PRLR-12 METROLOGY AND

COMPUTER NUMERICAL CONTROL

MACHINES LAB MANUAL

Roll No.

Name

Section

National Institute of Technology

Tiruchirappalli- 620015
 INDEX

Exp. Marks Faculty

Date Experiment Name
No. Awarded Signature

Measurement of linear dimensions using Comparators

1

Non-contact (Optical) measurement Profile projector.

2
Measurement of angles using sine bar
3

4 Calibration and use of Precision Measuring Instruments

Measurement of Geometric features using a
5 Coordinate Measuring Machine
Measurement of Gear parameters and adjacent base
6
pitch error using Gear Tooth Vernier Caliper

7 Measurement of Surface Finish using a stylus-based instrument

8 Statistical Process Control exercise

Exp. Marks Faculty

Date Experiment Name
No. Awarded Signature

1 Plain turning and facing operations on CNC turning centre.

2 Step turning operation on CNC turning centre

3 External threading operation on CNC turning centre

4 Profile milling operation on CNC vertical milling centre.
Circular pocketing/ rectangular pocketing /drilling operations
5 on CNC vertical milling centre.
6 Mirroring operation on CNC vertical milling centre.

7 Inspection on CMM
 MEASUREMENT OF LINEAR DIMENSIONS USING
EX. NO.: 1 DATE:
COMPARATORS

AIM:
To check the dimensional limits of the gives work piece with a standard specimen using
comparator.

APPARATUS REQUIRED:

• Comparator
• Standard specimen
• Micrometer

DESCRIPTION:

The comparator is a one of the types of comparators used to only check the specimen. There are
graduations in the dial gauge and there is a counter dial in the gauge. There is a plunger, by this sensitive
plunger the pointer in the dial gauge points out the reading. By using the slip gauge, the values of the
specimen were verified. The least of mechanical comparator is 0.01mm.

PROCEDURE:

1. Measure the height of the specimen using a vernier height gauge.

2. Take a standard specimen and get the value in the comparator.
3. Check for the deviation from standard value using the dial gauge.
4. Check all the test pieces, note down the variations, and mention, Accepted, (or), Rejected.

DIAGRAM:

MECHANICAL COMPARATOR
TABULATION:

Height of the Standard

Specimen Tolerance:

Trail Dial gauge reading Actual Reading Deviation Sample

No. (mm) (mm) Accept/ Reject
Divisions (mm)

RESULT:

The dimensional limits of the given work piece are checked with a standard specimen using
mechanical comparator.
 NON-CONTACT (OPTICAL) MEASUREMENT
EX. NO.: 2 DATE:
PROFILE PROJECTOR.

AIM:

To measure
1) Major diameter, minor diameter, and the pitch of the screw thread using Profile
Projector.
2) Projected circular object

APPARATUS:

• Profile Projector
• Threaded job
• Projected object

PROFILE PROJECTOR:

A profile projector projects a magnified profile image of an area or feature of a workpiece

onto a screen, most commonly using diascopy illumination. Dimensions can be measured directly
on the screen or compared to a standard reference at the correct magnification. For accuracy, the
magnification mustn’t change with perspective, i.e., its position or the viewpoint of the operator.
Telecentric lenses are, therefore, highly desirable. The screen often has a grid and this grid can
often be rotated through 360 degrees to align with an edge as displayed on the screen. Point
positions, measurements, and calculations may also be performed using a simple digital readout
device. Episcope lighting is used to measure features such as bores, bosses, pockets, pads, etc.,
which would not be revealed on a profile view. A computer may be added to a profile projector
system for edge determination, therebyeliminating some human error.

PROCEDURE:

The use of the Profile Projector for taking the various measurements is explained below:

1) For taking linear measurements, the workpiece is placed over the table. Then it is focused and
one end of the workpiece is made to coincide with a cross-line on the screen (by operating
micrometer screws). The table is again moved until the other end of the workpiece coincides
with the cross line on the screen and the final reading is taken. From the final reading, the
desired measurement can be taken.

2) To measure the screw pitch, the screw is mounted on the table. Then it is focused (by adjusting
the height of the optical head) until a sharp image of the projected contour of the screw is seen
on the ground glass screen. The contour is set so that some point on the contour coincides with
the cross line on the screen. The reading on the thimble of the longitudinal micrometer screw is
noted. Then the table is moved by the same screw until a corresponding point on the contour
(profile) of the next thread coincides with the cross line. The reading is again noted and the
difference between the two readings gives the screw pitch.
3) To determine pitch distance the lateral movement to the table is given.
4) To determine the thread handle, the screen is rotated until a line on the angle of screen rotation is
noted. The screen is further rotated until the same line coincides with the other flank of the threads.
The angle of the thread on the screen will be different in two angular readings. Different types of
gradated and engraved screens and corresponding eyepieces areused for measuring different elements

Tabular Column: (For projected gear profile measurement)

Sample MAIN SCALE CIRCULAR SCALE FINAL READING =

READING (mm) READING (mm) MSR + (CSR X LC)
(mm)
Major Diameter
Minor Diameter
Pitch Distance

Tabular Column: (For projected circle measurement)

S. No MAIN SCALE CIRCULAR SCALE FINAL READING =
READING (mm) READING (mm) MSR + (CSR X LC)
(mm)
Result:

Thus, the key Pitch of the screw thread is obtained as and diameter of
projection is obtained as
 EX. NO.: 3 MEASUREMENT OF ANGLES USING SINE BAR DATE:

AIM:

To measure the taper angle of given specimen using Sine bar.

APPARATUS REQUIRED:

• Sine bar
• Slip gauge
• Surface plate

DESCRIPTION:

Sine bars are always used along with slip gauge as the device for the angle measurement.
Generally, sine bars are made from high carbon, high chromium, and corrosion resistant steel. These
materials are highly hardened, ground and establish. In sine bars two cylinders of equal diameter are
attached at the ends parallel to each other. The distance between two cylinders is 100mm, 200mm, or
300mm. There are some relief holes was made in the sine bar mainly to reduce the weight also facilitate
handling.

PROCEDURE:

1. Clean the surface plate and place the set-up on the surface plate
2. Note down the length of the sine bar
3. Note down the dimensions of the slip gauges available
4. For the given angle, calculate the height of the slip gauge required
5. Bring all the selected slip gauges together, so that the combination gives the height.
6. Place the sine bar with the contact roller on top of the combination of slip gauges
on the surface plate Measure the built-up angle to ascertain accuracy if angle/gap
gauges are available.
DIAGRAM:

FORMULA USED:

Where,

Taper angle of the work piece

H-height of assemble slip gauge
L-Length of sine bar

Here, h is the required slip gauge combination in mm and L is the spacing between the
rollers in mm.
RESULT:

Thus the taper angle of given work pieces are determined using sine bar as follows:

1. Taper Angle( Component 1=____________

2. Taper Angle( Component 2=____________
EX.NO.:4 CALIBRATION AND USE OF PRECISION MEASURING DATE:
INSTRUMENTS

AIM:

To compare the accuracy of Vernier Caliper, Micrometer and Vernier Height Gauge, to check
the various dimentions of a given specimen.

APPARATUS REQUIRED:

• Vernier caliper
• Micrometer
• Vernier Height Gauge
• Specimen

PROCEDURE FOR VERNIER CALIPER, HEIGHT GAUGE:

1) Check the zero reading for error.

2) Place the work piece to be measured in between the measuring face.
3) Adjust the sliding jaw until there is no further movement of sliding bar.
4) Note the main scale, Vernier reading for the calculation of workpiece dimension.
5) Tabulate the readings.
6) Then the dimension of work piece is calculated and average value is taken.

PROCEDURE FOR MICROMETER:

1) Check the zero position for error.

2) Place the specimen to be measured.
3) Adjust the spindle by rotating the ratchet unit at began to slip.
4) Note the reading on the main scale and the thimble scale.
5) By calculating the division on both scales the reading was tabulated.
6) Thus the thickness of the work piece was measured.
TABULATION:
Least count = 0.02mm
S.No Slip Gauge Vernier Scale Reading Error
Inserted(mm) MSR(mm) VSR MSR+(VSR×LC)mm mm
1

CALIBRATION OF VERNIER HEIGHT GAUGE

Least count = 0.02mm
S.No Specimen Vernier Scale Reading Error
MSR(mm) VSR MSR+(VSR×LC)mm mm
1

CALIBRATION OF MICROMETER
Least count = 0.01mm

S.No Slip Gauge Micrometer reading Error

inserted (mm) MSR(mm) VSR MSR+(VSR×LC)mm mm
1

MODEL CALCULATION:
Error(mm)= Actual reading-Indicated Reading
=…………………….mm
MODEL GRAPH:

RESULT:

i. Length of the Specimen -________________

ii. Height of the specimen -________________
iii.Thickness of the Specimen -________________

Thus the accuracy of vernier caliper, vernier height Guage, Micrometer compared for a given
specimen.
 MEASUREMENT IN COORDINATE MEASURING
‘EX. NO.: 5 MACHINE DATE:

AIM:
To measure the specified dimension of the given component using .

APPARATUS:
• Coordinate measuring machine
• Probe-Renishaw
DESCRIPTION:
A Coordinate measuring machine (CMM) is a 3D device for measuring the physical geometrical
characteristics of an object. This machine may be manually controlled by an operator, or it may be
computer controlled. Measurements are defined by a probe attached to the third moving axis of this
machine, X, Y and Z. A coordinate measuring machine is also a device used in manufacturing and
assembly processes to test a part or assembly against the design intent. By precisely recording the X, Y
and Z coordinates of the target, points are generated which can then be analyzed via regression which
can then be analyzed via regression algorithms for the construction of features. These points are
collected by using a probe that is positioned manually by an operator or automatically via Direct
Computer Control (DCC). DCC CMMs can be programmed to repeatedly measure identical parts, thus a
CMM is a specialized form of industrial robot.

PROCEDURE:
1) Calibration of machine is done using a sphere ball attached to the granite table. Take at least 8
points on sphere.
2) Fix the object whose dimension needs to be measured using the jigs and fixtures.
3) Using joysticks, move the probe whose tip is made of ruby slowly and carefully to the surface
whose measurements must be taken.
4) For measurements of a line, the probe is touched at 2 Places (starting and ending point).
5) For measuring circular profile, probe is touched at 3 Points, for cylinder it is touched at 8 points.
6) Same profiles are again measured with vernier calipers (length of line, circle diameter, cylinder
diameter) to compare the two readings.

DIAGRAM:
SAMPLE SPECIMEN:

TABULATION:

S.No. Feature Required Obtained dimensions Tolerance

dimension
1 Straightness L1= L2= L3= L4=
2 Circularity R1= R2= R3= R4=
3 Concentricity R1= R2= R3= R4=
R1= R2= R3= R4=
4 Parallelism S1= S2= S3= S4=
S1= S2= S3= S4=
5 Perpendicularity S1= S2= S3= S4=
S1= S2= S3= S4=
6 Angularity S1= S2= S3= S4=

RESULT:
 MEASUREMENT OF GEAR PARAMETERS AND
‘EX. NO.: 6 ADJACENT BASE PITCH ERROR USING GEAR DATE:
TOOTH VERNIER CALIPER

AIM :
To measure gear parameter by gear tooth Vernier.
APPARATUS REQUIRED :
• Gear tooth Vernier Caliper
• Gear specimen,(SPUR GEAR),
• Vernier Caliper.
SPECIFICATION:

Geartooth Vernier Range = Horizontal=0-10 mm

Vertical= 0-8 mm, L.C = 0.02mm

PROCEDURE:

1. The N,D of the given gear block are measured.

2. The module m’ it then calculated.
3. Theoretical values of ‘W’ and ‘d’ are computed.
4. Theoretical values of ‘W’ is set in horizontal Vernier scale of gear tooth Vernier and
Corresponding actual’ value scale.
5. Theoretical values of ‘c’ is set and ‘W’ is measured along.
6. Horizontal scale.
7. This procedure is repeated for 5 teeth and value tabulated.

FORMULA USED:
• h= (Nm/2)[1+2/N-cos(90/N) ]
• m
• T=

• %Error= (Ws-W)/Ws

• Where,

h-Addendum
N-number of teeth
M-module, W= chordal thickness m
Do- outside diameter of gear, T- theoretical tooth thickness, Ws= Standard chordal thickness mm,
MODEL CALCULATION:

RESULT:
Thus, the chordal thickness and addendum of gear is measured using gear tooth Vernier.
EX.NO.:7 MEASUREMENT OF SURFACE FINISH USING A DATE:
STYLUS-BASED INSTRUMENT

AIM:
To measure the surface roughness parameters such as Ra, Rq, Rz are measure using surface
roughness tester.

APPARATUS:

• Mitutoyo make surface roughness tester

• Calibrated specimen
• Surface plate
• Specimen

DESCRIPTION:

A surface roughness tester is required to assign a numerical value to the degree of surface
roughness. This will enable the analyst to assess whether the surface quality meets the functional
requirements of a component. A typical surface roughness tester is shown in Fig. Various methodologies
are employed to arrive at a representative parameter of surface roughness.

PROCEDURE:

1) Connect AC adopter to the measuring instrument & Switch on the power supply

2) Attach the drive detector unit & connect to all the cable connection as shown when mounting
thedetector to the drive unit, take care not to apply excessive force to the drive unit.
3) Adjust or modify the measurement condition such as sample length, number samples,
Standardrequired for the measurement
4) Calibrate the instrument using standard calibration piece

5) Carefully place the detector on the work piece. Care should be taken to see that work piece
&detector are aligned properly
6) Press the start button to measure the work piece & result are displaced on the console

7) Press print button to take the printout.

DIAGRAM:

SURFACE ROUGHNESS TESTER (MITITUYO)

TABULATION:

Arithmetic Mean
Root Mean Square Ten-Point Mean
Value of Surface
Sl. Specimen Value of Surface Surface Roughness
Roughness (Ra)
No. Type Roughness (Rq) (Rz) (Microns)
(Microns)
(Microns)

5
RESULT:
Thus the surface roughness parameters Ra, Rq, Rz are measure using surface roughness tester.

a) Rz =___________________ microns
b) Ra =___________________microns
c) Rq =___________________microns
d) Rt =___________________microns
 EX.NO.:8 STATISTICAL PROCESS CONTROL EXERCISE DATE:

AIM:

To inspect the given machined parts, and determine the process capability, the 3 limits for X-
chart, and the percent defective.

APPARATUS REQUIRED:
Specimens of ‘N' groups of ‘n' size each, comparator, slip gauge
SPECIFICATIONS:
Mechanical Comparator – Mitutoyo -1 div = 1μm
DESCRIPTION:
In mass production, it is not possible to achieve absolute accuracy. Therefore, the degree
of variability is controlled so that parts lie within the prescribed tolerances. Whenever the
variability in any article is due to change factors, the pattern of variability follows the law of
probability. Generally, the distribution of dimensions with inherent sources of variation follows a
formal distribution curve.

Quality control techniques fall broadly into two categories known as the method of
attributes and method of variables. In the method of attributes, an effort is made to
determine whether the given parts are satisfactory or whether it lies within the specified
range or not. In the method of variables, the size of the specimen is measured and an
attempt is made to analyze and control the results of a process.

The processing capability of a machine or manufacturing process can be defined as the

minimum tolerance to which the machine can be expected to work and produce no
defective under the specified conditions. Such conditions lead to improved equipment
maintenance, improved operator training, and reduced costs.
PROCEDURE:
1. The machined parts are divided into ten subgroups of five each i.e., the sample size, n = 5, and
the number of subgroups N = 10.
2. The desired dimension is set on the comparator by using appropriate slip gauges, and the
desired dimensions of the given components are measured and properly recorded.
3. x̅ and R for the N groups are calculated. Where X is the average of x̅ values of the subset
and R = (X -X)

4. Calculate R, UCLR, and LCLR

𝑅̅= Σ R/ 10, and LCLR = D4R and LCLR = D3R

where D3 and D4 are constants for a given n, the values being taken from IS-397 Part 1

5. Range chart (R-chart) is drawn now.

 a) If all the plotted values falls within the control limits, then the intial data is said
to be homogeneous, and the R is now termed RH.
b) If any points fall outside the control limit, then eliminate that point from
the list, DE calculates R, URLR and LCLR and again draws R-chart.

Then go to step a) or b).

6. Then the grand mean X is calculated considering only the homogeneous data.
7. The Control limits for X-Chart is calculated as follows:
Central line = X

UCLX = X+A2RH

LCLX = X-A2RH, A2 is a constant for a given ‘n’

FIGURE: X-CHART

The procedure mentioned in steps 5 (i and ii) are followed for

9. U = Upper Specification Limit

L = Lower Specification Limit
S = Std. deviation of the process = RH/d2
6s = Process Capability
(U-L) = Given tolerance
i. If 6s (U-L), the process capability is low. There will be a lot of rejects.
UCL = XH+ 3, LCL= XH-3, are the limits for the whole process. Then by using the
normal distribution concept the percentage rejects are calculated.
ii. If 6s < (U-L), the process capability Is high, i.e., the given process is capable of meeting
given specifications.
Tabular column:
Subgroup Comparator Reading Actual reading Average Range
No x̅ R
1 div = 1 1μm mm mm mm
1 2 3 4 1 2 3 4
1

RESULT:
 ‘EX. NO.: 7 INSPECTION ON CMM DATE:

AIM:
To Inspect the produced component on VMC by CMM

APPARATUS:
• Coordinate measuring machine
• Workpiece obtained by CNC.
• Probe-Renishaw
DESCRIPTION:
A Coordinate measuring machine (CMM) is a 3D device for measuring the physical
geometrical characteristics of an object. This machine may be manually controlled by an
operator, or it may be computer controlled. Measurements are defined by a probe attached to the
third moving axis of this machine, X, Y and Z. A coordinate measuring machine is also a device
used in manufacturing and assembly processes to test a part or assembly against the design
intent. By precisely recording the X, Y and Z coordinates of the target, points are generated
which can then be analyzed via regression which can then be analyzed via regression algorithms
for the construction of features. These points are collected by using a probe that is positioned
manually by an operator or automatically via Direct Computer Control (DCC). DCC CMMs can
be programmed to repeatedly measure identical parts, thus a CMM is a specialized form of
industrial robot.

PROCEDURE:
7) Calibration of machine is done using a sphere ball attached to the granite table. Take at
least 8 points on sphere.
8) Fix the object whose dimension needs to be measured using the jigs and fixtures.
9) Using joysticks, move the probe whose tip is made of ruby slowly and carefully to the
surface whose measurements must be taken.
10) For measurements of a line, the probe is touched at 2 Places (starting and ending point).
11) For measuring circular profile, probe is touched at 3 Points, for cylinder it is touched at 8
points.
12) Same profiles are again measured with vernier calipers (length of line, circle diameter,
cylinder diameter) to compare the two readings.
DIAGRAM:

SAMPLE SPECIMEN:
TABULATION:

S.No. Feature Required Obtained dimensions Tolerance

dimension
1 Straightness L1= L2= L3= L4=
2 Circularity R1= R2= R3= R4=
3 Concentricity R1= R2= R3= R4=
R1= R2= R3= R4=
4 Parallelism S1= S2= S3= S4=
S1= S2= S3= S4=
5 Perpendicularity S1= S2= S3= S4=
S1= S2= S3= S4=
6 Angularity S1= S2= S3= S4=

RESULT: