SASI Final Metrology & Instumentation EXPERIMENTS

Metrology and Instrumentation Lab
Department of Mechanical Engineering
Exp.No.1
Date:
MEASUREMENT OF LENGTH, HEIGHT AND DIAMETER BY VERNIER

CALLIPERS, VERNIER HEIGHT GAUGE AND MICROMETER
AIM
To measure the length, height, and diameter of a given work piece by using Vernier callipers,
Micrometer and Vernier height gauge respectively and to find error in those instruments by using
slip gauges (calibration).
APPARATUS
Vernier callipers, Micrometer, Vernier height gauge, surface plate, slip gauges.
SPECIFICATIONS
Vernier calipers: Range: 0 - 200mm; Least Count: 0.02mm
Micrometer : 0 25mm; Least Count: 0.01mm
Vernier height gauge : Least count=0.02 mm
THEORY
Vernier callipers
The principle of vernier callipers is based on the difference between two divisions
which are nearly equal for obtaining small difference. It enables to enhance the accuracy of
measurement. The vernier calipers (Fig. 1.1) consist of two scales. One is fixed and the other is
movable. The fixed scale, called main scale is calibrated on L-shaped frame and carries a fixed jaw.
The movable scale, called vernier scale slides over the main scale and carries a movable jaw.
The movable jaw as well as the fixed jaw carries measuring tip. When the two jaws are closed
the zero of the vernier scale coincides with the zero of the main scale. For precise setting of the
movable jaw an adjustment screw is provided. Also, an arrangement is provided to lock the sliding
scale on the fixed main scale
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Fig. 1.1 Vernier calipers
Vernier height gauge

This is also a sort of vernier calliper equipped with special base block and other attachments.
The vernier height guage (Fig. 1.2) consists of:
1. A finely ground and lapped base, which is massive and robust in construction to ensure
rigidity and stability.
2. A vertical graduated beam or column supported on the massive base.
3. Sliding vernier head carrying the vernier scale and a clamping screw.
4. An auxiliary head which is also attached to the beam above the sliding vernier head. It has
fine adjusting and clamping screw.
5. A measuring jaw or scriber attached to the front of the sliding vernier.
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Fig. 1.2 Vernier height guage
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Micrometer
The micrometer screw gauge essentially consists of an accurate screw having about 10 or 20
threads and revolves in a fixed nut. The end of the screw forms one measuring tip and other
measuring tip is constituted with a stationary anvil in the base of the frame. The screw is threaded
for certain length and is plain afterwards. The plain portion is called sleeve and its end is measuring
surface. The spindle is advanced or retracted by turning a thimble connected to the spindle. The
spindles slide fits over the barrel and barrel is a fixed part attached with the frame. The barrel is
graduated in units of0.05cm i.e., 20 divisions/cm, which is the lead of the screw. For one complete
revolution, the thimble travels 25 divisions on the spindle. Thus it subdivides 2 each revolution of
the screw in to 25 equal parts i.e., each division corresponds to 0.002cm. A lock nut is provided for
locking a dimension by preventing the motion of spindle. Ratchet screw is provided at the end of
the thimble cap to maintain sufficient and uniform measuring pressure so that standard conditions
of measurement are attained. Ratchet stop consists of an overriding clutch held by a weak spring.
When the spindle is brought into contact with the work at the correct measuring pressure, the clutch
starts slipping and no further movement of spindle takes place.
Fig. 1.3 Micrometer
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OBSERVATIONS
Vernier calipers
Least count=0.02 mm
Table 1.1 Determination of error of vernier calliper
S.No.
Slip gauge
Reading
(mm)
Main
Scale
Reading
MSR (mm)
Vernier
Scale
Reading
VSR (mm)
Total reading
MSR+(VSRxLC)
Error
1
2
3
4
5
6
7
8
9
10
Table 1.2 Measurement of length using vernier calipers

S.No. MSR
Total reading
VSR
MSR+(VSRxLC)
Micrometer
Least count=0.01mm
Table 1.3 Determination of error of micrometer
S.No.
Slip gauges
(mm)
Micro meter reading

MSR
VSR
Total reading
Error
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Table1.4 Measurement of diameter using vernier callipers

S.No.
MSR(mm)
VSR
Total reading
MSR+(VSRxLC)

Least count=0.02 mm
Table1.5 Determination of error of vernier height guage
S.No.
S.No.
Slip gauges
(mm)

VSR
Total reading
MSR
Error
Table1.6 Measurement of height using vernier height gauge

Vernier height gauge reading
Slip gauges
(mm)
MSR
VSR
Total reading (mm)
PROCEDURE
1. In the measurement of length, a work piece is kept first in the vernier caliper and then,
movable jaw is moved so that the fixed jaw and movable jaw hold the work piece.
2. Then tighten the screw for a perfect fit between the jaws. Then note the readings on main scale
and on vernier scale so that length of work piece is obtained. Now the slip gauges are
arranged to obtain the same length and then these slip gauges are measured with vernier
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callipers.
3. Similarly in the height measurement, the height of a work piece is also measured with
vernier height gauge and the slip gauges are arranged to the obtained height.
4. Now these slip gauges are measured by height gauge .If there is any error then it is recorded.
5. Similarly in the case of diameter measurement, the diameter of a work piece is first
measured using a micrometer.
6. The slip gauges are arranged to the same value of diameter and are measured by
micrometer. If there is any error then it is recorded.
PRECAUTIONS
1. The work piece should not be clamped in the caliper jaws and waved in air.
2. No play should be there between sliding jaw and scale, otherwise the accuracy will be lost.
3. Vernier calipers must always be held at short leg of main scale, and jaws never be pulled.
GRAPHS
Slip gauge reading Vs. Error , by taking these values on X and Y axis respectively for vernier
callipers, micro meter and vernier height gauge should be drawn.
RESULT
By using vernier callipers, micrometer and vernier height gauge, measured values are
The length of job..
The height of job..
The diameter of job..
VIVA QUESTIONS
1. A positive allowance will always result in a _____ fit.
2. How slip gauges are wrung?
3. What are the possible errors in vernier instruments?
4. _____ is equal to the differences of the two limits of size of the part.
5. What is the process for making slip gauges?
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Exp.No.2
Date:
MEASUREMENT OF BORES USING DIAL BORE INDICATOR

AIM
To find the internal diameter of hole sing using dial bore indicator.
APPARATUS
Work piece, vernier caliper and dial gauge indicator set with anvil.
SPECIFICATIONS
Measuring Diameter :
250-450
Measuring_Depth mm:
400
THEORY
Dial gauge indicators are the instruments designed for checking bore diameter by
comparative method. The instruments principle of operation is shown in figure. The instrument
basically consists of a hallow tube into which a lever pivoted about one end of the lever is linked
to the movable contact of the instrument i.e. the instrument has three contacts equally spaced
along the circumference of the head. This instrument can check in the orderof11-18cm in
diameter. The range of setting is about 0.06to 0.22cmwith scale division valueof 0.002 mm
and 0.01 mm respectively.
PROCEDURE
1. First of all take the work piece where internal diameter is to be calculated.
2. Now take the vernier calipers and place the knife edges inside the work piece and note
the reading for internal diameter of work piece.
3. See the reading that is obtained from micrometer. If the reading is say 34.8mm, then
take the anvil of size 34mm and washers of size 0.5mm and fit it to the body of the
gauge.
4. Now set the dial gauge indicator for zero position and then make readings at any
position inside the work piece.
5. This should be done carefully as the anvil movable screw will wear in rough handling
of the gauge.
6. The above step is repeated for different positions inside the work piece. Now set
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micrometer to 34.8mm and keep this micrometer in dial gauge indicator and note down
the reading.
7. Now calculate the internal diameter by using given formulae.
Actual size = (anvil length + washer length) (R1R2)
where,
R1= reading obtained from dial gauge when the same dial gauge is kept in
micrometer
R2= reading obtained from the work piece
OBSERVATIONS
Table 2.1 Measurement of bore using vernier calipers
S.No.
Vernier callipers reading

Main scale reading (MSR)
Vernier scale reading (VC)
Total reading
MSR+(VCxLC)
1
2
3
4
5
6
Least count of vernier callipers =0.02mm

Average reading=.............mm
Table 2.2 Accurate measurements using dial bore indicator
Micrometer
S.No.
reading
mm
(d)
Bore gauge
reading
(R1) mm
Work piece
reading
(R2) mm
Final reading
d+(R1 R2) x0.01mm
1
2
3
4
5
6
7
8
9
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10
Accurate diameter of hole using dial bore indicator ismm
Fig. 2.1 Dial bore Indicator
RESULT
Internal diameter of the work piece by using vernier caliper is
Diameter obtained by using dial gauge indicator is
mm
mm
VIVA QUESTIONS
1. What is the working principle of dial bore indicator?
2. Auto collimator is used for.
3. What are the practical applications of a dial test indicator?
4. List out various materials used for making surface plates.
5. What are the different types of dial indicators?
Page 10
Exp.No.3
Date:
MEASUREMENT OF THICKNESS OF GEAR TEETH BY GEAR TOOTH

VERINIER CALLIPER
AIM
To measure the thickness of gear teeth by using gear tooth veriner calliper.
APPARATUS
Gear toothed venire caliper, Spur gear
SPECIFICATION
Range- 1-26mm; Least Count-0.02mm
THEORY
The tooth thickness is defined as the length of an arc, and it is not possible to measure it
directly. it is generally measured at pitch circle and is, therefore, the pitch line thickness of the tooth.
In most of the cases, it is sufficient to measure the chordial thickness of the tooth, i.e. the chord
joining intersection of the tooth profile with the pitch circle.
In this method, gear tooth vernier caliper is used to measure the thickness of gear tooth at the
pitch line. The gear tooth vernier calliper consists of 2 perpendicular vernier arms with vernier scale
on each arm. One of the arms is used to measure the thickness of gear teeth and other for measuring
depth. The calliper is so set that it slides on the top of tooth of gear under test and the lower ends of
the calliper jaws touch the sides of the tooth at the pitch line. The reading on the horizontal vernier
scale gives the value of chordial thickness (W) and he reading on vertical vernier scale gives the
value of chordial addendum. These measured values are then compared with the calculated values.
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Fig. 3.1 Vernier gear tooth calliper
Fig. 3.2 Chordal thickness method
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PROCEDURE
1. First calculate the choral thickness and choral addendum theoretically by given in a mathematical
relation.
2. Fix choral addendum on the vertical scale of the gear tooth vernier calliper. Then calculate the
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thickness the tooth by horizontal scale of gear tooth vernier caliper.

3. Compare the experimental and theoretical values. Note down error, if any.
4. Repeat the above procedure for different teeth.
Table 3.1 Determination of actual thickness of the gear tooth
Theoretical
S.No. Tooth
thickness
Actual tooth thickness

MSR
VSR
Total Reading
[MSR+
(VSRxLC)]
Error
PRECAUTIONS
1. Accuracy in measurement is limited by the least count of the instrument.
2. Need different settings for variation in given pitch.
3. As the user is concentrated on both the jaws, the calliper has to be calibrated at regular intervals.
RESULT
Actual chordal tooth thickness measured by using gear tooth vernier calliper is .
VIVA QUESTIONS
1. What are the different nomenclatures of gear?
2. Name the instruments for checking gears.
3. What is meant by addendum and dedendum?
4. Name the various types of errors in gears.
5. Gear tooth caliper is used to find the chordal thickness of the following type of gear
tooth.
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Exp.No.4
Date:
TOOL MAKERS MICROSCOPE

AIM
To study the gear tooth nomenclature, rake angle.

APPARATUS
Tool makers microscope, gear wheel cutting tool.
SPECIFICATIONS
Measuring range100 x 50mm; Light Source Tungsten bulb (24V, 2W); Power
Supply100 / 110 / 120 / 220 / 240V AC, 50 / 60Hz; Max. Work piece height107mm; Functions
with green filter, light intensity adjustable
DESCRIPTION
Tool makers microscope consists of optical head which can be adjusted vertically
along the ways of a supporting column. The optical head can be clamped in any position by a screw.
The working table is mounted on a heavy hollow base. The table has a compound slide by means of
which the part to be measured can have longitudinal and lateral movements. These movements are
controlled by accurate micrometer screws having thimble and vernier. At the back of the base a light
source is arranged which provides a horizontal beam of light which is reflected from a mirror but
goes upwards the table. As shadow image of the outline of contour of the part passes through the
objective of optical head and is projected by a system of three prisms. Cross lines are engraved on
the ground glass screen which can be rotated through 360and the measurements are made by
these cross lines.
PROCEDURE
The illuminating lamps are switched on the required intensity. The following length of
the micro scope is adjusted to get a clear view of the tool under the observation. Through the
micrometres adjustment the depth and thickness of gear are calculated by keeping the line of the
eyepiece parallel to the edge of the shank. The angle of cutting tool is measured through the
adjustment of inclined lines with the edges of the tool bit and subsequent measurement through the
circular scales provided, either at the eyepieces oratthe work table. Thus the measurements are
completed using the toolmakers microscope.
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PRECAUTIONS
1. The microscope should be placed in its box after the experiment has been completed.
2. Readings should be taken without parallax error.
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OBSERVATIONS
Table 4.1 Determination of pitch of screw
S.No.
Description
Initial reading R1
Final reading R2
Actual reading
R1~R2
2
Table 4.2 Determination of Rake angle
S.No.
Description clearance
angle of Tool bit
Angle in degrees
Initial
Final
Actual angle
Fig. 4.1 Toolmakers Microscope
RESULT
Hence the gear tooth nomenclature, rake angle of cutting tool and pitch of screw are
measured by using tool makers microscope.
VIVAQUESTIONS
1. Optical gauge works on the principle of
2. What are the different optical measuring instruments?
3. A feeler gauge is used to check.
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4. What are the different types of gears?

5. The element that makes a microscope a measuring instrument is
Exp.No.5
Date:
SURFACE ROUGHNESS MEASUREMENT BY TALYSURF

AIM
To measure the surface roughness using talysurf
APPARATUS
Taly surf, work piece, surface plate
SPECIFICATIONS
Straightness error -0.40um / 50mm ; 50mm horizontal traverse
THEORY
Talysurf is an electronic instrument working on carrier modulating principle. This
instrument gives the information rapidly and accurately. The measuring head of this instrument
consists of a diamond stylus of about 0.002mm tip radius and skid as shoe which is drawn
across the surface by means of motorized driving unit, which provides three speeds giving 20 x
20 horizontal magnifications and a speed suitable for average reading. There are 2 resistances
from an oscillator. As the armature is pivoted about central leg, any movement of the original
AC current flowing the coils is modulated the output of the bridge thus consists of modulation
this is further demodulated so that the current flow is directly proportional to the vertical
displacement of the stylus only.
The demodulated output is caused to operate aspen recorder to produce a permanent record and
the meter to give a numerical a casement directly. In recorder of this instrument the making
medium is a electrical discharge, there is a specially reacted paper which blanks at the point of
the stylus. So this has no distortion due to drag and stylus. So this has the records strictly
rectilinear one.
PROCEDURE
The power supply to the Talysurf measuring instrument is given and it is checked with the
reference sample for current roughness
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1. The instrument is placed on the specimen properly and then the measurement is
stored by pressing start/stop button. Note down Ra & Rzvalues using parameter
button.
2. Repeat the experiment on specimen by changing the distribution.
3. Repeat the above process for the remaining specimen and tabulate the
readings.
S.No.
Table 5.1 Determination of surface roughness

Measurement roughness value mm Average Average
Ra
Rz
Sample, direction Ra Rz
Grade
Fig. 5.1 Circuit of Talysurf
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RESULT
Hence the surface roughness is measured by using TalySurf.
VIVA QUESTIONS
1. Roughness is otherwise known as..
2. What is the full form of R.M.S?
3. Surface roughness on a drawing is represented by..
4. Difference between roughness and waviness.
5. The value of one micron in mm
Page 20
Exp.No.6
Date:
ANGLE AND TAPER MEASUREMENT

USING BEVEL PROTRACTOR AND SINE BAR
AIM
To measure the taper angle of the given work piece using bevel protractor and sine
bar.
APPARATUS
Sine bar, slip gauges, bevel protractor, magnetism and dial indicator.
SPECIFICATIONS
With magnifying glass and acute angle attachment; Two blades 150mm and 300mm;
Least count 5
THEORY
Bevel Protractor:
It is the simplest instrument for measuring the angle between the two faces of a
component. It has the following ports.
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 bevel protractor is placed on its back on a surface plate, there shall be no
perceptible rock .It can be moved along the turret throughout its length and can also be reversed, it
is about 150 or 300 mm long13 mm wide ad 2 mm thick and ends bevelled at an angle of 1D to
60 with an accuracy of 5 of arc. Its working edge should be straight top to 0.02mm and
parallel up to 0.03mm over the entire length of 300mm.
Scale on the body
The body contains a men scale engraved on it and which can be locked in any position, an
adjustable blade which is attached to a circular plate containing vernier scale. The vernier scale
has 24 divisions coinciding with 23 main scale divisions. Thus the least count of the instrument is
5. The main scale is graduated either as a full circle marked 0-90-090 with a vernier.
Slip gauges
These are ultimate measuring tool for checking dimensions in mechanical engineering.
These are rectangular blocks of hardened steel with two parallel and opposing surfaces. The
distance between the surfaces determines the nominal size. The echo of a slip gauge is 9 x 30mm
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for nominal size up to10 mm, sine bar.-sine bar used in conjunction with slip gauges constitute a
very good device for acts of angles. Two cylinders of equal diameter are attached at the each other
and at equal distance from the upper surface of the sine bar. The distance between the axis of
cylinder is 200 mm. Sine bars are made from high carbon, high chromium, and corrosion resistant
steel.
PROCEDURE
Procedure for using bevel protractor to measure angles

The given component is so adjusted it between the base plate and the adjustable blade
such that no gap should exists between them. After the adjustment ,the scale is locked in that
position in order to avoid errors in measuring the angle. Read and note the angle included in
between the faces of the component.
Procedure for using sine bar to measure and check taper
The length in between two markings on the face of the given component is measured.
Using the angle obtained in measurement by bevel protractor and distance between the sine bar
rollers (200 mm), the height of slip gauges is calculated. Now sine bar is placed on the surface
Plate and the component are placed on the side bar such that the midpoint of the component
should coincide with the mid position of sine bar. Slip gauges are placed below the roller to raise
the smallest height of the component. A magnetism and with dial indicator is used to check the
flatness of the component is the surface of the component and the surface plates are mutually
parallel to each other. If any deviations are observed in the dial indicator, then there is an error in
angle. Otherwise the measured angle is accurately and it is the angle of tapered face of the given
component.
PRECAUTIONS
1. To avoid the error in measuring angle, the adjustable blade is to be locked at required
positions.
2. The parallel error is
to be avoided in reading and noting valued through bevel
protractor.
3. The given component should be placed at the middle of the sine bar to avoid errors in taper
measurement.
Page 22
OBSERVATIONS
Measurement of angle using bevel protractor: Least count=
Table 6.1 Readings from bevel protractor
Angle of bevel edge
S.No.
MSD
Total reading
[MSD+(VSDx LC]
VSD
angle of bevel edge = Measurement of angle using side bar:

Height of slip gauges for an approximate angle of h=sin L Then
deflection in dial indicator for a length of 200 mm
Sin1=h/L
Fig. 6.1 Sine bar
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Fig. 6.2 Bevel protractor
RESULT
The angle of work piece by using bevel protractor and sine bar is..
VIVA QUESTIONS
1. How length of a sine bar is measured?
2. What is the material used for making sine bar?
3. Difference between normal slip gauge and angle slip gauges.
4. Sine bar is used in connection with..
5. What is the reason for the holes in the sine bar?
Page 24
Exp.No.7
Date:
USE OF SPIRIT LEVEL IN FINDING THE STRAIGHTNESS OF A BED

AND FLATNESS OF A SURFACE
Date:
AIM
To determine the flatness of surface plate by using spirit level.
APPARATUS REQUIRED
Surface plate, Spirit level
THEORY
The spirit of level consists of a sealed glass tube mounted on a base. The inside surface of
the tube is ground to a convex barrel shape having large radius. The precision of the level
depends on the accuracy of this radius of the tube. A scale is engraved on the top of the glass
tube. The tube is nearly filled with either there or alcohol, except a small air or vapour in the
form of a bubble.
The bubble always tries to remain at the highest point of the tube. If the base of the spirit
level is horizontal, the centre point is the highest point of the tube. So, that when the level is
placed on a horizontal surface, the bubble rests at the centre of the scale. If the base of the level
is fitted through a small angle, the bubble will more relative to the tube a distance along its radius
corresponding to the angle.
The figure shows two positions of the base of the level(OA1and OA2) and corresponding
positions of the bubble (Bl,B2). When the base OA1is horizontal, the bubble occupies position
B1.Let be the small angle through which the base is fitted. The bubble now occupies the
position B2. Let h be the difference in heights between the ends of the base.
Then1Rand h=L
Keep symbols in itallic
Therefore =
Where R =radiusof curvature of the tube L = length ofbase
Finally h=L/R
Page 25
PROCEDURE
1. Place the spirit level on the surface plate for which we have to find out the flatness
2. Find the base length of the spirit level
3. Note the radius of curvature of the spirit level tube
4. Find the twill it in the bubble.
5. Finally find out the difference in heights between the ends of the base.
Table 7.1 Determination of surface flatness
S.No.
Distance travelled
by the bubble
Difference in height
between ends
Angle
PRECAUTIONS
1. Clean the surface plate and ensure there are no dust particles.
2. Take the bubble reading without any parallax error.
RESULT: Flatness of the surface plate can be found by using spirit level.
VIVA QUESTIONS
1. Define flatness.
2. What are the various methods of testing of surface plate?
3. For what purpose spirit level is used?
4. What is meant by auto collimator?
5. What is an angle plate?
Page 26
Exp.No.8
Date:
MACHINE TOOL ALIGNMENTTEST FOR LATHE

AIM: To perform alignment test on lathe machines
Test for level of installation
(a)
In a longitudinal
(b) In transverse direction
APPARATUS
Measuring instruments, Spirit level, gauge block to suit the guide ways of the lathe bed.
PROCEDURE
The gauge block with the spirit level is placed on the bed ways on the front position,
back position and in the cross wise direction. The position of the bubble in the spirit level is
checked and the readings are taken.
Permissible error:
Front guide ways- 0.02 mm/metre convex only. Rear guide ways - 0.01to 0.02 convexity.
Bed level in cross-wise direction- 0.02/ meters. Straightness of slide ways(for machines more
than 3 mm turning length only, measurement taken by measuring tight wire and microscope or
long straightedge). Tailstock guide ways parallel with movement of carriage 0.02 mm/m. No twist
is permitted.
Fig.8.1 Guide ways of lathe

The error in level may be corrected by setting wedges suitable points under the support
feel orpads of the machine.
Measuring instruments: Cylindrical test mandrel (600mm long), dial indicator.
Straightness of saddle in horizontal plane: Procedure
The mandrel is held between centres. The dial indicator is mounted on the saddle. The
spindle of the dial indicator is allowed to touch the mandrel. The saddle is then moved
longitudinally along the length of the mandrel. Readings are taken at different places. Permissible
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error is 0.02 mm over length of mandrel
Page 28
Fig. 8.2 Mandrel held between centers

Alignment of both the centres in the vertical plane:
Measuring instruments: Cylindrical mandrel 600mm long, dial gauge.
Procedure
The test mandrel is held between centres. The dial indicator is mounted on the saddle in
vertical plane as shown in figure. Then the saddle along with the dial gauge is travelled
longitudinally along the bed ways, over the entire length of the mandrel and the readings are taken
at different places.
Permissible error: 0.02 mm over 600 mm length of mandrel (Tail stock centre is to lie
higher only).
Fig. 8.3 Alignment of both the centres in the vertical plane

True running of taper socket in main spindle:
Instruments required: Test mandrel with taper shank and 300mm long cylindrical measuring
part, dial gauge.
Procedure
The test mandrel is held with its taper shank in a head stock spindle socket. The dial gauge is
mounted on the saddle. The dial gauge spindle is made to touch with the mandrel. The saddle is
then travelled longitudinally along the bed ways and readings are taken at the points A and B as
shown in figure.
Permissible error: Position A 0.01mm, position B 0.02 mm.
Page 29
Fig. 8.4 True running of taper socket in main spindle

Parallelism of main spindle to movement:
(a) In a vertical plane(b) In a horizontal plane Measuring instruments: Test mandrel with taper
shank and 300mm long cylindrical measuring part, dial gauge.
Procedure: The dial gauge is mounted on the saddle. The dial gauge spindle is made to touch the
mandrel and the saddle is moved to and fro. It is Checked in Vertical as well as in horizontal plane
Fig. 8.5 Parallelism of main spindle to movement

Movement of upper slide parallel with main spindle in vertical plane:
Measuring instruments: Test mandrel with taper shank and 300mm long cylindrical measuring part,
dial gauge.
Procedure
The test mandrel is fitted into the spindle and a dial gauge clamped to the upper slide. The slide
is transverse along with the dial gauge plunger on the top of the stationary mandrel. Permissible error:
0.02 mm over the total movement of the slide.
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Fig. 8.6 Movement of upper slide parallel with main spindle in vertical
plane
True running of locating cylinder of main spindle:
Measuring instrument: Dial gauge.
Procedure
The dial gauge is mounted on the bed, touching at a point on
main spindle. The main spindle
is rotated by hand and readings of dial gauge are taken.
Fig. 8.7 True running of locating cylinder of main spindle

Permissible error: 0.01mm.
True running of head stock centre: Measuring instruments: Dial gauge.
Procedure
The live centre is held in the tail stock spindle
and
it is
rotated. Its trueness is
checked by means of a dial gauge.

Permissible error: 0.01mm.
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Fig. 8.8 True running of headstock centre

Parallelism of tailstock sleeve to saddle movement:
Measuring instruments: Dial indicator
Procedure
Tail stock sleeve is fed towards. The dial gauge is mounted on the saddle. Its spindle
is touched to the sleeve at one end and the saddle is moved to and omits checked in
H.P. and V.P. also.
Permissible error:
(a) ) 0.01/100 mm (Tail stock sleeve inclined towards tool pressure only).
(b) 0.0 1/100 mm (Tail stock sleeve rising towards free end only).
Fig. 8.9 Parallelism of tail stock sleeve to saddle movement

Parallelism of tail stock sleeve taper socket to saddle movement:
(a) In V. P.
(b) In H.P.
(c) Measuring instruments:-The mandrel with taper shank and a cylindrical measuring
part of 300 mm length, dial gauge.
Procedure
Test mandrel is held with its taper shank in tail-stock sleeve taper socket. The dial Gauge is
mounted on spindle. The dial gauge spindle is made to touch with the mandrel. The
saddle is then transverse longitudinally along the bed way and readings are taken.
Permissible error:Page 32
(a) 0.03/300 mm (mandrel rising towards free end only)

(b) 0.03/300 mm (Mandrel inclined towards tool pressure only).
Fig. 8.10 Parallelism of tail stock sleeve taper socket to saddle movement
RESULT
Alignment test on lathe machines is performed.
VIVA QUESTIONS
1.
What are the alignment tests in lathe?

2. List the various geometrical checks made on machine tools?
3. Name the various instruments required for performing the alignment tests on
machine tools.
4. Define spindle centre rubout.
5. Differences between geometrical and practical tests on the machine tools?
Page 33
Exp.No.9
Date:
MACHINE TOOL ALIGNMENT TEST ON MILLING

MACHINE
AIM
To perform alignment test on milling machine
MEASURING INSTRUMENTS
Spirit level
PROCEDURE
A spirit level is placed directly on the table at points about 25 to 30 cm a part, at A, B, C for
longitudinal tests and D, E and F for the transverse test. The Metrology Lab Department of mechanical
Engineering
Readings are noted. Permissible error:
Direction A-B-C, 0.04 mm Direction D-E-F, 0.04 mm
Fig. 9.1 Parallelism of work table surface
PARALLELISM OF THE WORK TABLE SURFACE TO THE MAIN SPINDLE

Measuring instruments: Dial indicator, test mandrel 300mm long, spirit level.
Procedure
The table is adjusted in the horizontal plane by spirit level and is then set in its mean position
longitudinally. The mandrel is fixed in the spindle taper. The dial gauge is set on the machine
table, and the feeder adjusted to touch the lower surface of the mandrel. The dial gauge readings at
and (B) are observed, the stand of the dial gauge being moved while the machine table remains
Stationary.
Page 34
Permissible error: 0.02/300 mm.
Fig. 9.2 Parellelism of the clamping table
Instruments: Dial gauge, straight edge.

Procedure
A dial gauge is fixed to the spindle. The dial gauge spindle is adjusted to touch the table
surface. The table is then moved in longitudinal direction and readings are noted. If the table
surface is uneven it is necessary to place a straight edge on its surface and the dial gauge feeder is
made to rest on the top surface of the straight edge.
Permissible error: 0.02 up to 500 mm length of transverse, 0.03 up to 1000 mm and
0.04 above 1000 mm length of transverse.
Page 35
Fig. 9.3 Parallelism of the cross table
PARALLELISM OF THE CROSS (TRANSVERSE) MOVEMENT OF THE WORK

TABLE TO THE MAIN SPINDLE
(a) In vertical plane (b)In horizontal plane
Instruments: Dial gauge, test mandrel with taper shank.
Procedure
The work table is set in its mean position. The mandrel is held in the spindle. A dial gauge fixed
to the table is adjusted so that its spindle touches the surface of the mandrel. The table is
moved cross-wise and the error is measured in the vertical plane and also in the horizontal
plane. Permissible error: 0.02 for the overall transverse movement of the work table.
Fig. 9.4 Internal taper of the spindle

Page 36
TRUE RUNNING OF INTERNAL TAPER OF THE SPINDLE

Instruments- 300 mm long mandrel and dial gauge.
Procedure
The test mandrel with its taper shank is held in the main spindle. Dial gauge is kept scanning
the periphery of the mandrel. Spindle is rotated and dial gauge readings are noted at different points
say A and B as shown.
Permissible error: Position A: 0.01mm, Position B: 0.02mm.
Fig. 9.5 Squareness of the slot
SQUARENESS ON THE CENTRE T-SLOT OF WORK TABLE WITH MAIN SPINDLE

Instruments: Dial gauge, special bracket.
Procedure:
To check the perpendicularity of the locating slot with the axis of the main spindle. The table
should be arranged in the middle position of its longitudinal movement, and a bracket with a
ten on at least 150 mm long inserted in the locating lot as shown in figure. A dial gauge should be
fixed in the taper, the feeder being adjusted to touch the vertical face of the bracket. Observe the
reading on the dial gauge when the bracket is near one end of the table, the swing over the dial
gauge and move the bracket so that the corresponding readings can be taken near the other end of
the table.
Permissible error: 0.025mm in 300 mm.
Page 37
Fig. 9.6 Parallelism

of the T-Slot
PARALLELISM OF THE TLONGITUDINAL MOVEMENT

Instruments: Dial gauge, special
Procedure
The general parallelism of
SLOT WITH THE

OF THE TABLE
bracket.
longitudinal movement of the table
is checked by using150
mm long broken having a ten on
which enters the slot, the
the
T-slot
with
the
dial gauge is fixed to the spindle taper and adjusted so that its feeder touches the upper surface of the
bracket. The table is then moved longitudinally while the bracket is held stationary by the hand of
the operator and dial gauge deviations from parallelism are note down.
Permissible error: 0.0125mm in 300 mm.
Fig. 9.7 Parallelism between the main spindle and guiding surface
PARALLELISM BETWEEN THE MAIN SPINDLE AND GUIDING SURFACE OF THE
OVERHANGING ARM
Instruments: Dial gauge, mandrel.
Procedure
The overhanging arm is clamped in its extreme extended position. The dial gauge is fixed to
the arbour support. The feeder of the dial gauge is adjusted to touch the top or ride of the test
Page 38
mandrel. The arboreal then is moved along the overhanging arm and the deviations from
parallelism observed on the dial gauge.
RESULT
Alignment test on milling machines is performed.
Page 39
VIVA QUESTIONS
1. What are the alignment tests in lathe?
2. List the various geometrical checks made on machine tools.
3. Name the various instruments required for performing the alignment tests on
machine tools.
4. Define spindle centre rub out.
5. Differences between geometrical and practical tests on the machine tools?
Page 40
Experiment No: 10
Date:..
CALIBRATION OF A PRESSURE GAUGE
Aim
To calibrate the pressure gauge
Apparatus
1. Pressure Cell having sensor, which has strain gauges, bonded on steel diaphragm for
measurement
2. Pressure trainer with LED display (indicator)
3. Accessories: foot pump, Bourdon pressure gauge with pressure chamber
Specifications
Range Pressure Cell : 0-5 kg / cm
Accuracy: 0.5 kg / cm
Theory
Transducer that measures force, torque or pressure usually contains an elastic member
that converts the quantity to be measured to a deflection or strain. A deflection sensor or,
alternatively, a set of strain gauges can be used to measure the quantity of interest (force, torque
or pressure) indirectly.
Pressure cells are devices that convert pressure into electric signal through measurement
of either displacement, strain or piezoelectric response. Diaphragm type pressure transducer with
strain gauge as sensor is used here for measurement of pressure.
This type of pressure transducers use diaphragm as the elastic element. Strain gauges are
bonded on the diaphragm and the pressure is applied to the specimen. The material gets
elongated or compressed due to the force applied. The strain induced by the specimen depends
on the material resulting in change in the resistance of the gauge. Since the strain gauges are
connected in the form of Wheat stone bridge, any change in the resistance will imbalance the
bridge. The imbalance in the bridge will intern gives out the output in mV proportional to the
change in the resistance of the strain gauge.
Connection Details
Power
Page 41
3-pin mains cable is provided with the instrument. Connect the 3-pin socket to the
instrument at the rear panel and to the AC mains (230 V).
Sensor
Connect one end of the cable attached with connector to the sensor and the other end to
the instrument. While connecting, match the colors of the wires and the connectors.
Procedure
1. Check connections made and switch ON the instrument by rocker switch at the front
panel. The display glows to indicate the instrument is ON.
2. Allow the instrument in ON position for initial warm-up
3. Adjust the potentiometer in the front panel till the display shows 000
4. Apply pressure on the sensor using the loading arrangement provided.
5. The instrument reads the pressure coming on to actual reading.
Fig. 10.1 Bourdon Tube Pressure Gauge

Page 42
Fig. 10.2 Typical Diaphragm Pressure Gage

Table 10.1 Values of pressure
S.No.
Actual pressure, (X)

kg/cm2
Indicator Reading, (Y)

kg/cm2
Error (Y-X)
% Error
1
2
3
4
5
6
7
8
9
10
Formula
Percentage error=
( Indicator reading Actual reading)

100
Actual reading
Graphs
Draw a graph between actual reading and indicated reading
Page 43
Calculations
Result
Page 44
Page 45
Experiment No: 11
Date:..
LINEAR DISPLACEMENT MEASURMENT
Aim
To measure the linear displacement using Linear Variable Differential Transformer
(LVDT) and evaluate the error of trainer
Apparatus
LVDT setup with micrometer, LVDT displacement trainer
Specifications
LVDT Range: 10mm
Micrometer Range: 0 - 25mm
Accuracy: 1mm
Theory
The LVDT consists of a single primary winding P and two secondary winding S1 and S2
wound on a cylindrical former. The secondary windings have equal number of turns and are
identically placed on either side of primary winding. The primary winding is connected to an
alternate current source. Movable soft iron core is made up of nickel iron for high permeability,
which is hydrogen annealed. The assembly is paced in stainless steel housing and the lids
provide electrostatic and electromagnetic shielding. When alternate current (AC) is supplied to
primary winding, the magnetic flux is generated by the coil. If the core movement disturbs flux
generated, the voltage will be induced in secondary coils.
The net output voltage is the
difference between two secondary voltages. The position of the core determines the flux linkage
with each winding. The voltage in the secondary winding towards which the core is displaced
increases. Simultaneously induced voltage decreases in the other secondary coil. Thus the result
will be a voltage rise in one secondary coil and a decrease in the other.
The output voltage of an LVDT is a linear function of core displacement with in a limited
range of motion.
Procedure
1. Connect the power supply cord at the rear panel to the mains.
Switch on the
instrument by pressing the toggle switch. The display glows indicating the instrument
is ON.
2. Allow the instrument in on position for 10 minutes for initial warm up.
Page 46
3. Rotate the core of micrometer knob till it reads 10.0 and adjust the Digital Process
Measurement (DPM) potentiometer till the display shows 10.0
4. Give the linear displacement to core through plunger by rotating the head scale of
micrometer.
5. Tabulate the reading by rotating (some readings in clock wise i.e., secondary coil-1
side, some reading in counter clockwise i.e., secondary coil-2 side) the head scale in
steps of 1 or 2 mm.
6. The displacement (actual) of micrometer is noted and the displacement of LVDT
core (theoretical) as measured in trainer is noted.
6. Evaluate the error, which is the difference between actual and measured values.
Fig. 11.1 LVDT Circuit Diagram
Page 47
S.No.
Table 11.1 Calibrated values of LVDT

Actual Reading, A
Indicated Reading
Error (A-B)
(Micrometer reading)
(LVDT reading) B
% Error
1
2
3
4
5
6
7
8
9
10
11
12
Calculations
Result
Page 48
Page 49
Experiment No: 12
Date:
FLOW MEASUREMENT
Aim
To measure the flow of water by using rotameter
Apparatus
Rotameter, measuring flask, water pump, timer
Specifications
Flow Range: 0.5-l liters per minute
Accuracy: 0.25lit
Theory
The rotameter essentially consists of a tapered glass tube and circular cross section
active element called bob or float inside it. The tube is provided with suitable inlet and outlet
connections. The float or bob material has a specific gravity higher than that of the fluid to be
measured. Spiral slots cut on a part of the float cause it to rotate slowly about the axis of the tube
and keep it centrally. This spinning also helps to prevent accumulation of any sediment on the
top side of the float.
The stability of the float or bob is ensured by equilibrium of downward
force, which is weight of float and upward forces which are bouncy and inlet fluid pressure. With
the increase in flow rate the float rises in the tube and there occurs an increase in annular area
between the float and the wall of the tube.
The discharge through rotameter, Q= Cd Vf A2 {2gVf (f -)/Af }1/2
--------Eq.(12.1)
Cd = Coefficient of discharge
Vf = Volume of the float
f = Density of the float material
= Density of the fluid
Af = cross sectional area of float
A= annular area between float and tube
Procedure
1.
Fill the collecting tank with water till the float valve of pump is completely
immersed in the water (approx. 20 l)
2. Clear dust particles if any from the water.

Page 50
3. Connect the pump card to 230V power supply. Switch on the instrument and the
timer will be switched ON.
4. Switch on the motor. Set the flow rate 01 lpm by using control knob provided on the
rotameter.
5. Now press the button on the timer. Then the countdowns start and stop the motor
exactly at 60 sec.
6. Note down the tank level and tabulate the readings.
7. Conduct the experiment for different flow rates and different times.
Fig. 12.1 Rotameter
Page 51
Table 12.1 Values of water level for different times

S.No.
Rotameter reading (lpm)
Actual Flow (lpm)
Error
% Error
1
2
3
4
5
6
7
8
9
10
Page 52
Actual discharge
V
Q=
T
d2
Volume V= 4 h
Where d= Internal diameter of the collecting jar
h= Level of water in the jar
Error = Rotameter reading - Actual Flow
Calculations
Result
Page 53
Page 54
Experiment No: 13
Date:
SPEED MEASUREMENT
Aim
To measure the speed by using magnetic pick up and photo reflective pick up and
calculate the error
Apparatus
Speed measurement trainer, speed measuring setup
Specifications
Sensor type: Photo reflective & Magnetic pickup
Range:
20 to 200 rpm
Accuracy:
10 RPM
Theory
Magnetic Pickup
A magnetic pickup consists of small permanent magnet with a wire coil wound round it.
This magnetic pick up is placed near a metallic toothed wheel, whose speed is to be measured as
shaft rotates. The teeth far in front of magnetic field expands when it is in in front of tooth space
and collapses when it is in front of teeth. There by a pulse of voltage is induced in the coil
because of field collapse. The frequency of the pulse depends upon the number of teeth on the
wheel and its speed of rotation. Since the number of the teeth is known, the speed of rotation can
be determined by measuring the pulse frequency. The pulse is amplified and squared and fed into
a counter of frequency measuring unit.
Speed (N) = Pulse per sec/Number of teeth
Photo-Electric Pick Up
This equipment consisting of an opaque disc mounted on rotating shaft. The disc has a
number of evenly spaced peripheral holes. A light source is placed on one side of the disc and a
light sensor on the other side but in line with the light source. When opaque portion of the disc is
between light source and light sensor no light falls on the sensor. Consequently, no output results.
But a pulse of voltage will be produced every time a hole appears between them. The frequency
of pulse generation is determined by the number of holes in the disc and its speed. Since number
of holes is fixed, the speed can be calculated.
Page 55
The pulse frequency of the pulse is amplified and squared and fed into a counter of
frequency measure unit.
Speed (N) = Pulse per sec/ Number of teeth
Procedure
1.
Switch on the instrument by pushing the toggle switch provided at the rear side of the
trainer. LED display glows to indicate the instrument is ON.
2. Allow the instrument for ten minutes in ON position for initial warm up.
3. Select the sensor (magnetic or photo-reflective pick-up) with the help of toggle switch
4. Switch on the electric regulator. The regulator regulates the speed of the motor shaft and
toothed wheel.
5. The display indicates exact rpm of motor shaft as well as toothed wheel.
6. Vary the speed of motor tabulate speed from both the sensors. Compare the two readings
Fig. 13.1 Toothed Rotar Tachometer
Page 56
Fig. 13.2 Photo Reflective Tachometer
Table 13.1 Speed values for both sensors

S.No
.
Actual
Reading
(Digital
Tachometer )
A
Speed of the Speed of the

Error
Motor (PhotoMotor
(rpm)
reflective) (Magnetic pick (A-B)
rpm B
up) rpm C
Error % Error
(rpm
for
)
Photo(A-C) reflectiv
e
% Error
for
Magneti
c pickup
1
2
3
4
5
6
7
8
9
10
11
12
Calculations
Page 57
Result
Page 58
Page 59
Experiment No: 14
Date: .
ANGULAR MEASUREMENT USING CAPACTIVE TRAINER

Aim
To measure angular displacement using a capacitive trainer
Apparatus
Variable capacitor, angular displacement trainer
Specifications
Displacement/ Angle: 0- 180
Accuracy:
1/2
Theory
A capacitor comprises two or more metal plate conductors separated by an insulator. As
voltage is applied across the plate equal and opposite electric charges are generated on the plate.
Capacitance is defined as the ratio of charge and applied voltage.
C= EoErA(N-1)/t Farads
----------------Eq.(14.1)
where A= Over lapping area between plates
t= Distance between plates
Eo= Permeability of free space
Er= Relative permeability of the medium present in between the plates
N= Number of capacitors
Procedure
1. Check the connections and the switch on the instrument by rocker switch.
2. Allow the instrument in ON position for 10 minutes for initial warm up.
3. Adjust the potentiometer in the front panel till the display reads 00
4. Give a small linear displacement to the plates in the capacitive transducer.
5. Take the actual linear displacement that can measure directly on the scale and linear
displacement is measured by the trainer.
6. Calculate the error, which is difference between actual to measured values.
Page 60
Fig. 14.1 Capacitance Transducer change by area

Table 14.1 Values of angle
S.No.
Actual Reading
(A)
Indicated Reading (B)
Error (A-B)
% Error
1
2
3
4
5
6
7
8
Page 61
Calculations
Result
Page 62
Page 63
Experiment No: 15
Date: .
TEMPERATURE MEASUREMENT USING THERMO COUPLE

Aim
To measure the temperature of a given physical measurand (water) using thermo couple
and calculate the error of measurement
Apparatus
Thermo couple (TC), temperature measuring trainer, thermometer, electric kettle
Theory
The Seebeck effect is a phenomenon in which a temperature difference between two
dissimilar electrical conductors or semiconductors produces a voltage difference between the two
substances.
The Peltier effect is a temperature difference created by applying a voltage between two
electrodes connected to a sample of semiconductor material. This phenomenon can be useful
when it is necessary to transfer heat from one medium to another on a small scale.
Thomson effect, the evolution or absorption of heat when electric current passes through
a circuit composed of a single material that has a temperature difference along its length. This
transfer of heat is superimposed on the common production of heat associated with the electrical
resistance to currents in conductors.
In operation, the hot junction of the thermocouple is exposed to the environment whose
temperature is to be measured. Due to the temperature gradient at the two junctions an emf is
developed.
The Output voltage of thermocouple is given by
Eo=C1(T-To)+C2(T2-To2) --------------- Eq. (15.1)
where C1, C2 are the thermoelectric constants for a given thermocouple
T, To are the hot junction and cold junction temperatures
Procedure
1. Check connections made and switch on the instrument by rocker switch at the front
panel. The display light glows to indicate the instrument is ON
Page 64
2. Keep the instrument in on position for ten minutes for initial warm up.
3. Then pour water into the kettle up to th and place sensor (TC probe) and thermometer
inside the kettle.
4. Adjust the potentiometer in the front panel, till the display shows room temperature
5. Note down the initial water temperature from thermometer and set FINAL SET
potentiometer to display initial water temperature.
6. Switch on the heater and wait till the water starts boiling
7. Note down the boiling water temperature in the thermometer and TC display.
8. Note down the temperature in TC display for every 10 rise in boiling water
9.
Note down the temperature and evaluate the error of TC
Fig. 15.1 Thermocouple Probe

Page 65

S.No.
Actual Reading
(Thermometer
Reading) C

Indicated Reading
(Thermocouple Reading) C
Error C
% of
Error
1
2
3
4
5
6
7
8
9
10
Table 15.1 Values of temperature obtained at consequence intervals
Calculations
Result
Page 66
Page 67
Experiment No: 16
Date: .
MEASUREMENT OF LOAD USING STRAIN GAUGE

Aim
To measure the load (weight) of give sample and calculate the error of load measuring
trainer
Apparatus
Load measurement trainer, load cell, sample weights
Specifications
Material:
Accuracy:
Steel
15 grams
Theory
The principle of elastic resistance strain gauge is that when a conductor is subjected to
mechanical deformation, i.e. its length and diameter are altered and a change in it resistance
occurs. The change in resistance is measured and correlated to strain or the physical effect. A
resistance wire gauge consists of a fine grid of wire of 0.025mm or less in diameter. The grid
consists of long parallel loops cemented to carrier (base) which may be a thin sheet of paper,
Bakelite or Teflon. The grid is covered on the top to prevent mechanical damage. The carrier is
bonded with an adhesive material to the specimen under study. The wires cannot buckle as they
are embedded in a matrix of cement and hence faithfully follow both the tensile and compressive
strains of the specimen.
The gauge factor is a measure of its sensitivity and given by
Gf = (R/R) =1+2+ ( /
---------------
Eq. (16.1)
where R is the resistance
is the strain
is the Poissons ratio
is the resistivity of material

The strain gauge and elastic member combination, used for weight measurement, is
called a load cell.
Page 68
Procedure
1. Make the connections as per the given color code and switch ON the instrument. The
display glows to indicate the instrument is ON.
2. Allow the instrument in ON position for 10minutes for initial warm up
3. Adjust the potentiometer in the front panel till the display reads 000.
4. Apply the load on the sensor in the loading arrangement using sample
weight.
5. The instrument reads the load on the sensor and displays through LED.
6. The experiment is repeated for different loads and the values are tabulated.
Fig. 16.1 Beam Type Load Cell mounted on a Wooden Base

Table 16.1 Indicated values at different loads
S.No
Actual Load (A)

Kg
Indicated Load (B)

kg
Error (A-B)
% Error
1
2
3
4
5
6
7
Page 69
8
9
10
Calculations
Result
Page 70
Page 71
Experiment No: 17
Date:
TEMPERATUE MEASUREMENT USING THERMISTOR

Aim
To measure the temperature of a given physical measurand (water) using thermistor and
calculate the error of measurement
Apparatus
Thermistor, temperature measuring trainer, thermometer, electric kettle
Theory
Temperature measuring sensor is based on principle that the resistance of material
changes with temperature gradient. Thermister has negative temperature coefficient. As the
temperature increases, the resistance of thermister decreases, and as the temperature decreases,
the resistance of the thermister increases. They are fabricated from semi conducting material,
which includes oxides of copper, cobalt, manganese, nickel and titanium, that exhibit very large
change in resistance with temperature. These metallic oxides are milled, mixed in appropriate
proportions and are pressed into the desired shape with appropriate binder and finally sintered.
The electrical terminals are embedded before sintering or backed after wards. Thermistors may
be shaped in the form of beads, disk washer and rods.
Resistance with temperature can be expressed by
Rt= Roe(1/T-1/To)
------Eq. (17.1)
where Rt is the resistance at temperature T
Ro=Resistance at absolute temperature

= Constant which is determined experimentally
Procedure
1. Check connections made and switch on the instrument by rocker switch at the front
3. Then pour water into the kettle up to th and place sensor (Thermister probe) and
thermometer inside the kettle.
Page 72
7. Note down the boiling water temperature in the thermometer and Thermister display.
8. Note down the temperature in Thermister display for every 10 rise in boiling water
temperature and evaluate the error of Thermister.
Table 17.1 Values of temperature obtained at consequence intervals
S.No
Actual Reading
Indicated Reading
Error
% Error
1
2
3
4
5
6
7
8
9
10
Calculations
Result
Page 73
Page 74
Experiment No: 18
Date: ..
TEMPERATURE MEASUREMENT
Aim
To measure the temperature of a given physical measurand (water) using Resistance
Temperature Detector (RTD) and evaluate the error of temperature measuring trainer.
Apparatus
RTD temperature measuring trainer, temperature sensor, thermometer, kettle
Theory
The resistance of a conductor changes when its temperature is changed and this effect can
be used for measurement of temperature. Resistance Temperature Detector (RTD) or resistance
thermometer can be calibrated to read degrees of temperature instead of units of resistance. The
sensor is simply a conductor fabricated either as a wire wound coil or as film of foil grid. The
change in the resistance in conductor with temperature is given by equation 1.
R/R = 1 (T-T0) + 2 (T-T0) 2 + 1 (T-T0)3 + 4 (T-T0) 4 + + n (T-T0) n
..Eq. (18.1)
where T0 is the reference temperature
R is the resistance and
1, 2 are the temperature coefficients
However for most metals quadratic relationship may be used
R/R = 1 (T-T0)
All metals produce a positive change in resistance with temperature. The commonly
used materials are platinum, nickel, copper, etc. In this type the temperature range is 250 to
1,000C. Most commonly used elements are of wire wrapped around an insulating support
constructed of glass, ceramic, or mica. The mounted element is provided with a protective
enclosure. Industrial RTDs are essentially coils of fine wire wound on frame and are placed in
protective sheath. They are the hermetically sealed.
Procedure
1.
Check connections made and switch on the instrument by rocker switch at the front
Page 75
3. Then pour water into the kettle up to th and place sensor (RTD probe) and thermometer
inside the kettle.
7. Note down the boiling water temperature in the thermometer and observe the change of
resistance of RTD with the rise in temperature display.
8. Note down the readings in intervals of 10 degrees.
Fig. 18.1 RTD Probe

Page 76
Table 18.1 Values of temperature & Resistance obtained at consequent intervals

S.No.
1
2
3
4
5
6
7
8
9
10
11
12
Thermometer Reading
Resistance in Ohms
Error
% Error
Calculations
Page 77
Result
Page 78
Experiment No: 19
Date: ..
MEASUREMENT OF VIBRATION AMPLITUDE OF AN ENGINE BED AT

VARIOUS LOADS USING A SEISMIC PICKUP
Aim
To measure the vibration parameters of an engine bed at various points using a seismic
pickup
Apparatus
1. Vibration indicator
2. Piezoelectric pickup and its connecting wire and socket
3. An external filter
Theory
The study and measurement of vibration in any structure or machine is of paramount
importance for the following reasons:
1. Undesirable vibration is a waste of energy and causes wear & subsequent break-down
resulting in high maintenance costs.
2. The noise produced due to vibrating bodies or structures cause human fatigue resulting
in reduced efficiency.
3. Undamped vibrations transmitted to structures might excite vibrations at natural
frequencies and cause permanent damage.
The accelerometer trainer consists of a piezoelectric vibration sensor. When the
piezoelectric element in the sensor is strained by an external force, electric charges accumulate
on opposite surfaces forming a charge proportional to the force. This electric charge, when
applied to a very high impedance amplifier, produces a voltage signal proportional to the
acceleration to which the piezoelectric element is subjected to. With this unique configuration
vibrating frequencies up to 3000Hz can be very easily measured.
Buffer amplifiers, integrators and equalizers built in the vibration indicator help to
measure vibration displacement, velocity and acceleration just by operating a rotary switch. Both
AC & DC recorder outputs are calibrated, buffered and brought to the recorder terminals
facilitating easy recording.
Page 79
Fig 19.1 Principle of seismic instrument

Procedure
1. Mount the vibration sensor rigidly on the vibrating body as shown in the fig. 19.1. All
the given directions must be followed to obtain accurate results. In this case the highest
frequency is reduced to 1,000Hz.
2. Clamp the cables to the vibrating body as shown in figure. This is essential to avoid
cable chipping and sub vibration damage to the cable.
3. Keep the vibration indicator at a suitable place and connect the power cord before
switching on mains power to the indicator. After verification, connect one end of mains
cable to the socket on the rare panel and other end to power source.
4. Inter connect the accelerometer and vibration indicator using the cable provided with
accelerometer.
5. Keep IN/OUT switch on the rare panel in OUT position
6. Select the parameter of interest on the function switch.
7. To start selected function, switch on the instrument and wait for 1minute for the
capacitors to get charged.
8. Now the indicator is ready for making vibration measurement.
9. Select range A if reading is below 20 when measuring acceleration or velocity and 200
while measuring displacement.
10.
Select range B for vibration levels between 20 & 200 for acceleration and velocity,
between 200 & 2000 m for displacement.
Page 80
11.
Select range C for vibration levels beyond 200 for acceleration and velocity, beyond
2000 m for displacement.
12. In order to analyze the vibrating motion an external active filter can be connected to
indicator and adopt the following procedure.
Calculations
The vibration amplitude of engine bed
Trial 1:
Trial 2:
Trial 3:
Trial 4:
Trial 5:
Vibration amplitude = average of 5 trails.
Result
Page 81
Experiment No: 20
Date: .
Study and Calibration of McLeod Gauge for Low Pressure

Aim
To Measure the pressure by using McLeod gauge
Apparatus
1. McLeod Gauge
2. Low pressure System
Theory
Pressure of gases containing vapors cannot normally measured with a McLeod gauge, for
the reason that compression will cause condensation. By using McLeod gauge a pressure from
0.01 micron to 50 mm Hg can be measured. Generally McLeod gauge is used for calibration
purpose.
Fig 20.1 Schematic Diagram of McLeod Gauge

Page 82
Procedure
1. Locate the position in the system of which pressure has to be measured.

2. Connect unknown pressure source to the instrument at point 'P' as shown in figure
20.1.
3. Mercury level is adjusted to fill the volume represented by darker shading (Under
these conditions, unknown pressure fills the bulb B and capillary C. Volume of
unknown pressure is volume of bulb and capillary.)
4. Mercury is then forced out of reservoir D up into the bulb and reference column E.
5. Continue the forcing of mercury till it reaches to cutoff point F. (A known volume of
gas is trapped in the bulb and capillary).
6. Mercury level is then further raised until it reaches a zero reference point in E.
7. Volume remaining in the capillary is read directly from the scale.
8. The difference in the height of two columns is the measure of trapped pressure.
9. Initial pressure is then calculated by using equation P1 = P2V2 /V1 (Boyle's Law )
10. Carry out the same procedure for other readings.
Table 20.1 Values of mercury Level
S.No.
Difference Between in
heights of columns (h) cm
Final Volume
V2 =At*h cm3
Initial Pressure
in cm of Hg
P1=P2*V2/V1
1
2
3
4
5
6
Calculations
Page 83
Result
The pressure measured by the McLeod Gauge is . cm of Hg.
Page 84
VIVA VOCE QUESTIONS

RTD (Resistance Temperature Detector)
1. What is full form of RTD?
2. What do you mean by calibration?
3. What is the principle of RTD?
4. Which materials are used for making sensors in RTD?
5. What is meant by accuracy?
6. What is meant by precession?
7. What is meant by sensitivity?
8. What is meant by threshold?
9. What is the maximum temperature a platinum RTD can measure?
Page 85
10. What is measured using RTD?
2. Speed Measurement
1. What is the function of a transducer?
2. What is the principle of photo-reflective pick up?
3. What is the principle involved in magnetic pick up?
4. What is the unit for speed?
5. What is the function of Electronic Counter (EC)?
3. Flow Measurement (Rotameter)

1. How flow measuring devices are classified?
2. What is the unique feature of Rotameter compared to other flow measuring devices?
3. What are the forces acting on a bob/float?
Page 86
4. Why are vertical slots cut on a bob/float?
5. Which materials are used to make bob/float?
6. What is the formula for discharge in Rotameter?
7. What are the basic constructional features of Rotameter?
4. Thermo Couple
1. What is meant by Thomson effect?
2. What is meant by Peltier effect?
3. What is meant by Seebeck effect?
4. What are the materials used for J type sensor?
5. What are the materials used for K type sensor?
6. What is the temperature range J type thermo couple measure?

Page 87
7. What is the temperature range K type thermo couple measure?
8. What is the basic output of a thermo couple?
5. Strain Gauge
1. What parameter does the strain gauge measure?
2. What do you mean by piezo-electric transducer?
3. What do you mean by magneto-striction transducer?
4. What is meant by gauge factor?
5. Define strain.
6. What is meant by Poissons ratio?
7. What are piezo-electric materials?

Page 88
8. What is meant by Wheat-stone bridge circuit?
9. What is meant by null-mode of a bridge circuit?
10. What is meant by deflection of bridge circuit?
11. What do you mean by strain gauge rossets?
6. LVDT
1. What is the full form of LVDT?
2. What is the principle involved in LVDT?
3. Why is an LVDT called as transformer?
4. What is the least count of micrometer?
5. The two secondary windings of LVDT are connected in .. (series/parallel)
6. What is the difference between analog meter & digital meter?

Page 89
7. Pressure Gauge
1. What is the principle involved in a pressure gauge?
2. What are the constructional features of sensor in pressure gauge?
3. What is the function of diaphragm in sensor of pressure gauge?
4. What do you mean by gauge pressure?
5. What do you mean by vacuum pressure?
6. What do you mean by absolute pressure?
8. McLeod Gauge
1. Which pressures are measured by McLeod gauge?
2. What is the principle involved in McLeod gauge?
9. Thermister
1. What is the principle involved in a thermister?
Page 90
2. What does the temperature range of a thermister?
10. Capacitance Transducer

1. Capacitance transducer is used to measure ____________________ parameter.
2. What is the principle involved in capacitance transducer?
11. Vibration Meter

1. Vibration is expressed in ____________________ units.
2. What is the principle involved in vibration meter?
Page 91

SASI Final Metrology & Instumentation EXPERIMENTS

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SASI Final Metrology & Instumentation EXPERIMENTS

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Metrology and Instrumentation Lab

Department of Mechanical Engineering

MEASUREMENT OF LENGTH, HEIGHT AND DIAMETER BY VERNIER

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Fig. 1.1 Vernier calipers

Vernier height gauge

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Fig. 1.2 Vernier height guage

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Fig. 1.3 Micrometer

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Table 1.2 Measurement of length using vernier calipers

Micro meter reading

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Table1.4 Measurement of diameter using vernier callipers

Vernier height gauge

Vernier height gauge

Table1.6 Measurement of height using vernier height gauge

Total reading (mm)

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Metrology and Instrumentation Lab

Department of Mechanical Engineering

MEASUREMENT OF BORES USING DIAL BORE INDICATOR

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Vernier callipers reading

Vernier scale reading (VC)

Least count of vernier callipers =0.02mm

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Accurate diameter of hole using dial bore indicator ismm

Fig. 2.1 Dial bore Indicator

Metrology and Instrumentation Lab

Department of Mechanical Engineering

MEASUREMENT OF THICKNESS OF GEAR TEETH BY GEAR TOOTH

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Fig. 3.1 Vernier gear tooth calliper

Fig. 3.2 Chordal thickness method

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Metrology and Instrumentation Lab

Department of Mechanical Engineering

thickness the tooth by horizontal scale of gear tooth vernier caliper.

Actual tooth thickness

Metrology and Instrumentation Lab

Department of Mechanical Engineering

TOOL MAKERS MICROSCOPE

To study the gear tooth nomenclature, rake angle.

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Metrology and Instrumentation Lab

Department of Mechanical Engineering

Fig. 4.1 Toolmakers Microscope

Metrology and Instrumentation Lab

Department of Mechanical Engineering

4. What are the different types of gears?