Comparators Comparing the manufactured part to the master part envisaged by the designer Dimensional variation from the master part can be amplified and measured so as to get the deviation and the instruments for doing that are called comparators ◦ Mechanical Comparators ◦ Optical Comparators ◦ Pneumatic Comparators
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Design Considerations The instrument must be sufficiently robust The system response should be faster The contact plunger should be provided with a hardened steel or diamond to minimize wear & tear Means should be provided for easy lifting of the plunger
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Design Considerations Magnification should be as high as possible, but it should also be capable of measuring the wide range The recording scale should be linear The system should have good repeatability Comparator should be versatile
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Mechanical Comparators Dial Indicators
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Johansson Mikrokator
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Sigma Comparator
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Optical Comparator
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Zeiss Ultra optimeter
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Pneumatic comparator
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Angular Measurements Angle Measuring Devices: Bevel Protractors & Angle Gauges measure the angle between the surfaces of a part or assembly
Bevel Protractor: It normally can read about 5 minutes of a
degree. It consists of a sliding blade which can be set at some with respect to the stock. The reading can be obtained with the help of main scale and Vernier scale.
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2/3/2018 Prof.P.V.Rao I.I.T Delhi 14 Angle Gauges A series of fixed angles are used for comparative assessment of angle between two surfaces
By making use of different permutations &
combinations, we could set an angle nearest to 3”. The dimensions of the angle gauges are 75 mm length && 16 mm width.
The set consists of 10, 30, 90, 270 & 410
1’, 3’, 9’, 27’ and 3”, 6”, 18”, 30”.
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Angular Gauges
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Sine Bar A sine bar is a high precision angle measuring instrument. It is used in conjunction with other accessories such as slip gauges, angle gauges, etc.
It consists of a bar carrying two rollers set at a
known centre distance. The options are 100 mm, 250 mm, etc.
They are available in several designs.
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Sine Bar
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Sine Centre
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Autocollimator Autocollimators are used to detect small misalignments If a parallel beam of light is projected from the collimating lens and if a plane reflector R is set up normal to the direction of the beam, light will be reflected back along the same path and light will be brought back to focus exactly at the position of the light source
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Autocollimator contd.. If the reflector is tilted through a small angle (q), the parallel beam will be reflected through twice the angle (2q) and would be brought to focus in the same plane as the light source but to one side of it. The image will not coincide but there will be a distance equal to focal length times the angle of reflection (2f q) where f is the focal length of the collimating lens.
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Autocollimator contd.. The distance between the reflector and the lens has no effect on the separation between the source and the image. For high sensitivity, a long focal length is required Although the distance of the reflector does not effect the reading, if it is moved too far back, reflected rays will miss the lens completely and no image will be formed.
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Types of Gear Inspection Element by Element Inspection of Gear: Laborious, useful in error analysis, can’t be used by the gear manufacturers. ◦ Tooth thickness measurement ◦ Base pitch measurement Composite Error Checking: Used in Gear Inspection by conducting only one test Parkinson Gear Tester
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Gear Tooth Vernier
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Base Pitch Measuring Instrument
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Involute Property
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Parkinson Gear Tester
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Thread Inspection - Terminology Pitch: It is the distance measured parallel to the axis between the corresponding points on adjacent surfaces in the same axial plane. Lead: It is the axial distance advanced by the thread in one revolution. Lead is equal to the same multiples of pitches as the number of starts.
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Thread Terminology Contd.. Included angle: It is the angle between the flanks of the thread measured in an axial plane.
Pitch diameter: It is the diameter of tee imaginary
coaxial cylinder which intersects the surface of the thread in such a manner that the intercept on the generator of the cylinder is equal to half the pitch.
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Thread Terminology Contd.. Major Diameter: It is the diameter of imaginary coaxial cylinder that just touches the crests Minor Diameter: It is the diameter of imaginary coaxial cylinder that just touches the roots Helix Angle (q): tan q = p/p d
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Thread Inspection Measurement of Major Diameter: Bench micrometer is normally used for this measurement.
It has measuring anvils so that the thread can be held
between them.
It has fiducial indicator so that the required pressure
can be applied for all the measurements
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Bench Micrometer
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Thread Inspection Measurement of Minor Diameter: Bench micrometer can not be used for Minor Diameter. So, another one, Floating Carriage micrometer is normally used for this measurement.
In this instrument, the thread is held between
the centres so that the influence of helix angle can be nullified in this arrangement. 2/3/2018 Prof.P.V.Rao I.I.T Delhi 33 2/3/2018 Prof.P.V.Rao I.I.T Delhi 34 Thread Inspection Measurement of Pitch (effective) Diameter: Again Floating Carriage micrometer is normally used for this measurement.
Here, the prisms used in the measurement of minor
diameter are replaced by the steel wires whose size is chosen such that they pitch at the effective diameter.
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Thread Inspection Diameter of the best wires: If the wires used make contact exactly at the pitch diameter, then such wire is called the best wire. The diameter of such wire can be estimated from the formula.
Compression & Rake correction.
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Measurement of Internal Threads Measurement of Major Diameter: The major diameter of internal thread is normally measured using horizontal comparator fitted with ball end styli of radius less than the root radius of the thread to be measured. When the thread is mounted on a comparator, it aligns itself with the axis of the machine and measurement would be done along the helix of the thread as indicated above.
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Measurement of Int. Threads
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Measurement of Internal Threads Measurement of Minor Diameter: Calibrated rollers and slip gauges are used for this measurement as shown below.
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Measurement of Internal Threads Measurement of Effective Diameter: The effective diameter of internal thread is measured using the horizontal comparator using ball ended styli of the best size wire. Measurement of Flank angle: The semi cast of the thread form may be made using dental plaster and measurement is obtained as done for external thread.
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Thread Gauges Thread inspection can also be carried out using gauges designed according to the Taylors Principles: Limit gauges for Internal threads: ◦ Full form Go Gauge ◦ Truncated Effective Diameter NOGO gauge ◦ Minor Diameter NOGO gauge
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Go & NoGo Gauges
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Thread Gauges Limit gauges for External threads: ◦ This is usually carried out using caliper type gauges ◦ Full form Go Gauge ◦ Truncated Effective Diameter NOGO gauge ◦ Major Diameter NOGO gauge