn the knob provided on the compressor to release the pressure if present.
3. After the pressure is released, the knob is tightened and the initial adjustment is done
before starting the experiment.
4. Adjust the zero setting on the indicator to display zero, initially on the display board.
5. Make sure that the pressure gauge is also indicating zero pressure inside the
compressor.
6. Note down the pressure after operating the compressor, which develops pressure from
pressure gauge and corresponding reading in the pressure indicator.
7. Repeat the experiment for 7-8 readings, calculate error and % error, plot the graph of
error Vs actual reading.

OBSERVATION:

 Rm = Measured reading in kg/cm2 = ………….

 Ra = Actual reading in kg/cm2 = ………….
 Error E = Ra - Rm
 % Error = (E/ Ra) х 100

TABULAR COLUMN:

Sl. No. Actual reading Ra Measured reading Rm Error % Error

(in kg/cm2) (in kg/cm2)

RESULT: The graph of actual reading Vs % error is obtained.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Fig: Actual reading Vs % Error

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT:2
CALIBRATION OF THE GIVEN THERMOCOUPLE

AIM: To calibrate the given thermocouple using resistance thermometer.

APPARATUS: Thermocouple, heating coil to heat the water in beaker, resistance

thermometer and digital indicator to indicate the temperature of both thermocouple and
resistant thermometer.

PROCEDURE:

1. Turn the type selector to the desired position according to the given RTD probe.
2. Connect the RTD probe to the resistance thermometer temperature indicator.
3. Connect the given thermocouple to the thermocouple temperature indicator.
4. Place the thermocouple junction wire and RTD probe into a beaker containing the
water at room temperature.
5. Connect the power supply to both the temperature indicator.
6. Record the room temperature from the RTD temperature indicator.
7. Adjust the zero, setting of thermocouple temperature indicator until the display shows
the room temperature.
8. The heating coil is connected with power supply and water is heated in the beaker.
9. Record the RTD and thermocouple (J, K, T -types) temperature indicator reading
simultaneously at regular intervals.

OBSERVATION:

 Ta = Temperature of water by RTD °C

 Tm = Temperature of water by thermocouple °C
 Error = Ta - Tm
 % Error = [(Ta - Tm)/Ta] х 100

TABULAR COLUMN:

Sl. Temperature of Temperature of water by Error % Error

No. water by RTD Ta thermocouple Tm
(in °C) (in °C)

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

RESULT: Using the resistance thermometer, the given thermocouple is calibrated.

Fig: Actual reading Vs % Error

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 3
LOAD CELL

AIM: To calibrate the given load cell to its performance using weights.

APPARATUS: Load cell, weights, power supply unit, set of cables.

PROCEDURE:

1. Connect the load cell to the digital indicator.

2. Connect the power mains to the indicator.
3. Select the standard weights to the maximum of 8 - 10 kg.
4. Switch ON the power supply, adjust zero on the indicator on meter without load.
5. Keep a known weight on the platform of load cell.
6. Note down standard weight and corresponding reading on meter.
7. Repeat the procedure for several readings 6-7 times and calculate error and % error.
8. Plot a graph of error Vs actual readings and % error Vs actual reading to obtain
calibration curve.

CALCULATIONS:

 Rm = Measured reading in kg.

 Ra = Actual reading in kg.
 Error E = Ra ~ Rm
 % Error = (E/ Ra) х 100

TABULAR COLUMN:

Sl. No. Actual reading Ra Measured reading Rm Error % Error

(in kg) (in kg)

RESULT: The graph of actual reading Vs % error is obtained.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Fig: Plot of Actual reading Vs Error

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 4
CALIBRATION OF LVDT
AIM: To calibrate the gauge length by means of Linear Variable Differential Transducer
(LVDT).

APPARATUS: LVDT with screw gauge (±10 mm Capacity) read out display.

PROCEDURE:

1. Connect the LV DT and Digital displacement meter to main supply.

2. Adjust the knob to set zero of the displacement indicator to indicate zero.
3. Connect the LV DT sensor to the displacement indicator through the cable.
4. Rotate the micrometer knob to clock wise or anti clock direction, to bring the LVDT core
to null position, At this position indicator will read zero
5. Note down the micrometer reading .This is initial reading of micrometer
6. Repeat the above procedure for both ascending and descending order of screw gauge
reading and note down the corresponding reading.

OBSERVATION:
Screw gauge reading (A) = ....................... mm
Read out device reading (M) = ................. mm
Error (E) = A - M = .................................. mm
% Error = E х 100/A

TABULAR COLUMN:

Sl. Screw gauge Read out device Error % Error

No. reading A reading M
(in mm) (in mm)

RESULT: Graph of the read out Vs screw gauge reading is plotted.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Fig: Plot of Read out Vs Screw Gauge

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 5
DETERMINATION OF YOUNG’S MODULUS
AIM: To compute Young’s modulus using four-arm Strain Gauge Bridge.

APPARATUS: Strain meter, four-arm cantilever strain gauge, Strain Gauge Bridge.

PROCEDURE:

1. Mount the sensor provided on the measuring bar; rigidly clamp the weight applying
anchor to it.
2. Connect the sensor table to the sensor and the other end to strain indicator with proper
terminals.
3. Switch ON the instrument and adjust strains indicator to read zero.
4. Now put on the weight on the weight hanger, say 100 gm.
5. Increase the load gradually and make simultaneous observations of load applied in N
and strain in micro strain.
6. Apply the weights up to 1 kg. Note down the strain gauge reading.
7. Compare the values of the strain from strain indicator and strain from theoretical
formula.
8. Plot a graph of stress Vs strain and calculate the slope.

OBSERVATION:

 Width of the plate ‘b’ in mm =

 Thickness of the plate ‘h’ in mm =
 Cross sectional area ‘A’ in mm2 =
 Length of cantilever beam L in mm=

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Tabular Column (Full Bridge):

Load Applied Strain

Measured strain Bending Modulus of
Indicator
SL W in (N) Stress
Reading in  x10-6 Elasticity
No.
gms N
Micro strain =6wl / bh2 2
E =/  (N/mm )
4
1

Calculation:
Example

Load Applied, W =0.2 x 9.81 (200g/ 1000)= 1.962 N

Bending Stress, =6WL/ bh2 = (6 x1.962x250) / (42 x32)=7.78 N /mm2

For Four Arm Modes,(Full Bridge)

Measured Strain, m = x10-6/4 =-------------------

Young‘s modulus, E =/m ---------------------- N/mm2

RESULT: Young’s modulus of the specimen is computed and tabulated using four-arm
Strain Gauge Bridge.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Fig: Strain Gauge

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 METROLOGY

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT:1
(1a) MEASUREMENT OF THREAD PROFILE USING TOOLMAKERS
MICROSCOPE
AIM: To determine the major diameter, minor diameter, pitch of thread, depth of thread,
angle of thread using toolmakers microscope.

APPARATUS: Toolmakers microscope, screw thread.

THEORY: Toolmakers microscope is based on the principle of optics. The main application
of this microscope is:
1. Determination of relative position of various hard on work piece.
2. Measurement of angle by using a protractor microscope eye piece.
3. Measurement and comparison of thread from which matter profiles engraved in the
eye piece measurement of pitch and effective diameter.

PROCEDURE:

1. Switch on the microscope.

2. Fix the specimen on the V-block.
3. Place the V-block with specimen on x-y stage. Adjust the cross line in the eye piece to
coincide with a point on one thread.
4. Note down the initial reading. Move the x-y stage so that the cross line coincides with
the corresponding point on next thread.
5. Note down the final reading. Difference of final and initial reading gives the pitch.
6. A cross line is made to coincide with one of the thread tip and initial reading is noted.
7. Move the x-y stage and coincide the cross-line to the diametrically opposite thread tip.
8. Note down the final reading.
9. Similarly, minor diameter is found by coinciding the cross-line to the root of the
thread.
10. Align the cross-line to the flank of the thread and note down the initial & final reading
by aligning to other flank of the thread from the dial.
11. The difference of the initial & final reading gives the thread angle.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

OBSERVATION:

1. Least count of x-y direction microscope = 0.005

2. Major diameter reading: i. Initial reading R1 =------------mm
ii. Final reading R2 =----------- mm
3. Major diameter = R1 - R2= =------------ mm
4. Minor diameter reading: i. Initial reading R3 = ----------- mm
ii. Final reading R4 =----------- mm
5. Minor diameter = R3 - R4 =------------ mm
6. Pitch reading: i. Initial reading R5 = ----------- mm
ii. Final reading R6 =----------- mm
7. Pitch = R5 - R6 = ---------- mm
8. Thread angle reading: i. Initial reading R7 = ------------ mm
ii. Final reading R8 = ------------ mm
9. Thread angle = R7 - R8 = -----------mm

TABULAR COLUMN:

Sl. No. Major diameter Minor diameter Pitch Thread angle

(in mm) (in mm) (in mm) (in degrees)

RESULT: Given thread profile is examined.

Fig: Toolmaker’s Microscope

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 1b
MEASUREMENT OF THREAD PROFILE USING
OPTICAL PROFILE PROJECTION
AIM: To determine major diameter, minor diameter, pitch and angle of threads, outer dia of
washers (thickness, major dia, minor dia) etc using profile projector

PROCEDURE:

1. Clean the external surface of the specimen.

2. Bring the measuring surface in to focus by moving the stage up & down with the
focusing wheel.
3. Look in to the screen to make sure that the line are kept vertical to the stage note.
4. Check the cross line position against the X-Y stage movement direction.
5. Align the measuring direction of the work piece with that of stage of the transverse.

LINEAR MEASUREMENTS:

a) Set the measuring digital micrometers to zero for both X & Y directions.
b) Locate the measuring point on the work piece with one of the cross lines. Note down
the reading.
c) Move the X-Y stage by turning the handle & align another measuring point with the
same cross line. Note down the reading.

ANGLE MEASUREMENTS:

a) Align an edge of the work piece with the cross line of the screen & the end edge with
the center of the cross line.
b) Turn the screen to align the cross line with the other edge of the work piece.
c) Take the readings from the circumference.

OBSERVATION:

TABULAR COLUMN 1:

Sl. No. Major dia Minor dia Pitch Thread

(in mm) (in mm) (in mm)

The resolution of the angle is 1" with the main scale & 1' with the vernier scale.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

To find the thickness:

X- axis or Y-axis can be used.

TABULAR COLUMN 2:

Sl. No. Initial reading Final reading Thickness = Difference

RESULT: The required parameters of the given specimen are determined using the optical
profile projector.

Fig: Profile Projector

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Fig: Schematic Diagram of Profile Projector

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 2
a). SINE BAR
AIM: To measure the taper angle from the given specimen using sine bar.

APPARATUS: Surface plate, Sine bar, Slip gauge, dial indicator, withstands.

THEORY: The sine bar is basically designed for the precise setting out of angles and is
generally used in conjunction with slip gauges and surface plates. The principle of operation
of the sine bar relies upon the application of trigonometry. In the right angled triangle ABC,
as shown in the figure, the ratio of the hypotenuse (BC) to the opposite side (AB) is referred
to as the sine of the angle θ.
Using the above principle, it is possible to set out precisely any angle by using standard
length of side AB and marking off the length of side BC equal to AB multiplied by the sine
of the angle. The sine bar is placed on a surface plate with slip gauges of the required height
(H) under one roller and opposite to the angle θ.

PROCEDURE:

1. Place the sine bar on surface plate.

2. Place the taper specimen, whose taper angle has to be measured, such that the taper
portion is towards the projected side of the sine bar.
3. With the help of dial indicator, check the level of specimen surface.
4. Add the slip gauges at the projected end of the sine bar.
5. Again with the help of dial indicator, check the level of the specimen surface. If the
indicator moves in anti-clockwise direction, we have to remove more slip gauges till
the dial indicator pointer does not oscillate. And if the pointer moves in clockwise
direction, we have to add some of the slip gauges.
6. Note down the total height of the slip gauges (h) and the distance between the centers
(l). Using the values of h and l, calculate the angle of the taper of a given specimen
using the formula,
 h
Taper angle θ = sin-1 
 
 l 

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

TABULAR COLUMN:

Sl. No. Length of the sine Height of the slip Angle measured
bar (l) gauges (h) (in degrees)
(in mm) (in mm)

RESULT: The taper angle for various specimens are determined and tabulated.

Fig: Sine Bar

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 2
b). SINE CENTER

AIM: To measure the taper angle of the given specimen using sine center.

APPARATUS: Surface plate, sine center, specimen, slip gauges and dial indicator with stand.

THEORY: It works on the same principle as that of the sine bar. Sine center is as shown in
the figure. They are mounted on surface plates and are used for mounting conical work pieces,
which can not be held on a convectional sine bar. Sine center consists of a self contained sine
bar, hinged at one roller and mounted on its own datum surface. The top surface of the bar is
provided with a pair of clamps and center for holding the work as shown in the figure.
The semi circular cone angle α is calculated using the formula,
D - d]
α = tan-1 [
[ 2l ]
The conical work piece is mounted between the center of the sine center. Then to make the
top conical surface horizontal, the sine center has to be tilted through θ by building a stack of
slip gauge of height h.
H
 sin θ =
L
H
 θ = sin -1
=α
 
 L 
PROCEDURE:

1. Place the sine center on surface plate.

2. Fix the specimen between the centers.
3. See that the taper end is towards the sine center.
4. Choose the combination of slip gauges to get a height.
5. Place the combination below the rollers of sine center. Check with the dial indicator
whether the taper surface is parallel to surface plate or not. If parallel, find the angle
by using the given formula. If not parallel, then change the height of the slip gauges to
make the taper surface parallel to surface plate.
6. Note down the height of the slip gauges and calculate taper angle. Verify with the
theoretical values and tabulate the readings.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

OBSERVATION:

Length of the sine center (l) = ...................... mm

Height of slip gauges (h) = ..................... mm
Diameter of the specimen: Bigger dia (D) =................ mm
Smaller dia (d) = ............... mm
Length of the taper (L) = ................... mm

FORMULA:

1. Angle measured (exp) = (θ/2) = sin-1(h/l)

2. Angle measured (the) = (θ/2) = tan-1(D-d/2L)

TABULAR COLUMN:

Sl. No. Length of the Height of the Angle Theoretical

sine center ‘l’ slip gauge ‘h’ measured angle
(in mm) (in mm) (in degrees) (in degrees)

RESULT: The taper angle of various specimens are determined and tabulated.

Fig: Sine Center

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 2
c) BEVEL PROTRACTOR

AIM: To measure the unknown angle of given specimen using bevel protractor.

APPARATUS: Surface plate, specimen, bevel protractor.

THEORY: A bevel protractor as per Indian standard practice is of two types, namely,
a. Mechanical bevel protractor
b. Optical bevel protractor
General description of various components:
1. Body: It is designed in such a way that its back is flat and there are no projections
beyond its back. So that when the protractor is placed on its back, on the surface plate
there shall be no perceptible rock.
2. Stock: The working edge of the stock is about 90 mm in length and 7 mm thick. The
working edge of the stock must be perfectly straight.
3. Blade: It can be moved along, throughout the length and can be reversed. It is about
150-300 mm long, 13 mm wide and 2 mm thick and ends beveled at angle 45° and
60° with accuracy of 5 min of arc.

PROCEDURE:

1. Place the specimen on the surface plate.

2. Place the fixed or stationary arm parallel to lower end or Base of the specimen.
3. Move the adjustable or movable arm to make it parallel to inclined surface.
4. Note the reading of the main scale of vernier scale.
5. Repeat the same for different inclined specimen.

OBSERVATION:

Least count of bevel protractor: 60'/12 = 5'

TABULAR COLUMN:

Sl. No. Angle measured θ

(in degrees)

RESULT: Unknown angles of the specimen are measured and tabulated.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Fig: Bevel Protractor Fig: Least Count Calculation

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 3
AUTO COLLIMATOR

AIM: To determine the surface straightness of the surface plate.

APPARATUS: Auto collimator set up with powering unit, surface plate.

PROCEDURE:

1. Place the auto collimator with the stand on a surface plate to be inspected.
2. Place the reflector along the axis of auto collimator.
3. Adjust the micrometer for half of the main scale divisions.
4. Adjust the stand so that the auto collimator appears to be pointing straight at the flat
reflective surface.
5. View through the eyepiece and try to locate the cross line image of the target and
check the return cross line image.
6. Adjust micrometer for the reference position (say A), note the readings on the
micrometer.
7. Move the reflector through the next position (50 mm), say B.
8. Observe through the eye piece if the surface plate flatness is exact, then the two
horizontal lines will coincide, if not, there will be a gap between the positions A and
B.
9. By means of micrometer, coincide the horizontal lines again and note down the
readings at position B.
10. Repeat the above procedure for different positions of plane reflector.
11. Tabulate the readings and plot a graph to known straightness of surface plate.

OBSERVATION:

TABULAR COLUMN:

Sl. Position Initial reading of Final reading of Difference in Level X

No. (in mm) micrometer micrometer micrometer (in microns)
reading θ

Tan θ = X/25

X = (25 x Tan θ) x 1000

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

RESULT: The surface straightness of the given surface plate is determined using the
autocollimator.

Fig: Schematic Diagram of Autocollimator

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur
Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur
 EXPERIMENT: 4
MEASUREMENT OF CUTTING FORCES USING LATHE TOOL
DYNAMOMETER
AIM: To determine the various cutting forces & power required in turning.

APPARATUS: LATHE, specimen, tool, dynamometer etc.

PROCEDURE:

FOR L. T. D. OPERATION:

1. Mount the dynamometer on the top of the lathe cross slide & clamp it rigidly fastened
with bolts.
2. Use an orthogonal cutting tool (approach angle 90°).
3. Adjust the speed and feed of the lathe machine and start the machine. Feed the tool
manually to start cutting and then feed it automatically.
4. Wait to stabilize the output bridges and measure the output for vertical and horizontal
forces.
5. The vertical and horizontal forces on the dynamometer should not exceed the limit of 500 kg.

OPERATING INSTRUCTION FOR BRIDGE BALANCE UNIT:

1. Place the sensing unit of the dynamometer in proper position.

2. With the help of the cables, carefully connect PU1 socket on the sensing unit to PU1
socket on the strain gauge amplifier unit. Repeat the same for PU2 channel.
3. Connect the instrument to 230 volts I phase supply and switch ON the supply.
4. Ensure that Range selector switch is in full clockwise position.
5. Now the instrument is ready for use.
6. Obtain balance on 2 each channel by operating balance pots the indicator for all the two
channels under specified conditions.

PRECAUTIONS:

1. Amphonel socket connections must be done carefully. See that during actual use of the
instrument cables are not damaged or spoiled in anyway.
2. Zero adjustment must be done delicately.
3. Do not apply excessive loads on the sensing unit than specified.
4. To ensure long life, the balance pots P1 & P2 must also be operated very carefully.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

FORMULAE:

1. Cutting speed, V = πdN/60,000 m/S

Where,
D = Diameter of the work piece in mm
N = Speed in rpm
2. Power required = Fx V watts
Where,
Fx = Feed force in N
V = Cutting speed in m/S
TABULAR COLUMN:

Sl. Speed N Feed f Depth of Feed Thrust Main Cutting Power

No. (in rpm) (in mm/rev) cut force Fx force Fy cutting speed V (in W)
(in mm) (in N) (in N) force Fz (in m/S)
(in N)

RESULT: Various cutting forces and the power required for turning is determined and
tabulated.

Fig: Force diagram Fig: Lathe tool dynamometer

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 5 (a)
MEASUREMENT OF EFFECTIVE DIAMETER: 2 - WIRE METHOD
AIM: To measure the major, minor & effective diameter of the given threaded specimen.

APPARATUS: Test specimen, micrometer, pitch gauge & set of wires.

PROCEDURE:

1. Find out the pitch of the given screw thread using pitch gauge.
2. Get the diameter of wires from tables.
3. Fix the wires over both sides of the screw gauges as in figure.
4. Fix the gauge over the specimen & read the effective diameter over the wire.
5. Calculate the effective diameter using given formula.

OBSERVATION:

Pitch of thread P =......................... mm

Wire diameter d =......................... mm
Dimension over the wires M = ......................... mm
Thread angle =......................... degrees

FORMULAE:
Diameter under the wires, D = M – 2d
Constant K = (P/2) Cot (θ/2) - d {Cosec (θ/2) - 1}
Also,
K = (0.866P - d), if θ = 60°
K = (0.9605P – 1.1657d), if θ = 55°

TABULAR COLUMN:

Sl. Pitch P Dimension Dimension Constant K Effective

No. (in mm) over wire M under wire D (in mm) diameter E
(in mm) (in mm) (in mm)

RESULT: Major, minor and effective diameter of the given threaded specimen has been
measured and tabulated using 2 - wire method.

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Fig: Screw Pitch Gauge

Fig: Types of Pitch Gauges

Fig: 2 - Wire Method

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 5(b)
MEASURE OF EFFECTIVE DIAMETER (THREE WIRE METHOD)
AIM: To measure the effective diameter by 3 wire method.

APPARATUS: Screw thread micrometer, pitch gauge and set of wires.

THEORY: Effective diameter or pitch diameter in case of straight thread is the diameter of
the pitch cylinder (the imaging cylinder which is co-axial with the axis of the screw and
intersects the flank of the threads in such a way as to make the width of threads and width of
the space between the threads equal).
The effective diameter cannot be measured directly, but can be calculated from the
measurements made. In this procedure of measuring effective diameter, instead of using vee-
prisms, two cylinders or wires are inserted in the grooves of the thread. The diameter of the
wire must be known accurately. It may, however, have any value within the range which
permits the wires to contact the straight flank of thread and to protrude above the crests. A
correct value of the effective diameter will be obtained only if the wires make contact at the
pitch line. Wires of this size are called ‘best size’ wires. The diameter of the wires used
should be such that they contact the flanks at a distance from the pitch line not exceeding
one-twentieth of the length of the straight flank. The effective diameter can be measured by
two wire or three wire method.

PROCEDURE:

1. First find out pitch of the given screw thread.

2. Get the diameter of the wire from the tables.
3. Fix the wires over both sides of the screw gauge.
4. Fix the specimen in between the gauge.
5. Calculate the effective diameter.

TABULAR COLUMN:

Sl. No. Pitch Dimension over wires M Effective diameter E

(in mm) (in mm) (in mm)

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

FORMULAE:

E = M - d [1 + Cosec (θ/2) + P/2 Cot (θ/2)]

Here, θ = 60° (screw thread)
Therefore, E = M - 3d + 0.866025P
Where,
P: Thread pitch in mm
d: Diameter of the wire
M: Reading of micrometer

RESULT: Major, minor and effective diameter of the given threaded specimen has been
measured and tabulated using 3 - wire method.

Fig: 3 - Wire Method Fig: 3 - Wire Method

Fig: Thread Micrometer

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 6
COMPARATOR

AIM: To measure the surface roughness using Mechanical Comparator and to conduct the
acceptability test.

APPARATUS: Surface plate, mechanical comparator, dial gauge, slip gauge.

PROCEDURE:

TO FIND THE SURFACE ROUGHNESS:

1. Fix the dial gauge to the mechanical comparator device.

2. Align the comparator table by moving the dial indicator probe all over the
circumference of the table. The dial indicator should read zero.
3. Take the given specimen and place it on the comparator table.
4. Adjust the dial indicator to read zero when the probe is in contact with the surface of
the specimen.
5. Move the dial indicator probe diagonally and observe the indicator reading.
6. If the indicator reads zero, the surface is said to be smooth.
7. If not, find the variation from the set standard and calculate the % error.

TO CONDUCT THE ACCEPTABILITY TEST:

1. Fix the dial indicator on the dial gauge to the mechanical comparator.
2. Align the comparator table by moving the dial indicator probe all over the
circumference of the table. The dial indicator should read zero.
3. Set the standard for acceptance.
4. Set the limits tolerance using the batches on the dial indicator.
5. If the given specimen is within the range, the specimen is accepted.
6. If it is below the range, the specimen is rejected and if it is above the range, the
specimen is sent back for rework.
OBSERVATION:
1. Dial indicator standard ………….
2. Number of the specimen checked for surface roughness ……………

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

TABULAR COLUMN:

Sl. No. Standard Observations Variations

ACCEPTABILITY TEST:

OBSERVATION:

1. Standard to be accepted ……………..

2. Tolerance …………..

Sl. No. Standard Tolerance Observations Results

RESULT: The surface roughness of the given specimen is measured using mechanical
comparator.

Fig: Mechanical Comparator

Fig: Electronic Comparator

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 EXPERIMENT: 7
MEASUREMENT OF GEAR TOOTH PROFILE

AIM: To find the thickness of the given gear tooth and to draw the gear tooth profile using
gear tooth vernier caliper.

APPARATUS: Surface plate, gear tooth vernier, specimen, thread.

PROCEDURE:

1. Place the gear blank on the table.

2. Measure the perimeter of the given gear by the thread.
3. Count the number of teeth on the gear blank.
4. Calculate the addendum, dedendum, module, pitch, clearance, thickness using the
given formula.
5. Set the addendum dimension on vertical limb of gear tooth vernier.
6. Measure the tooth thickness for set addendum.
7. Set the vertical limb to read zero and note down the thickness of the tooth.
8. Set the vertical limb to read 2 mm and note down the thickness of the tooth. Similarly,
increase the vertical limb by 2 mm and take the corresponding tooth thickness.
9. Repeat till the full depth of the tooth.
10. Above reading will give the data to draw the tooth profile.
11. Draw the graph of the tooth depth Vs tooth thickness to get tooth profile.

Observation

Diameter of gear blank,D = MSR + (VSR x LC) mm

Number of teeth on gear T =-------------
Module m = D/T=-------------
Theoretical thickness of tooth, Wt =T x m x sin (90/T) in mm
TABULAR COLUMN 1:

Sl. Pitch Dedendum Addendum Clearance Thickness (in mm)

No. (in mm) (in mm) (in mm) (in mm) Theoretical Practical

TABULAR COLUMN 2:

Sl. No. Depth Width

(in mm) (in mm)

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

LC = 1 MSD - 1 VSD
49
=1 -
50
50 - 49 1
= =
50 50
LC = 0.02 mm

RESULT: The thickness of the given gear tooth profile is tabulated and gear tooth profile is
graphically represented.

Fig: Gear Tooth Terminology

Fig: Gear Tooth Vernier Caliper

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 Viva Questions

1. What is metrology and measurement?

2. Define accuracy and precision.

3. What is calibration?

4. What are the classifications of methods of measurement?

5. What are the objectives of metrology?

6. Define error. Mention the classifications of error.

7. What is meant by LVDT?

8. What are force, acceleration and velocity?

9. Define stress and strain.

10. What are gears? Define pitch and module.

11. What are the types of gears?

12. What is dynamometer?

13. Define thermocouple. What are the laws of thermocouple?

14. What is EMF? Expand it.

15. What is meant by RTD?

16. Define addendum and dedendum.

17. What is comparator? What are the types of comparators?

18. What are the advantages of electrical and electronic comparators?

19. What are the advantages of mechanical comparators?

20. What is meant by spirit level?

21. What is the use of dial indicator?

22. What are the materials used for thermocouple?

23. What are the different effects of thermocouple?

24. What is a slip gauge?

25. What is screw gauge, vernier caliper and bevel protractor?

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 26. Define angle. What are the methods used for the measurement of angles?

27. What is sine principle?

28. What is sine bar and sine center?

29. What are the limitations of sine bars?

30. What are relief holes?

31. What are the applications of slip gauges?

32. What are the uses of angle gauges?

33. What is transducer? What are the types of transducer?

34. What is clinometer?

35. What is autocollimator?

36. What is the principle of autocollimators?

37. What are the types of autocollimators?

38. What are the accessories of autocollimator?

39. What do you mean by surface roughness?

40. What is the instrument used for surface roughness?

41. What is surface table, name the material and use of it?

42. What do you mean by microscope?

43. What is the use of profile projectors?

44. What are AC and DC generators?

45. What are signal generators?

46. What is motor?

47. Define KE and PE.

48. What is load cell and types of load cells?

49. What is vacuum?

50. What is beam and types of beams?

51. What is cantilever beam?

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur

 52. What is wheat stone’s bridge circuit?

53. What is bourdon tube and its use?

54. What is torque and torque meter?

55. What is meant by stroboscope?

56. What are the various methods used for checking the squareness and parallelism part?

57. How the accuracy of a straight edged is specified and how it can be checked?

58. What is the use of pressure transducers?

Department of Mechanical Engineering, S J C Institute of Technology, Chickballapur