Mechanical Engineering / SSJCET, Asangaon

Experiment No: 1

Aim: - Use of dial indicator, as Mechanical Comparator to inspect the given component.

Apparatus: - Dial Gauge indicator with comparator Stand, Slip gauges, Surface plate &
Suitable Components. Component for Inspection Should be Ground pins, rollers or bushes etc.
within ±0.03 mm tolerance for diameter or height.

Theory: -
Proposition 1: Comparator
Comparator is a device which small deviation of a component, magnifies & displays it Suitable,
readable scale for comparison with standard or basic size.

Picks
Magnifies small deviation Accurate &
Comparator precise
measurement
Displays On readable scale for
Comparison with standard

In case of mass production it is the best choice for speedy inspection which gives accurate and
precise readings.
Preposition 2: Dial gauge indicator
It is the versatile Mechanical component. It is used for direct measurement & deviation in
geometrical parameter such as taper & ovality etc.

Procedure:-
1) Read the Drawing for given component correctly.
2) Select the proper dial gauge indicator to suitable least count and range.
3) Mount dial indicator on the comparator stand.
4) Built correct combination of slip gauge.
5) Take the built up slip gauge combination and give pressure to the plunger considering
the tolerance zone.
6) Set Zero dial gauge indicator by relating the bezel of the dial.
7) Clean & dry the component to be checked.

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8) Insert the component between the contact point of plunger & flat table of comparator.
9) Adjust the tolerance pointer considering the tolerance.
10) Note the deflection of pointer & record that deviation.
11) If the deviation of the pointer within the tolerance pointer accept the component & if
not reject the component.

Observations:-
1) Dimension to be measured with tolerance = (as per drawing)

2) Slip gauges combination selected = + + = mm

Observation Table for deviation :

Observed Readings
Sample Deviation with sign Total Accepted/
No. (±) from set size Reading Rejected
1
2
3
4
5
6
7
8

Sample calculation:-
1) Total Reading = Basic size ± Deviation
=

=
2) Total Reading = Basic Size ± Deviation

=
=

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Conclusion:-

1) Out of components checked in the experiment as listed above samples

are rejected.
2) Dial indicator has (calibrated/ non calibrated ) scale.
3) Dial indicator can be used for ( direct / comparison / direct and
comparison ) type measurement.

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Experiment no:-2
AIM: -Measure the Screw Thread by Using Screw Thread Micrometer, Screw Pitch Gauge &
Optical Profile Projector

APPARATUS: - Optical Profile Projector, old templates, drawing thread component, trace
paper.

THEORY:-

1) Screw Thread Micrometer: - This equipment is used to measure pitch diameter of screw.
It look like standard micrometer experts that the anvils. Specially contact to reach into the
screw thread groove and touch the pitch diameter of the screw thread.
2) Optical Profile Projector: - It is instrument whereby used lenses & beam of light profile
of small shape can be magnified the enlarged image can be compare with accurate
drawing to scale of a magnification such as comparison can revere only deviation in the
sizes & contours of the objects & to get numerical assignment of such deviation,
measurement can be made on the enlarge shadow.
CONCEPT STRUCTURE:-

Optical Profile
Projector

Geometrical parameters
of Screw Thread

And Compare Profile

Standard Template

By projecting

Shadow of the object on

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PROCEDURE: -

Optical Profile Projector:-

The profile projector is basically an optical instrument/comparator which makes use of

the enlarged image principle. The purpose of optical projector is to compare the shape or profile
of relatively small engineering component onto a screen. The magnification of the system will be
equal to the size of the object image in screen divided by size of the component.
The object to be tested are placed on the worktable. light beam after pulling the object to
be projected pallets into projection. are usually made of an acrylic plane are used for
measurement. (paddy)the worktable is providing with means for measurement like micrometer
angles can be measured by rotating screw.
1) Switch On Project At.
2) Plane & Clean Work piece Or Glass of Table.
3) Focus It Properly By Moving Focusing Wheel & Moving The Worktable To Obtain
Proper Image.
4) Horizontal Measurement Can Be Taken By Right Hand Side Micrometer&Vertical
Measurement.
5) To measure pitch take the distance between two similar points on adjacent flank or crest
or root to an adjacent thread, parallel to the axis of the screw thread. For achieving this
adjust the reference line on the projector to the corresponding point sand note the
micrometer readings between these points.
6) Adapt Similar Procedure For Measurement Of Depth Of Screw.
7) For Measurement of Depth Reference Line between Flanks & Note down Angle.
8) Image of th e component can compared with master template or chart.

Screw Thread Micrometer: -

The screw thread micrometer is just like an ordinary micrometer with the difference that
is equipment with a special anvil and spindle. The anvil an internal V which fits over the thread,
the end of the spindle of a thread micrometer is pointed to 60 degree V is grooved in the anvil.
The anvil is free to rotate. Thus V anvil can adjust itself to the helix angular of the thread being
measured. When the conical spindle is brought into contact with the ‘V’ of the anvil micrometer
reads zero. A setting gauge is also provided to remove zero errors if any.
The screw thread micrometer with different that equipment with spindal a setting gauge
is also provided to remove zero errors.if any different sets of anvils are provided or different set
type of thread & contact points.

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OBSERVATION TABLE:-
Dimension to be measured Reference point Reference point difference
reading-1 reading-2

Major Diameter

Minor Diameter

Pitch

Depth

Angle

Effective

Tabel of observation for dimention for screw thread micrometer:

Sr. No Main scale reading Vernier reading Total reading Anvil set

RESULT:-
1) Pitch Of Given Component (By the screw pitch gauge) is :-.........
2) Pitch Of Component (From Observation Table)is :- .........
3) Depth Of Threadis :- .........
4) Angle Of Threadis :- ........
5) Effective diameter measured by micrometer is:- .........

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CONCLUSION:-

• Optical Profile Projector is used for direct measurement (direct

measurement/comparison) of screw thread profile.
1. Accuracy : It is based on operator skill & proper calibration and micrometerscale.
2. Ease of measurement- Micrometer measurement and movement it is very easy.

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Experiment no:-3

AIM: -To compare surface using Optical Flats

APPARATUS: - Monochromatic light source set of optical Flats

THEORY:-
Optical Flats are usually made of Circular discs of eight glasses or fused quartz with one
or both faced lapped to high order of flatness.

The face of Optical flat acts as a datum against which the flatteners at the reflecting
surface may be determined by interpreting shape of fringe pattern produced.

In addition to the determination of length interferometric technique may also be used to

measured the flatness of suitable surface by interpreting the shape of the fringe pattern produced.

PROCEDURE: -
1) For testing polish switch ON monochromatic light source.
2) Sufficiently polish the surface to be tested so that it will light.
3) The optical flat is placed on the surface to be tested.
4) Monochromatic light sources is then directed on the flat surface through optical
flat.
5) Observe fringe pattern and draw sketches in table.
6) Interpret the nature of surface 100 m observed pattern by making use of diagram.
Table:

Sr. No Observed figure Nature of surface

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Limitations :
(1) Before using optical flat, it should be ensured that both flat & work piece are clean from dust.
(2) Optical flat should never be slide over workpiece but lifted form it. It interference bund are
not good flat should never and set down again, applying vertical fringe pressure of various
location on the upper surface to obtain satisfaction

Application :
(1) To check the flatness of given surfaces.
(2) To check the parallelism of working face and thickness.

CONCLUSION:-

(1) Optical flat can be useful to compare the flatness of given surface using
monochromatic light sources.
(2) Optical flat works on the Principle of monochromatic.

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Experiment no:-4

AIM: -Measure the gear tooth elements using gear tooth caliper and verify the profile using
optical profile projector.

APPARATUS: - Gear tooth vernier calipers, vernier calipers, optical profile projector with
suitable magnification (10X,20X) and appropriate gear samples.(even no teeth)

THEORY:-
Preposition 1: Need of inspection of gear elements

The inaccuracy gear manufacturing causes many errors such as, incorrect addendum,
clearance, wrong profile and difference in tooth thickness etc. from nominal value.
These errors affect the performance of gear drive. Hence it is necessary to control the
various elements of gear elements while manufacturing.

Preposition 2: Analytical and functional inspection of gear

The measurement of gear parameters, especially the spur gear can be classified in to
two groups

1. Analytical parameters: Tooth thickness, circular pitch, addendum depth spacing over ‘X’
no of teeth etc.
2. Functional parameters: Profile checking, runout, backlash, contact area, and composite
error etc.
Preposition 3: Gear tooth vernier

Gear tooth verniercaliper is used to measure the chordal thickness of gear tooth. It has
two verniers one is horizontal and another is in vertical position. The least count of gear
tooth vernier is 0.02mm.

PROCEDURE: -

1. Take suitable gear and clean it (with good surface finish).

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2. Find the blank diameter OD by verniercaliper.(In case of gear having even number of
teeth OD is measured on top land of opposite gear tooth).

OD= ................ mm
3. Count the no of teeth ‘N’ of the gear.
N=… .................. mm

4. Calculate the pitch circle diameter (PCD)

PCD=(N x OD) / (N+2) = ………………………
=……………………….

5. Calculate the module (m)

M=PCD / N=…………………
=…………………

6. Set the chordal depth (addendum ‘da’) on the vertical side of the gear tooth vernier
da=(N x m/2)[1+(2/N)-cos(90/N)]

da=

7. Insert the jaws of the instrument on the tooth to be measured

8. Adjust the horizontal vernier side and the reading. It gives the chordal thickness (W) of
the tooth,W=… ............ mm.
9. Repeat the procedure over the length of the same tooth at 2/3 different place and note
reading.
10. Repeat the observatios for2/3 different teeth.
11. Find out the theoretical value of chordal thickness(W)
W=N x m sin(90/N)
=… ................ mm
12. Compare theoretical (calculated) and experimental value of W and state the reasons
variations in conclusion.

Verification of tooth thickness with profile projector :

1. Take the same gear used above for tooth thickness calculation.
2. Select suitable magnifying lens (10X).
3. Take the projection of tooth to be measured on screen .
4. Fix the tracing of the booth tooth to be measured on the screen by using clamping pins.
5. Compare the tracing and projected image.
6. Note the reading of deviation in chordal addendum (da) and tooth thickness (W) by
moving the image by micrometers.
7. Record the deviation in observation tables.

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OBSERVATION TABLE:-
Observations for optical profile projector :

Parameters Ref.point reading no. 1 Ref.point reading no.2 Difference(deviation)

Chordal addendum

(da)

Tooth thickness (W)

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Observations for optical profile projector :

Practical chordal thickness (W)

SR.NO. Reading1 Reading 2 Reading 3 Reading 4

Teeth 1

Teeth 2

Teeth 3

CONCLUSION:-

1. Variation in the measurement of chordal thickness on the same tooth is observed/not

observed.

(tick the correct)……………………..

2. Variation in theoretical and practical value of chordal thickness isdue to following

reasons.

1.

2.

3.

3. Gear tooth verniercaliper is used to find the thickness of gear tooth of .........type gear

4. Chordal thickness is…....... Than radial thickness. (more / less)

5. Chordal depth is… ...... than radial depth. (more / less)

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Experiment no:-5

AIM: -To measure the effective diameter of external screw thread using floating carriage
micromerter (Two wire method ) .

APPARATUS: - Work floating carriages micrometer, wire ,plug gauge, Threaded

components.

THEORY:-
The effective diameter of screw thread may be as contained by placing two wires or rod at
identical diameter between the flank of the thread.

-Measuring distance over the outside of these wire .

-The effective diameter DE is calculated as ,

DE = Y + 2CD

where,

DE = effective Diameter of each wire

Y = distance under wire .

Construction: -
1) The machine ensure that the axis of the micrometer is maintained at 90 degree to axis
of screw under test .
2) The lower side is capable of movement parallel with thread axis.
3) The wire used is made of hardness to sustain the wear and tear is used these are given a
high degree of accuracy and flush by lapping to suit different pitches
Working :-
1) By fixing the specimen in anvil applying equal pressure on both side specimen.
2) To ensure the pressure indicator shown zero are position on indicator.
3) The zero position gives correct reading of effective diameter of specimen.
4) In two wire method rod should be in same flanks of specimen.
Procedure :-
1) Select a plain setting cylinder of a size to O/P under test.
2) Select a set of standard wire by referring chart ‘A’.
3) Add the selected setting cylinder between centres.
4) Calculate test wire size and large the standard wire so that they can contact setting
cylinder on both side.

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5) Set the following carriage of right angle to axis of corner so that anvil or micrometer head
and to audial indicator for contact the hanging wire as in frequency.
6) Apply the spring pressure by rotating the thimble screw so that froducial indicate is set to
zero error is avoided rotating the setting cylinder so that it rolls over the wire.
7) Note the micrometer reading Rc.
8) Replace setting cylinder by a thread component which is to be checked.
9) Apply the spring pressure as standard is in earlier step above.
10) Note the micrometer observation and calculate effective diameter.
Observation :

Diameter of setting cylinder =

Micrometer reading over on setting cylinder (RM)=

Micrometer reading over wire on threaded component (RC)=

Diameter of wire (d) =

Piston of thread (D)=

Calculation :
1) Dia. under wire (T) = D+(Rs+Rc)

2) R value (P) =

With work thread =D

Effective diameter DE = Y + 2CD

Limitations :

1) It can be measure the external diameter more than 25 mm.

2) It is not used for measurement of pitch.
3) Two wire method can be carried out Only on the diameter measuring machine
described for measuring the minor diameter because alignment is not possible by two
wires and can be provided only by floating carriage machine.
Application :

To measure effective diameter of thread.

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Result :

Effective diameter of thread component is found to be DE =

Conclusion :

1) Floating carriage microscope can be used to measure effective diameter of external

threads.
2) The significance at P value is to evaluate the effective diameter.

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