SUBMITTED BY :

BATCH 3
MAZHAR HUSSAIN - BT13MEC045
SAHIL MISHRA - BT13MEC046
N.SIVA PRASAD - BT13MEC047
 EXPERIMENT NO. 9
EVALUATION OF THE GEAR PROFILE AND ALIGNMENT USING ROLLING GEAR TESTER

NAME OF EXPERIMENT: Evaluation of the gear profile and alignment using rolling gear tester.

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

APPARATUS: Gear Roll Tester, Master gear, Slave gear, Dial Gauge (LC = 0.01mm)

INTRODUCTION:

This experiment is about measuring the degree of misalignment. In this experiment, a given
gear is compared with a hardened and ground master gear. This test shows the errors
present in tooth form, pitch and concentricity of pitch line.
This is the most commonly used test under production conditions. This consumes much less
time and gives quite accurate results. In rolling test, the gear to be tested is actually
compared with a hardened and ground master gear. This test is generally performed on a
most commonly used machine Parkinson Gear Tester. This test reveals any errors in tooth
form, pitch and concentricity of pitch line

FIGURE:

Rolling Gear Tester

According to this, whenever two gears are in mesh then any error in tooth profile, backlash
and misalignment of gear axis will lead to variation in central distance between the two
gears. This fact is utilized to inspect the errors in a given gear with respect to a master gear.
A illustrative figure of the gear tester is shown in the figure below,

PROCEDURE:

1) The distance between the centre of two spindles is adjusted to be equal to the centre
distance
2) A dial gauge is made to rest against the movable carriage and its reading is adjusted at zero
at this time.
3) The master gear is mounted on the spindle on fixed carriage and error to be tested on the
movable carriage.
4) Initially measure the centre distance and outer diameter (OD).
5) The gears when in mesh are then rotated by hand and the variations in the dial gauge
readings are observed.

OBSERVATION:
Dial gauge least count- 0.01 mm
Centre distance= 72+0.01*8=72.08 mm
OD=78+0.02*6=78.12 mm
No. of teeth=24.
TABLE:

Teeth Difference Teeth Difference

1 0 13 0.01
2 -0.04 14 0.03
3 -0.05 15 0.03
4 -0.06 16 0.03
5 -0.02 17 0.03
6 -0.01 18 0.02
7 -0.03 19 0.01
8 0 20 0.02
9 -0.02 21 0.02
10 -0.02 22 0.04
11 0 23 0
12 0 24 -0.02

CONCLUSION:

From this experiment, it is concluded that any defect in the gear tooth profile or eccentricity will
lead to variation in the central distance between the two gears. However, the exact reason of
deviation cannot be predicated here.
 EXPERIMENT NO:10
RADIAL AND AXIAL RUNOUT OF ROTATING CYLINDRICAL OBJECT

NAME OF THE EXPERIMENT :Radial and Axial Runout of rotating cylindrical object.
AIM: To perform the Radial and Axial Runout by using the Dial guage.

APPARATUS: Dial gauge, Marker ,Specimen , Centers.

INTRODUCTION:

Run-out is an inaccuracy of rotating mechanical systems, specifically that the tool or shaft does not
rotate exactly in line with the main axis. Run out is a surface control and it controls the surfaces
that are constructed. It is defined as the degree to which a shaft or coupling deviates from true
circular rotation.

FIGURE:

On rotating machinery, runout is defined as the degree to which a shaft or coupling deviates
from true circular rotation.

DEFINITIONS:

Axial runout: Axial run-out is the result of a rotating component not being parallel with the
axis, such as a drill chuck not holding the drill exactly in line with the axis.
Radial runout: Radial run-out is the result of a rotating component running off center, such
as a ball bearing with an offset centre. This means that the rotating tool or shaft, instead of
being centrally aligned, will rotate about a secondary axis.
PROCEDURE:

Use a dial indicator and magnetic base. Mark the reference point on the rotating cylinder.
Zero the indicator on the outside diameter at the mark. Slowly rotate the cylinder to look
for runout, and measure the maximum deviation in the dial gauge. And repeat it for both
axial and radial runouts. Take two reference points each for axial and radial runout. Note
down the readings.
OBSERVATION TABLE:

Radial runout Axial runout

Point 1 -7.5m Point 3 20m

Point 2 -7.5m Point 4 8m

CONCLUSION:

Radial and Axial Runout of rotating cylindrical object are measured using dial gauge of least count
0.01 mm .Radial Runout is measured around the datum axis whereas axial runout is measured
perpendicular to datum axis .
 EXPERIMENT NO. 11
STRAIGHTNESS MEASUREMENT

NAME OF EXPERIMENT : Straightness Measurement

AIM: Measurement of straightness using inclinometer.

APPARATUS:

Digital inclinometer (Least count 0.1 deg), sine bar, measuring surface, etc.

INTRODUCTION:

Straightness measurement is essential to ensure that a given surface has no error on its surface
geometry. Perfectly straight surfaces are a requirement of industries and various laboratories. Basic
measurement applications are to act as a reference surface for other measurements. Also, some
machines could require a perfectly straight components.

Straightness Error:

A line is said to be straight over a given length, if the variation of the distance of its points from two
planes perpendicular to each other and parallel to the general direction of the line remains within
the specified tolerance limits. The reference planes being so chosen that their intersection is parallel
to the
straight line joining two points suitably located on the line to be tested and the two points being
close to the ends of the lengths to be measured. The tolerance on the straightness of a line is
defined as the maximum deviation in relation to the reference straight line joining the two
extremities of the line to be checked.

Straightness tolerance symbol

Digital Inclinometers:

This enables very precise readings of angles. This type of inclinometer uses an internal gyroscope to
measure the direction of gravity's pull. The gyroscope remains in one position, no matter the
orientation. A solid object is placed along the gyroscope, and the angle between the gyroscope and
the object is determined via the inclinometer and displayed on an electronic readout.

Digital Inclinometer
Sine bar:

A sine bar consists of a hardened, precision ground body with two precision ground cylinders fixed at
the ends. The distance between the centers of the cylinders is precisely controlled, and the top of
the bar is parallel to a line through the centers of the two rollers. The dimension between the two
rollers is chosen to be a whole number (for ease of later calculations) and forms the hypotenuse of a
triangle when in use.

When a sine bar is placed on a level surface the top edge will be parallel to that surface. If one roller
is raised by a known distance, usually using gauge blocks, then the top edge of the bar will be tilted
by the same amount forming an angle that may be calculated by the application of the sine rule.

The hypotenuse is a constant dimension(100 mm or 10 inches in the examples shown).

The height is obtained from the dimension between the bottom of one roller and the table's
surface.

The angle is calculated by using the sine rule. Some engineering and metalworking reference
books contain tables showing the dimension required to obtain an angle from 0-90 degrees,
incremented by 1 minute intervals.

sin(angle) = H/L

Sine bar

PRINCIPLE OF EXPERIMENT:

The principle used for measurement here is very simple. The measuring surface is divided into a
number of divisions. The inclination of the first surface is measured and set as the reference. The
inclination of the rest of the divisions is measured with respect to the reference division.
 PROCEDURE:

1. Divide the measuring surface into six equally spaced divisions each of length 100mm.
2. Measure the inclination of the first division using a digital inclinometer (This shall be the
lower value in the display of the inclinometer).
3. Press one of the buttons on the inclinometer and set this inclination value as 0.
4. Measure the inclination of the rest of the divisions and note the values.
5. Do the same procedure from the other direction by setting the division at the other end as
the reference. You would now have two sets of readings : one form right to left and the
other from left to right.
6. Fill in the observation table with the corresponding values and complete the calculation.

OBSERVATION TABLE:

Case 1: Left to right

Position Inclinometer Reading Rise or fall over Cumulative rise or Adjustment to Error
100 mm base fall bring both
length ends to zero

(mm)

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

0 0 0 0 0 0

0-100 0 0 0 -0.145 -0.145

100-200 0 0 0 -0.290 -0.290

200-300 0 0 0 -0.435 -0.435

300-400 0 0 0 -0.580 -0.580

400-500 0.2 0.348 0.348 -0.725 -0.377

500-600 0.3 0.522 0.870 -0.870 0

Position Inclinometer Reading Rise or fall over Cumulative rise or Adjustment to Error
100 mm base fall bring both
length ends to zero

(mm)

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

0 0 0 0 0 0

0-100 0 0 0 -0.377 -0.377

100-200 0.1 0.174 0.174 -0.754 -0.580

200-300 0.3 0.522 0.696 -1.131 -0.435

300-400 0.3 0.522 1.218 -1.508 -0.290

400-500 0.3 0.522 1.74 -1.885 -0.145

500-600 0.3 0.522 2.262 -2.262 0

Graphs:

Case 1:

Straightness Error
0
0 100 200 300 400 500 600
-0.1

-0.2
Straightness
-0.3 Error
Error
-0.4

-0.5

-0.6

-0.7

Straightness Error = 0.580 mm

Straightness Error
0
0 100 200 300 400 500 600
-0.1

-0.2
Straightness
Error
-0.3
Error
-0.4

-0.5

-0.6

-0.7

Straightness Error = 0.580 mm

RESULT:

The straightness error is 0.580 mm and is calculated from both the directions. The necessary graphs
are also plotted.

CONCLUSION:

The straightness error was found to be the same from both directions. This is because the
straightness is a geometrical property of the surface. The straightness error is so large because the
measuring surface was not very flat.