1.

MEASUREMENT OF SPECIMEN DIMENSIONS USING

LINEAR AND ANGULAR MEASUREMENT
INSTRUMENTS

AIM
To measure the various linear and angular dimensions of the given sample
specimens
EQUIPMENTS/MATERIALS
Outside micrometer, Vernier Caliper, Universal Bevel Protractor, hollow cylindrical
specimen and triangular specimen
PRINCIPLE
For Vernier Caliper,
Final reading = MSR + (VSR x LC)
Where,
MSR Main Scale Reading
VSR Vernier Scale Reading
LC Least Count
For Outside Micrometer,
Final Reading = MSR + (CSR x LC)
Where,
MSR Main Scale Reading
CSR Circular Scale Reading
LC Least Count

PROCEDURE
1. The various dimensions of the hollow cylindrical specimen are measured
using the vernier caliper. The outside jaws are used for measuring the outside
diameter and height of the specimen. The internal diameter is measured using
the inside jaws.
2. For the triangular specimen, the angles are measured using the universal bevel
protractor. The thickness of the specimen is measured using the outside
micrometer.
3. The observations are recorded in the tabular column and final dimensions are
measured according to the formulas in the principle.
4. Each dimension is measured 3 times and the average value is taken as the final
dimension.




OBSERVATIONS
a. Hollow Cylindrical Specimen (Least Count of Vernier = 0.02 mm)
Dimension Sl. No
Vernier Readings
Final Reading
(mm)
MSR VSR
Outside
Diameter
1
2
3
Inside
Diameter
1
2
3
Height
1
2
3


b. Triangular Specimen
(Least count of Bevel protractor = 5 minutes)
Dimension Sl. No
Bevel Protractor
Readings
Final Reading
(degree, minutes)
Degree Minutes
Angle
ABC
1
2
3
Angle
ACB
1
2
3

(Least Count of Micrometer = 0.01mm)
Dimension Sl. No
Micrometer Readings
Total Reading
(mm)
MSR CSR
Thickness
1
2
3

RESULTS
Hollow Cylindrical Specimen
1. Mean internal diameter (Di) = mm
2. Mean external diameter (Do) = mm
3. Height (H) = mm


Triangular Specimen
1. Angle ABC =
2. Angle ACB =
3. Thickness (t) = mm


A


B C
Fig. 1 Triangular Specimen



H





Do


Fig. 2 Cylindrical hollow Specimen
t



Di
2. MEASUREMENT OF GEAR TOOTH THICKNESS
AIM
To measure the gear tooth thickness of a given specimen gear.
EQUIPMENTS/MATERIALS
Profile Projector, Gear Tooth Vernier Caliper and Spur Gear specimen
PRINCIPLE
The main parameters determining the profile of a spur gear are: Pressure angle,
circular pitch, tooth thickness, crest circle and root circle diameter. The measuring
principle is based upon the determination of the exact depth h from the crest of the
tooth at which the chordal thickness should be measured. The correct depth ensures
that the chordal thickness is measured at the pitch circle. For spur gears,
h = m + (d
p
/2) [1 cos (90
o
/Z)]
where,
m (module) = d
0
/(Z+2)
Z = number of teeth
d
p
= pitch circle diameter
Profile Projector is an optical device which is used to check profile of
components having special formed surfaces such as gears, screws and those objects
having regular or irregular profile. It has a high intensity light source. The light source
is placed on the principal focus of the collimating lens. The projection lens is a
combination of lenses and forms a real image of the object placed between it and the
collimating lens. The work-stage is 100x100 mm with micrometer screws. Two
digital micrometers are provided to control and measure the longitudinal and traverse
motion of the work table. It also comes with a digital display for 2 coordinate
displacement measurement and also angle measurement.
PROCEDURE
1. Count the number of teeth (Z) on the gear.
2. The outer diameter (d
o
) of the gear was found using a vernier caliper.
3. The module is then calculated using the relation
m = d
o
/ (Z+2)
4. The pitch circle diameter of the gear is calculated using the relation
d
p
= mZ
5. The chordal addendum (h) is calculated.
6. The gear tooth vernier has two scales, vertical and horizontal. The choral
addendum (h) is taken on the vertical scale and fixed. The vertical and
horizontal scale jaws are made to touch the top of the tooth and the chordal
tooth thickness was measured on the horizontal scale.
7. The reading was noted and the same procedure was repeated on other tooth
and the mean is taken.
8. The gear is placed on the work stage of the profile projector. The enlarged
profile of the gear is focused on the projector screen using the hand wheel on
the projector.
9. Tracing paper is fixed on the projection screen of the profile projector and the
image of the gear is traced using pencil.
10. Keeping the gear on the work stage as in the previous position, the tracing
paper is rotated upside down in such a way that the traced image mates with
the projected image of the gear to form a meshed gear system. Measurement
of gear thickness was done from the traced image of the gear.
11. The face width of the gear tooth is also measured using vernier caliper.

Fig.1 Gear Terminology

Fig. 2 Gear Tooth Vernier
OBSERVATIONS
Measurement of outer diameter of the gear (d
o
)
(Least Count of Vernier = 0.02 mm)
Sl. No
Vernier Reading Diameter
(d
o
) (mm) MSR VSR
1
2
3
Mean outside diameter (d
o
) =





Measurement of chordal thickness using gear tooth vernier
(Least Count of Vernier = 0.02 mm)
Sl. No
Vernier Reading Chordal
Thickness/ Gear
Tooth thickness
(tc) (mm)
MSR VSR
1
2
3
Mean Chordal Thickness =
Measurement of face width of gear tooth
(Least Count of Vernier = 0.02 mm)
Sl. No
Vernier Reading Width of gear
tooth
(w) (mm)
MSR VSR
1
2
3
Mean face width of the gear tooth (w) =

RESULT
1. Outside diameter of the gear (d
o
) = mm
2. Chordal thickness of the given spur gear
From, gear tooth vernier = mm
From, traced profile = mm
3. Face Width of the gear tooth (w) = mm
3. MEASUREMENT OF SURFACE ROUGHNESS

AIM
To study and determine surface roughness parameters using surface roughness tester.
APPARATUS
Surface roughness Tester, specimen
THEORY
The surface roughness measuring instrument traces the surfaces of various machine
parts, calculates their surface roughness based on roughness standards and displays
the results. A pick-up called the stylus attached to the detector unit will trace the
minute irregularities of the work piece surface. The vertical stylus displacement
during the trace is processed and digitally displayed on the liquid crystal display. The
tester can be operated in the measurement mode and calibration mode. The calibration
mode is set prior to measurement and performs calibration measurement. In the
measurement mode, the tester can start and stop measurements, calculate the
parameters and switch display contents and save measurement results.

PROCEDURE
1) Calibration: Calibration of a surface roughness measuring instrument is
performed by measuring a reference work piece (precision roughness
specimen)
(a) Press the [POWER/DATA] key to turn on the power.
(b) Press the [CAL/STD/RANGE] key. The calibration mode is entered. The current
calibration value is displayed. Check the displayed value against the value marked on
the roughness specimen. If they are the same value press the [n/ENT] key. If the
displayed value is different from that marked on the precision roughness specimen,
modify the calibration value. The following keys are used to enter a numeric value:
[CUTOFF] key to increment the numeric value; [mm/inch] key to decrement the
numeric value; [REMOTE] key for shifting the objective digit place for output;
[n/ENT] key for accepting the entered numeric value.
The entered calibration value is set.

(c) Place the precision roughness specimen and the calibration stage on a level table.
Set the tester so that the detector traversing direction is perpendicular to the cutter
mark of the precision roughness specimen. Press the [START/STOP] key. A
calibration measurement with the precision roughness specimen is performed. When
the calibration measurement has been completed, the measured value will be
displayed.
(d) Press the [n/ENT] key. The calibration factor is updated, completing the entire
calibration operation.
2) Measurement:
(a) To start the measurement set the tester on a work piece. For the surface
roughness measurement to be successful, it should be performed on a
firm base that is insulated from all sources of vibration. Confirm that
the stylus is in proper contact with the measured surface and that the
detector is parallel to the measured surface.
(b) Press the [START/STOP] key in the measurement mode. The detector
starts traversing to perform measurement. While the measurement is
being performed i.e., when the detector is traversing, ------ is
displayed on the LCD. After the measurement has been completed, the
measurement result will be displayed on the LCD.
(c) The objective parameter to be displayed can be switched by pressing
the [PARAMETER] key while measurement result is being displayed
on the LCD. A measurement parameter is now displayed (say Ra).
Press the [PARAMETER] key until the desired parameter value is
displayed on the LCD. Each time the key is pressed, the displayed
parameter changes in the following order: Ra -> Ry -> Rz -> Rq-> Ra.

3) Modifying the cutoff length: The cutoff length can be switched to 0.8, 2.5, or
0.25 mm (0.03, 0.1, or.01). For this, press the [CUTOFF] key in the
measurement mode. The cutoff length displayed changes in the following
order: 0.25 -> 0.8 -> 2.5mm, 0.01 -> 0.03 ->, 0.1 inch.
4) Modifying the number of sampling lengths: The evaluation length
(sampling length x number of sampling lengths) can be set by switching the
number of sampling lengths to either 1, 3, 5, or L. If L is selected,
the evaluation length can be set as desired within the range between 0.3mm
and 12.5mm. Pres the [n/ENT] key in the measurement mode. Each time the
[n/ENT] key is pressed, the displayed number of sampling lengths changes in
the order 1 -> 3 ->5-> L->1.
5) Switching the roughness standard: In the measurement mode, press the
[CAL/STD/RANGE] key twice. The surface roughness standard set up mode
is entered. Press the [CUTOFF] key until the desired surface roughness
standard appears on the LCD. Each time the key is pressed the display
changes. Press the [n/ENT] key if the desired standard is selected. This accepts
the standard roughness standard.

OBSERVATIONS AND TABULATIONS:
Ground surface

Glass plate

Ra
Ry
Rz
Rq

Results

Surface

Ra

Rz

Rq
Glass plate


Ground surface



Inference:





4. MEASUREMENT OF THREAD
AIM
To measure the characteristics of the given external thread using Tool Makers
Microscope.
EQUIPMENT
Externally threaded specimen and a Tool Makers Microscope
PRINCIPLE
A Tool Makers Microscope is essentially an optical microscope in principle. It has a
heavy base and on this, a worktable with a glass stage is supported on balls. The
longitudinal and traverse slide motion of the table is made possible by the micrometer
screws attached to the table. It is used for the magnified representation of the object
placed on the work-table. The elements of the external thread measured are: Major
diameter, minor diameter, pitch and thread angle. The major elements of an external
thread are shown in the figure.
PROCEDURE
In order to carry out the measurement, the threaded specimen is place on the work
table of the microscope. The crosswire is first made to coincide with the crest of the
thread on one side. The reading on the micrometer is noted and using the micrometer
head, the crosswire is made to coincide with the crest on the other side of screw and
reading is noted again. The difference between the readings gives the major diameter.
The same procedure is carried out to measure minor diameter (where the crosswire is
moved between the two roots of the thread) and pitch of the thread (where the
crosswire is moved between two adjacent crests)
The thread angle is measured by making use of the rotating crosswire which is
attached to a protractor. The crosswire is made to coincide with one slanting edge of
the thread and the Protractor readings are noted. Then the crosswire is made to
coincide with the adjacent side forming the thread angle and the protractor readings
are noted. The difference between the two readings will give the thread angle.

Fig. 3 Thread Terminology

OBSERVATIONS
Quantity
Measured
Micrometer Reading
Difference
Initial Final
Major Diameter
Minor Diameter
Pitch


Quantity
Measured
Readings
Vernier Reading
Total
MSR VSR
Thread
Angle
Initial Reading
Final Reading

Thread angle = Initial reading Final Reading
=
RESULT
The different thread characteristics measured are:
1. Major diameter = mm
2. Minor diameter = mm
3. Pitch = mm
4. Thread Angle =


5. MEASUREMENT OF TOOL SIGNATURE
AIM
To measure the tool signature of a single point cutting tool
APPARATUS
Tool makers microscope, single point cutting tool
PRINCIPLE
The signature of the cutting tool is the systematic representation of the various angles
of the cutting tool and the nose radius. A tool makers microscope is essentially an
optical microscope in principle. It has a heavy base and on this, a worktable with a
glass stage is supported on balls. The longitudinal and traverse slide motion of the
table is made possible by the micrometer screws attached to the table. It is used for
the magnified representation of the object placed on the work-table. The elements of
the tool signature which are measured are: Back rake angle, side rake angle, end relief
angle, side relief angle, end cutting edge angle and side cutting edge angle.

Fig. 4 Single Point Cutting Tool Geometry
PROCEDURE
In order to carry out the measurement, the tool specimen is placed on the work table
of the tool makers microscope. One edge of the tool is made to coincide with one of
the cross wires of the eyepiece. The protractor reading is then set to zero. It is then
rotated such that one of the edges of the tool coincides with the cross wire. The
reading on the protractor is noted. The same procedure is repeated to measure the
other angles also.
OBSERVATIONS
Sl. No
Angles
Initial
Reading
Final Reading
Final
Measurement
1 Back Rake
2 Side rake
3 End/Front clearance
4 Side clearance
5 End cutting edge
6 Side cutting edge
7. Lip angle

RESULTS
The various cutting tool angle measured are:
1. Back Rake Angle =
2. Side rake Angle =
3. End/ Front clearance Angle =
4. Side clearance Angle =
5. End cutting edge Angle =
6. Side cutting edge Angle =
7. Lip Angle =