practical manual

JSPM’s

JAYAWANTRAO SAWANT COLLEGE OF ENGG.,HADAPSAR, PUNE-28

DEPARTMENT OF MECHANICAL ENGG.

Practical Manual

SUB:-Metrology and Quality Control TE [MECH]

EXPT. No. 1Determination of Linear Dimensions using Measuring Instruments

1. Introduction

a. Classification of Methods of Measurements.

2. Non - Precision Measuring Instruments.

a. Steel Rule

b. Calipers

c. Slip Gauges

d. Surface Plates

3. Principles of Flat Surface Generation.

4. Testing Flatness of Surface Plates.

5. V-Blocks

6. Straight Edges

7. Spirit Level

8. Combination Set

9. Universal Surface Gauge

10.Engineer’s Square

11.Engineer’s Parallels

12.Radius Gauges

13.Feeler Gauges

14.Precision Linear Measurements

a. Vernier Caliper

b. Vernier Height Gauges

c. Micrometer Screw Gauges

P.T.O.

Aim: Linear Measurement using Precision / Non-precision Measuring Instruments.

Apparatus: Caliper Scale Screw, Filler, Radius Gauges, Combination set Vernier Calliper,

Vernier Height Gauge, Micrometer Screw Gauge, Micrometer Depth Gauge, Slip Gauges,

Spirit Level, Straight Edges.

A) Procedure for Vernier Calliper :-

1. Hold the job between fixed jaw and sliding jaw.

2. Read the number of divisions on main scale.

3. Examine the Vernier scale to determine which of its divisions coincide or most

coincident with a division on main scale.

4. The number of these divisions (Least Count) is added to main scale reading.

5. Note the readings as per observation table and calculate total reading.

B) Procedure for Micrometer Screw gauge :-

1. Hold the job between Anvil and Spindle.

2. Turn thimble using the ratchet until two ratchet clicks are heard.

3. Note the readings as per observation table.

Formula Used:-

Least Count (L.C.) = Smallest Division on Main Scale / Total no. of divisions on Vernier Scale

Observation Table:-

Sr.

No.

Main Scale

Reading (MSR)

Vernier Scale

Reading (VSR)

C= L.C. X VSR Total Reading = MSR – C

1

2

3

4

5

Result:- The Linear Measurement of given job

a) By using Vernier Calliper is = _________ mm.

b) By using Micrometer Screw Gauge = _________ mm.

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EXPT. No. 2Machine Tool Alignment tests on Milling Machine Tool

1. Cutter Spindle Axial Slip or Float.

2. Eccentricity of External Diameter.

3. True Running of Internal Taper.

4. Table Surface parallel with Arbor.

5. Surface parallel with longitudinal movement.

6. Transverse movement parallelism with spindle axis in vertical/horizontal

plane

7. Center T-slot parallel with longitudinal table movement.

8. Center T-slot Square with Arbor.

9. Column ways for knee square with table side inclination.

10. Overarm parallel with spindle in vertical/horizontal.

Aim:- Machine Tool Alignment Tests on Milling Machine tool

Apparatus:- Dial Indicator with stand, Dial Indicator, Mandrel

Procedure:-

a. Test two places at 180 degrees.

b. Slowly move mandrel for maximum eccentricity.

c. Test table surface for maximum travel.

d. Clock indicator moved transverse with table for A test on side of the mandrel and

for B test under mandrel.

P.T.O.

e. Clock indicator in spindle tenons in T-slots.

f. Clock in spindle tenon block, turnover method.

g. Clock in spindle square set vertically.

h. Clock in spindle for A compare reading on under overarm and mandrel.

i. For B compare reading on side of overarm and mandrel.

Result:-

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Practical Manual


EXPT. No. 3Study and Measurement of parameters using Tool Maker’s Microscope.

1. Construction and Working Principle of Tool Maker’s microscope2. Screw thread measurement.3. Gear measurement4. Tool wear measurement 5. Linear dimensions measurement6. Angle measurement

Aim:- Measurement of various elements by using Tool Maker’s Microscope

Apparatus:- Tool Maker’s Microscope Graticules.

Procedure:-

1. The Tool Maker’s microscope is based on principle of optics. It consists of heavy

hollow base. Light from the land at extreme light is collimating in the tube

connecting the lamp to the centre of this instrument and is reflected as parallel

beam by the prism at the end of tube.

2. On its way of this beam collects the image of object to be inspected and this enters

the microscope being turn by another prism into the inclined eyepiece.

3. Here the inspection may be made by eye in the normal way.

4. Magnification range 10 X to 100 X on the projection screen.

5. Linear movements of the table are controlled in accuracy of 0.0025mm.

P.T.O.

Observation table:-

Dimensions Main Scale

Reading

(MSR)

Vernier

Scale

Reading

(VSR)

C =

L.C. X VSR

(mm)

Total

Reading =

MSR + C

(mm)

Difference

between

initial and

final

Pitch Initial

Final

Major

Diameter

Initial

Final

Minor

Diameter

Initial

Final

Result:-

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Practical Manual


EXPT. No. 4Exercise on Design of Limit Gauges using Taylor’s Principles.

1. Tolerances

2. Ways of Expressing Tolerances

3. Tolerance Accumulation

4. Indian Standard (IS 919 – 1963 )

a. Definitions

b. Types of Fits

c. Deviation

d. Hole Basis & Shaft Basis System

5. Plane Gauges

a. Plane Plug Gauge

b. Plane Ring Gauge

6. Snap Gauge

7. Gap Gauge

8. Taylor’s Principle

9. Wear Allowance Consideration on Gauge Maker Tolerance

10.Gauge Design by

a. First System

b. Second System (Revised Gauge Limits)

c. Third System (Present British System)

11.Examples on designing of gauges

12.Examples on calculation of tolerances

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Practical Manual


EXPT. No. 5Study and Measurement of Parameters using profile projector.

1. Construction & working of profile projector.2. Screw thread measurement.3. Gear Measurement.4. Tool wear measurement.5. Linear dimensions measurement.6. Angle Measurement.

Aim: - Study & Measurement of Parameters using profile projector.

Apparatus: - Profile Projector.

Procedure: -

1. Place the measurand on the glass plate.2. Select a proper magnification 10x or 20x.3. Adjust the image for clarity by sliding the carriage of Profile Projector.4. Measure the required dimensions by using two micrometers.

Observation Table:-

Dimensions Main Scale Reading

MSR(mm)

Vernier Scale

ReadingVSR

C= L.C. X VSR(mm)

Total Reading = MSR + C

(mm)

Difference between Initial &

Final

(mm) (mm)Pitch Initial

Final

Major Diameter

Initial

Final

Minor Diameter

Initial

Final

Result:-1. Pitch of Screw thread = mm

2. Major Diameter of Screw thread = mm

3. Minor Diameter of Screw thread = mm

4. Thread Angle of Screw = degrees

5. Pin Diameter = mm

6. Tool Wear Measurement = mm

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EXPT. No. 6Interferometry:

1. Measurement of Surface Flatness using

Optical Flat.

2. Testing of Parallelism of any surface

with reference to the standard optically flat

surface.1. Interference of two rays.

2. Light source for Interferometry.

3. Interferometry applied to flatness testing.

4. Testing the parallelism with optical flat.

Aim: - Measurement of Surface Flatness using Interferometry.

Apparatus: - Monochromatic Light Unit, Optical Quartz, Master Surface.

Procedure: -

1. Flatness of working surface of an optical flat is tested by comparing its flatness

with a master flat of known flatness.

2. Testing is usually carried out by observing the interference fringes using

monochromatic light source.

3. The master flat is placed over the working surface of the flat under test.

Aim: - Testing the parallelism of any surface with reference to the standard optically flat

surface.

Apparatus: - Monochromatic Light Unit, Optical Quartz, Master Surface, slip gauges.

Procedure: -

1. The two blocks, one whose surface is made optically flat and other whose

surface is to be checked are wrung on a flat reference plane.

2. An optical flat is then placed on the top of both the blocks.

3. The distance L between the two gauges is measured very accurately.

Result: -

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EXPT. No. 7Surface Finish Measurement using Talysurf.

1. Meaning of Surface Texture and some definitions.2. Terminology as per Indian Standards.3. Methods of Measuring Surface Finish

Aim: - Surface Finish measurement using Talysurf.

Apparatus: - Talysurf.

Procedure: -1. This instrument is working on carrier modulating principle. The measuring head of

this instrument consists of diamond stylus of about 0.002mm teeth radius and skid or shoe which is drawn across the surface by means of a motorized driving unit which provides three speeds respectively. 20 X and 100 X magnification is also provided.

2. The arm carries the stylus and armature, which pivots about the centerpiece of E-shaped stamping. There are coils carrying AC current. As the armature is pivoted about the central leg any movement of the stylus causes the air gap vary and thus the amplitude of the original AC current flowing in the coils is modulated.

3. The output of the bridge thus consists of modulation only. This is further demodulated so that the current now is directly proportional to the vertical displacement of the stylus only.

Observations: -

Result: -

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Practical Manual


EXPT. No. 8Assignment No. 1:- Quality Control

1. Meaning of Quality.

2. Quality functions.

3. Objective of Quality Control.

4. Balance between cost of Quality and Value of Quality.

5. Total Quality Management.

6. Zero Defect Concept.

7. Quality Circles.

8. ISO 9000

Assignment No. 2:- Statistical Quality Control

1. Frequency distribution Curve

2. Variables and attributes

3. Different types of Control Charts – X-bar, R, P & C charts

4. Process Capability Analysis

5. OC Curve

6. Standard Sampling Tables

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Practical Manual


EXPT. No. 9Measurement of Screw Parameters using Floating Carriage Micrometer.

1. Screw Thread Terminology2. Measurement of various elements of threads

a. Measurement of Major Diameter, External / Internalb. Measurement of Minor Diameter, External / Internalc. Effective Diameter Measurement

Thread Micrometer Method One Wire Method Two Wire Method Three Wire Method

d. Best Wire SizeAim: - Measurement of screw parameters using Floating Carriage Micrometer

Apparatus: - Floating Carriage, Bench Micrometer, Standard wire set

Procedure: -

1. The Effective diameter of the screw thread is measured by two wires or rods of identical diameter between flank of the thread.

2. One wire is placed between two threads at one side and one on other side of the anvil of measuring micrometer.

3. First the micrometer reading is noted on a standard gauge nearly same to the effective diameter.

4. The micrometer reading is noted on the threaded workpiece.5. Actual Measurement over wires = size of the gauge ± difference in two micrometer

readings

Formulae: -

1. L.C. = smallest division on main scale/ total no. of divisions on vernier scale.

2. E = T + P, where E is effective dia., T is the dimension under wire, P is the std. value depending on the pitch.3. T = M – 2d, where M is dimension over wire, d is the dia of wire

4. P = 0.866 p – d for metric thread P = 0.9605 p – 1.1675 d for whitworth thread

5. Dimension over wire M = cylinder size + (R1 + R2)

6. Best wire size = p/2 secx/2.

Observation Table: -

Sr. no.

Pitch (p) (mm)

Wire Dia. (d)

(mm)

Std. Cyl. Size(mm)

MSR

(mm)

CSR

(mm)

VSR

(mm)

Dimension over wire

M (mm)

Dimension under wire

T (mm)

Effective dia

E =T + P(mm)

1

2

3

4

5

Result: -

1. Effective Diameter of Screw Thread = mm

2. Major Diameter of screw thread = mm

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Practical Manual


EXPT. No. 10Precision Angular Measurement.

1. Sine Principle & Sine Bar2. Characteristics of Sine Bar3. Use of Sine Bar4. Sine Centre5. Vernier Bevel Protractor6. Angle Gauges

Aim: - Measuring known angles by using Sine Bar.

Apparatus: - Dial Gauges, Slip Gauges,Surface Plate, Angle Plate, Clamping devices, Sine Bar.

Procedure: -

1. Place the workpiece on the top surface of sine bar with angle plate.

2. One of the cylinders or rollers of sine bar is placed on the surface plate and other roller is placed on the slip gauges of height H.

3. The height of slip gauge should be maintained, so that dial indicator should give zero deflection.

Formulae: -Angle Measured (θ) = sin-1 (H / L)

Observation table: -

Length of Sine Bar = mm

Sr. No. Height of Slip Gauge at zero dial position (H)

Angular Measure(θ) = sin-1 (H / L)

1

2

3

4

5

Result: -

Angular Measurement of given component = Degrees.

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