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ME06-TE-302053-ML-GSMCo E Laboratory
Manual-Measurement Lab (2019 course)
B.e. (mechanical) (Savitribai Phule Pune University)

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Genba Sopanrao Moze Trust’s

GENBA SOPANRAO MOZE COLLEGE OF ENGINEERING

Balewadi, Pune-411045

Department of Mechanical Engineering

THIRD YEAR ENGINEERING

Measurement Laboratory
Lab Manual

Prepared by:
Dr. V.B. Roundal

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VISION OF THE INSTITUTE

"EMPOWERMENT THROUGH TECHNOLOGICAL EXCELLENCE"

MISSION OF THE INSTITUTE

• Imparting Value Based Education

• Integrating Engineering and Industry
• Enhancing Employability and Entrepreneurship
• Developing Research Culture
• Creating Global Competency

Program Educational Objectives:

To develop successful professionals in Mechanical Engineering

PEO 1 with sound fundamental knowledge in Mathematics, Science and
Engineering.
To inculcate the students thrust for support higher studies and
PEO 2
research.
To equip students with ability to adopt modern tools, technology
PEO 3
and advanced software’s leading to lifelong learning.
PEO 4 To instill in the students leadership skills with ethics.

Graduate Attributes and Program Outcomes:

No Graduate Attributes Program Outcomes
Engineering An ability to apply knowledge of computing, mathematics, science
i. Knowledge and engineering fundamentals appropriate to the instrumentation
engineering.
ii. Problem Analysis An ability to identify, analyze and provide solution to the problem.
Design & An ability to design, implement and evaluate the process,
iii. Development of component, or program to meet desired needs having appropriate
Solutions consideration for public health and safety.
iv. Investigation of An ability to design and conduct experiments, as well as to
Complex Problem analyze and interpret data.
v. Modern Tools Usage An ability to use current techniques, skills, and modern tools
necessary for engineering practice.
vi. Engineer and Society An ability to understand the impact of engineering solution in
global, economic, environmental and social context.
vii. Environment & An ability to design a system, sustainable to social and
Sustainability environmental issues.
viii. Ethics An ability to understand and practice; professional ethics, legal
and social issues.

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ix. Individual & Team An ability to function effectively as an individual or as a team

work member, to accomplish the goal.
x. Communication An ability to communicate effectively at different levels.
xi. Lifelong Learning An ability to keep abreast with state of art technologies through
Lifelong Learning.
xii. Project management & An ability to apply the knowledge & understanding of
Finance Instrumentation & Control Engineering for product development.

Course Objectives:-
Students shall
1. Understand requirements of industrial drawings
2. Read, understand and explain basic Geometric Dimensioning & Tolerancing concepts
3. Apply various geometric and dimension tolerances based on type of fit
4. Include surface roughness symbols based on manufacturing process
5. Measure and verify position tolerances with applied material conditions
6. Understand requirements for manufacturing and assembly

Course Outcomes (COs):

On completion of the course, learner will be able to

EVALUATE causes of errors in Vernier calipers, micrometers by performing

CO-1 experiments in standard metrological conditions, noting deviations at actual and
by plotting cause and effect diagram, to reduce uncertainty in measurement.
ANALYZE strain measurement parameters by taking modulus of elasticity in
CO-2 consideration to acknowledge its usage in failure detection and force variations.
EXAMINE surface Textures, surface finish using equipment’s like Talysurf and
analyze surface finish requirements of metrological equipment’s like gauges, jaws
CO-3
of vernier calipers, micrometers, magnifying glasses of height gauge and more, to
optimize surface finish accuracy requirements and cost of measurement.
MEASURE the dimensional accuracy using Comparator and limit gauges and
CO-4 appraise their usage in actual measurement or comparison with standards set to
reduce measurement lead time.
PERFORM Testing of Flow rate, speed and temperature measurements and their
CO-5 effect on performance in machines and mechanisms like hydraulic or pneumatic
trainers, lathe machine etc. to increase repeatability and reproducibility.
COMPILE the information of opportunities of entrepreneurships/business in
CO-6 various sectors of metrology like calibrations, testing, coordinate and laser
metrology etc in an industry visit report.

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Genba Sopanrao Moze college of Engineering

25/1/3, Balewadi, Haveli, Pune- 411 045
Department of Mechanical Engineering
Subject: Measurement Laboratory (302053)
Academic Year: 2021-2022

CONTENTS
Page No. Signature
Title of the Experiment Date of
SN From To of Remarks
Performance
Teacher
Linear and angular Measurement:
Demonstration and calculations using
1
Vernier Caliper, Screw gauge, Dial gauge,
height gauge, Bevel protector etc.
Limit Gauges: Concepts, uses and
applications of Go –No Go Gauges, Taylor’s
2
principle and Design of gauges (Numerical
and student activity)
Determination of geometry and dimensions
of given composite object / single point
3
tool, by using Optical Projector / Tool
makers’ Microscope
Surface roughness measurement of a given
4
sample using surface tester
Verification of dimensions and geometry of
given components using Electric
5
/Mechanical /Optical /Pneumatic
comparator in context of manufacturing
Experimentation by using Gear Tooth
6
Vernier Caliper
Fundamentals of measurements and
7 Calibration process by using Dead weight
Tester/Strain Gauges
Applications of Open Education Resources
8 like Scilab in measurement / Students
should develop any online calculator

9 Industrial Visit

*Absent/Attended/Late/Partially Completed/Completed

CERTIFICATE
This is to certify that Mr./Miss/Mrs._____________________________________________________________________
Roll No.:_______ Exam. Seat No.:_T______________of TE Mechanical has carried out above practical’s
within Genba Sopanrao Moze college of Engineering, Balewadi as prescribed by Savitribai Pule Pune
University, Pune during the academic year 2021-2022. His/Her performance is satisfactory and
attendance is_______%.

Date:
Dr. V.B. Roundal Prof. S.R. Sandanshiv Dr. Ratna Raja Kumar Jambi
Faculty I/C HOD Principal

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Genba Sopanrao Moze College of Engineering, Balewadi Measurement Laboratory Manual

EXPERIMENT NO: 01
Linear and angular Measurement: Demonstration
and calculations using Vernier Caliper, Screw gauge,
Dial gauge, height gauge, Bevel protector etc.

Dept of Mechanical Engg. (ML-302053) 1

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Gen
nba Sopanrao
o Moze Colleg
ge of Enginee
ering, Balewa
adi Measurement Laborratory Manu
ual
EXPER
RIMENT NO
O: 01

Title: Linear and an

ngular Mea asurement: Demonstrration and d calculatio
ons using V
Vernier
Caliper, Screw gauge
e, Dial gaug
ge, height gauge,
g Beveel protecto
or etc.
Aim: To study of linear and angular
a dim
mensions off given com
mposite paart using prrecision
measuring
g instrumen
nts.

Apparatu
us:
Sr No. nstrument
In Ran ge Leastt Count
1 Vernier Caliper 0-200 mm
m 0.02 mmm
2 Outside Micrometer 0-25 mm
m 0.01 mmm
3 Vernier Depth Gaugge 0-200 mm
m 0.02 mmm
4 Vernier Height Gau
uge 0.02 mmm

Theory:
1. Vernierr Caliper:
The princciple of Verrnier is thaat when twwo scales o r divisions slightly diffferent in ssize are
used, the differencee between n them can c be utiilized to enhance the accurracy of
measuremment The Veernier Callip per essentiaally consistts of two stteel rules an
nd these can slide
along eachh other. Thhe details are shown in fig. below

1. Outsidee jaws: usedd to measurre external diameter

d orr width of an
n object.
2. Inside jaws:
j used to
t measure internal diaameter of an n object.
3. Depth probe:
p usedd to measure depths of an object o r a hole.
4. Main sccale: gives measuremen
m nts of up to one decimaal place (in ccm).
5. Main sccale: gives measuremen
m nts in fraction.(in inch))
6. Vernier gives meassurements up
u to two deecimal placees(in cm)
7. Vernier gives meassurements in n fraction(inn inch)

ng the total reading by

Measurin y Vernier ca
aliper

Deptt of Mechaniical Engg. (M

ML-302053)) 2

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Gen
nba Sopanrao
o Moze Colleg
ge of Enginee
ering, Balewa
adi Measurement Laborratory Manu
ual
Fig. 1 Verrnier Calip
per

Fig.2 Measuring
g by Vernieer Caliper

Sr Main
M Scale Reading
R (MSR) Veernier Scalee C(mm))= LC x Total
No. mm
m Reeading (VSR
R) VSR Reading
mm (mm)
(MSR) + C
1 13 21 0
0.42 13.42

2. Vernierr Height Ga auge

This is also
o a sort of a Vernier caliper as shoown in Figg. 4 equipp ped with a special base back
and other attachments which make the in nstrument ssuitable for height meeasurementt. Along
with the sliding
s jaw assembly arrangement is provideed to carrry a remo ovable clam
mp. The
upper and d the lower surface of the
t measuriing jaw are parallel to the base so that it can be used
for measu urement oveer or underr the surfacce. The Verrnier heightt gauge is merely u used to
scribe linees of certain distance above surfface. Howevver, dial in ndicator can be attacched in
the clam mp and many useful meeasurementts can be exactly m made as it exactly givves the
indication when diall tip just tou uches the surfaces. Forr all these m
measuremeents, use of surface
plates as datum
d surfaace is very essential.
e
Deptt of Mechaniical Engg. (M
ML-302053)) 3

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Gen
nba Sopanrao
o Moze Colleg
ge of Enginee
ering, Balewa
adi Measurement Laborratory Manu
ual

Fig. 3 Vern
nier Heightt Gauge

Vern
nier Depth G
Gauge
Deptt of Mechaniical Engg. (M
ML-302053)) 4

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Gen
nba Sopanrao
o Moze Colleg
ge of Enginee
ering, Balewa
adi Measurement Laborratory Manu
ual
3. Micrommeter
The micro ometer essentially conssists of U sh
haped framee as shown in Fig 5. Th he component to be
measured d is held betwween fixed anvil and movable
m spiindle. The spindle can b be moved wwith the
help of th
himble. There are two scales on micrometer
m r, a main sccale and a circular scaale. The
barrel is graduated
g n unit of 0.5 mm wherreas thimblle has 50 diivisions aro
in ound its perriphery.
One revolu ution of thim
mble movess 0.5 mm, which
w is the llead of the sscrew and tthe pitch.

Fig. 4 Outtside Micro

ometer

For Verniier Caliper//Micrometter/Vernierr Height ga auge:

1. Check th
he zero of main
m and Vernier scale to be coinciiding.
2. Read the instrumennt for at leasst three ran
ndom Vernieer positionss.
3. Measure the samplles at indicaated places and
a record aas per the foormat.

4. Observ
vation Table
e:

• ernier Calip
For Ve per
Dimensions Reading 1 (mm)) Reading Reading 3 (mm)
g 2 (mm) R Av
verage
D1
D2
D3

• For Miicrometer
Dimensions Read ding 1 (mm
m) Reading
g 2 (mm) Reading 3 (mm) Average
e
D1
D2
D3

Deptt of Mechaniical Engg. (M

ML-302053)) 5

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Gen
nba Sopanrao
o Moze Colleg
ge of Enginee
ering, Balewa
adi Measurement Laborratory Manu
ual

• For Ve
ernier Heig
ght Gauge

Dimensions Read
ding 1 (mm) Reading
g 2 (mm) R
Reading 3 (mm) A
Average
D1
D2
D3

5. Bevel Protractor
P
The universal bevel protractor
p with
w 5 minuttes accuracyy is common nly found in n all tool roo
oms and
metrology y laboratories. It has a base plate or stock w whose surfacce has high h degree of flatness
and surfacce finish. Thhe stock is placed on the work-p piece whosee angle is to o be measu ured. An
adjustablee blade attached to a ciircular dial is made to coincide w with the anggular surface. It can
be swiveleed to the required anglle and can be b locked in n to facilitatte accurate reading
nto position
of the circcular scale that
t is moun
nted on thee dial. The m main scale o
on the dial iis divided innto four
quadrantss of 90 degrrees each. Each
E divisioon on this sscale reads one degree. The degrrees are
numbered d from 0 to 90 on either side of 0th h division. T
The Vernierr scale has 2 24 divisionss, which
correspon nd to 46 divvisions on th
he main scaale. Howeveer, the divissions on the Vernier sscale are
numbered d from 0 to 60
6 on eitherr side of thee 0th division
n as shown in figure beelow

Fig.5. Angle
A measu urement on n Bevel Pro
otractor
Following figure illusttrates the use
u of bevel protractor ffor measureement of an
ngles. While case
(a) illustraates the use of acute an
ngle attachm
ment, case (b
b) shows ho
ow the anglee of an insid
de
beveled faace could bee measured.

Deptt of Mechaniical Engg. (M

ML-302053)) 6

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Gen
nba Sopanrao
o Moze Colleg
ge of Enginee
ering, Balewa
adi Measurement Laborratory Manu
ual

Fig.6. Bevel
B Protrractor
Observatiion Table

Dimensions Reading 1 (mm)) Reading

g 2 (mm) Reading 3 (mm) Av
verage
D1
D2
D3

6. Slip Gau
uges
Slip gaugees are ofteen called Johannes gaauges also,, as Johan nnes originaated them. These
are rectanngular block
ks of steel having a crross-section n of about 3 30 by 10 m mm. These aare first
hardened to resist weear and careefully stabilized so thatt they are in
ndependentt of any subsequent
variation in
i size or sh
hape. The longer gaugess in the set aand length bbars are hardened onlyy locally
at their measuring
m en
nds. After being
b hardened, blockss are carefu ully finished
d on the meeasuring
faces

Grade 2: This
T is the workshop
w grrade. Typiccal uses incl ude settingg up machine tools, positioning
milling cuttters and ch
hecking mecchanical wid
dths.
Deptt of Mechaniical Engg. (M
ML-302053)) 7

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Genba Sopanrao Moze College of Engineering, Balewadi Measurement Laboratory Manual

Grade 1: Used for more precise work, such as that carried out in a good-class tool room.
Typical uses include setting up sine bars and sine tables, checking gap gauges and setting dial
test indicators to zero.

Grade 0: This is more commonly known as the Inspection grade, and its use is confined to tool
room or machine shop inspection. This means that it is the Inspection Department only who has
access to this grade of slips. In this way, it is not possible for these slip gauges to be damaged or
abused by the rough usage to be expected on the shop floor.

Grade 00: This grade would be kept in the Standard Room and would be kept for work of the
highest precision only.

Angular Measurement Observation:

a. Center distance between rollers (l) = 200mm
b. Height of slip gauge (h) = 51.38 mm
c. Angle of given work piece ( )
ℎ
Sin =
ℎ
= sin
51.38
= sin
200
= 14.08
7. Applications:

Conclusion: Hence we have studied various linear measuring instruments.

8
Dept of Mechanical Engg. (ML-302053)

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Genba Sopanrao Moze College of Engineering, Balewadi Measurement Laboratory Manual

EXPERIMENT NO: 02
Limit Gauges: Concepts, uses and applications of Go
–No Go Gauges, Taylor’s principle and Design of
gauges (Numerical and student activity)

Dept of Mechanical Engg. (ML-302053) 9

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Genba Sopanrao Mo
oze College of
o Engineering, Balewadi Measurem
ment Labora
atory Manua
al

EXPER
RIMENT NO
O: 02

Title: Lim
mit Gaugess: Conceptss, uses an
nd applicattions of Go o –No Go Gauges, T
Taylor’s
principle and Design
n of gaugess (Numerical and stud
dent activitty).
Aim: To sttudy of limitt Gauges

Theory:

Definitionn of Limits:
The maximmum and miinimum perrmissible sizzes within w
which the acctual size off a componeent lies are
called Limits.

Tolerance e:
It is imposssible to makke anythingg to an exactt size; thereefore, it is esssential to aallow a defin
nite tolerance
or permisssible variatiion on everyy specified dimension.
d

Why Tolerances are specified??

• Variationns in properrties of the material
m beiing machineed introducce errors.
• The prod duction macchines them mselves may have some inherent in naccuracies..
• It is impo a operator to make peerfect settinggs. While seetting up thee tools and w
ossible for an work piece
on the macchine, somee errors are likely to creeep in.

Unilateral Tolerance e:
• Tolerancces on a dimmension may y be either unilateral
u orr bilateral.
• When thee two limit dimensionss are only on n one side oof the nomin nal size, (eitther above o
or below) th
he
tolerancess are said to be unilaterral.
• For unilaateral toleraances, a casee may occurr when one of the limitss coincide w with the basic size.

Deptt of Mechaniical Engg. (M

ML-302053)) 10

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Bilateral Tolerance:
When the two limit dimensions are above and below nominal size (i.e. on either side of the nominal
size) the tolerances are said to be bilateral.
Unilateral tolerances are preferred over bilateral because operator can machine to the upper limit of
the shaft (or lower limit of the hole) still having the whole tolerance left for machining to avoid
rejection of parts

TERMINOLOGY OF LIMIT SYSTEMS:

 Limits of size: The two extreme permissible sizes of a component between which the actual size
should lie including the maximum and minimum.
 Nominal size: It is the size of the component by which it is referred to as a matter of
convenience.
 Basic size: It is the size of a part in relation to which all limits of variations are determined.
 Zero Line: It is the line w.r.t which the positions of tolerance zones.
 Deviation: It is ·the algebraic difference between a limit of size and the corresponding basic size.
 Upper Deviation: It is the algebraic difference between the maximum limit of size and the
corresponding basic size. It is denoted by letters 'ES' for a hole and 'es' for a shaft.
 Lower Deviation: It is the algebraic difference between the minimum limit of size and the
corresponding basic size. It is denoted by letters 'El' for a hole and 'ei' for a shaft.
 Fundamental Deviation: It is the deviation, either upper or lower deviation which is nearest to
the zero line for either a hole or a shaft. It fixes the position of the tolerance zone in relation to
the zero line.
 Allowance: It is the intentional difference between the hole dimensions and shaft for any type of
fit.
 Size of tolerance: It is the difference between the maximum and minimum limits of size.

LIMIT GAUGES
A Go-No GO gauge refers to an inspection tool used to check a workpiece against its allowed
tolerances. It derives its name from its use: the gauge has two tests; the check involves the workpiece
having to pass one test (Go) and fail the other (No Go).
It is integral part of the quality process that is used in the manufacturing industry to ensure
interchangeability y of parts between processes or even between different manufacturers. ·

A Go - No Go gauge is a measuring tool that does not return a size in the conventional sense, but
instead returns a state. The stat e is either acceptable (the part is within tolerance and may be used)
or it is unacceptable (and must be rejected).
They are well suited for use in the production area of the factory as they require little skill or
interpretation to us e effectively and have few, if any, moving parts to be damaged in the often hostile
production environment.

PLAIN GAUGES
Gauges are inspection tools, which serve to check the dimensions of the manufactured parts. Limit
gauges ensure the size of the component lies within the specified limits. They are non-recording and
do not determine the size of the part. Plain gauges are used for checking plain (Unthreaded) holes
and shafts.
Dept of Mechanical Engg. (ML-302053) 11

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Genba Sopanrao Moze College of Engineering, Balewadi Measurement Laboratory Manual

Plain gauges may be classified as follows;

According to their type:

(a) Standard gauges are made to the nominal size of the part to be tested and have the measuring
member equal in size to the mean permissible dimension of the part to be checked. A standard
gauge should mate with some snugness.
(b) Limit Gauges These are also called 'go' and 'no go' gauges. These are made to the limit sizes of
the work to be measured. One of the sides or ends of the gauge is made to correspond to
maximum and the other end to the minimum permissible size. The function of limit gauges is to
determine whether the actual dimensions of the work are within or outside the specified limits.

According to their purpose:

(a) Workshop gauges: Working gauges are those used at the bench or machine in gauging the work
as it being made.
(b) lnspection gauges: These gauges are used by the inspection personnel to inspect manufactured
parts when finished.
(c) Reference or Master Gauges: These are used only for checking the size or condition of other
gauges.

According to the form of tested surface :

(a) Plug gauges: They c heck the dimensions of a hole
(b) Snap & Ring gauges: They check the dimensions of a s haft.

According to their design:

(a) Sing le li m it & double limit gauges
(b) Single ended and double ended gauges
(c) Fixed & adjustable gauge

LIMI T GAUGING
Limit gauging is adopted for checking parts produced by mass production. It has the advantage that
they can be used by unskilled persons.
Instead of measuring actual dimensions, the conformance of product with tolerance specifications
can be checked by a 'GO' and 'NO GO' gauges.
A ' GO ' gauge represents the maximum material condition of the product (i.e . minimum hole size or
maximum shaft size) and conversely a 'NO GO' represents the minimum material condition (i .e.
maximum hole size or minimum shaft size)

Plug gauges:
Plug gauges are the limit gauges used for checking holes and consist of two cylindrical wear resistant
plugs. The plug made to the lower limit of the hole is known as 'GO' end and this will enter any hole,
which is not smaller than the lower limit allowed. The plug made to the upper limit of the hole is
known as 'NO GO' end and this will not enter any hole, which is smaller than the upper limit allowed.
The plugs are arranged on either ends of a common handle.

Dept of Mechanical Engg. (ML-302053) 12

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Genba Sopanrao Mo
oze College of
o Engineering, Balewadi Measurem
ment Labora
atory Manua
al

Plug gauges are normally double ended forr sizes upto

o 63 mm and
d for sizes aabove 63 mm
m they are
single en
nded type.

The handlees of heavy plug gaugess are made of light mettal alloys wh
hile the han
ndles of smaall plug
gauges can
n be made of
o some nonmetallic maaterials.

Progressive plug gau uges:

For smalleer through holes,
h both GO
G & NO GO O gauges aree on the sam
me side sepaarated by a small
distance. After
A the full length of GO
G portion enters
e the h
hole, furtherr entry is ob
bstructed byy the NO GO
O
portion if the
t hole is within
w the to
olerance lim
mits.

Deptt of Mechaniical Engg. (M

ML-302053)) 13

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Genba Sopanrao Mo
oze College of
o Engineering, Balewadi Measurem
ment Labora
atory Manua
al

Ring gaugges:
Ring gaugees are used for gaugingg shafts. Theey are used in a similar manner to that of GO & NO GO
plug gaugees. A ring gaauge consistts of a piece of metal in which a ho
ole of requirred size is bo
ored.

SNAP (or)) GAP GAUG GES:

A snap gauuge usually consists of a plate or frrame with a parallel facced gap of th
he required
d dimension.
Snap gauges can be ussed for bothh cylindricall as well as n
non-cylindrrical work aas comparedd to ring
gauges wh hich are conveniently used only forr cylindricall work.
Double-ennded snap gaauges can be used for sizes
s ranging from 3 to 100 mm.
For sizes above
a m upto 250 mm a singgle ended prrogressive ggauge may b
100 mm be used.

Deptt of Mechaniical Engg. (M

ML-302053)) 14

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oze College of
o Engineering, Balewadi Measurem
ment Labora
atory Manua
al

Double
D Ende
ed gap gauge Progresssive gap ga
auge

e properties of Gauge Materials:

Desirable
The essenttial considerations in th he selection
n of materiaal of gauges are:
(a) Hardness
H to resist wear.
(b) Sttability to preserve sizee and shapee
(c) Corrosion resistance
(d) Machinability
M y for obtain
ning the requuired degreee of accuracy.
Low coeffiicient of fricction of expaansion to av
void temperrature effectts

Taylor's Principle
P off Gauge Dessign:
According to Taylor, 'Go' and 'No o Go' gaugess should be d designed to
o check maxximum and m minimum
material limits which are checked as below:
'GO' Limitt. This desig
gnation is ap pplied to thaat limit of thhe two limitts of size wh hich corresp
ponds to the
e
maximum material lim mit considerations, i.e. upper limitt of a shaft aand lower limit of a hole.
The GO gauges should d be of full form,
f i.e. theey should chheck shape aas well as siize.
No Go' Limmit:
This designation is ap pplied to thaat limit of th he two limitts of size wh
hich corresp ponds to thee minimum
material coondition. i.ee. the lower limit of a sh haft and thee upper limiit of a hole.
'No Go' gauuge should check only one part or feature of tthe compon nent at a timme, so that sp
pecific
discrepanccies in shape or size can n be detecteed. Thus a sseparate 'No o Go' gauge is required for each
different in
ndividual diimension.

Gauge Tollerance:
Gauges, lik
ke any otherr jobs require a manufaacturing toleerance due to reasonab
ble imperfections in the
workmansship of the gauge
g maker. The gauge tolerance should be k kept as miniimum as po
ossible

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though higgh costs are involved to o do so. The tolerance oon the GO & NO GO gau uges is usuallly 10% of
the work tolerance.
t
Wear Alloowance:
The GO gauges only are subjected d to wear duue to rubbin
ng against tthe parts duuring inspecction and
hence a prrovision hass to be madee for the weear allowancce. Wear allowance is taken as 10% % of gauge
tolerance and
a is allow wed between n the tolerance zone off the gauge aand the maxximum mateerial
condition. (i.e. lower limit
l of a ho
ole & upper limit of a sh
haft). If the w
work toleraance is less tthan 0.09
mm, wear allowance needn not bee given unless otherwisse .stated.

Numerica al 1:
Shafts of 75
7 0.02mm m diameter area to be cheecked by the ‘GO’, ‘NOT
T GO’ snap ggauge. Desiggn the gauge
e,
d NOT GO size dimensiions. Assum
sketch it and show itss GO size and me normal w
wear allowan nce and
gauge marrker’s toleraance.

Solution:
Dimension ns of shaft = 75 0.02 mm
ULS = 75.02 mm m
LLS = 74.98 mm m
Shaft tolerrance = 0.044 mm
Assume Gaauge Makerr's tolerancee = 10% of shaft
s tolera nce = 0.0044 mm
Wear
W allowaance = 10%
% of Gauge m
maker's toleerance = 0.0004
Diimension off No Go end = LLS
.
= 74.98 .
ULS − WA
W = 75.0 2 − 0.0004
= 75.0196 m
mm
Dimeensions of Go end = (UL
LS − WA)
.
= 75.0196 .

Skettch for the Gauge

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Numerical 2:
Design the general type Go and No Go gauge for component having 20H f fit.
1. = 0.45 √D + 0.001D(D in mm)
2. Fundamental deviation of the shaft = −5.5D .
3. IT 7 = 16i
4. IT 8 = 25i
5. Wear allowance 10% of gauge tolerance

Solution:
Basic size = 20 mm
20 mm lies in step range 18 to 24 mm
D = √18 × 24 = 20.78 mm
i = 0.45 √20.78 + 0.001D = 1.258 micron
= 0.0013 mm
For Hole H7
LLH = 20.00
ULH = Basic size + deviation
Deviation for upper 7 = 16i = 0.021 mm
ULH = 20.021 mm
Job tolerance = 0.021 mm
Gauge tolerance = 10% of job tolerance on each end (assumed) = 0. 0021 mm
Wear allowance
For the plug gauge = 10% gauge tolerance = 0.00021mm

Numerical 3:
Design a workshop type of Go and No Go ring gauge for inspection of 40f8 shaft. Use following data
i = 0.45√D + 0.001D
diameter step 30-50
fundamental deviation for f = −5.5D .
standard tolerance grade IT 8 = 25i

Solution:
Shaft 40f8
D = √30 × 50 = 38.73 mm
= 0.45 √D + 0.001D
i
= 0.45 √38.73 + 0.01 × 38.73
= 1.56micron = 0.00156 mm
Stand tolerance = 25i = 25 × 0.00156 = 0.039 mm
es = −5.5D . = −5.5 × 38.73 .
= −24.63 micron = −0.025 mm
ei = −0.025 − 0.039 = 0.064 mm
ULS = Basic size + e
= 40 − 0.025 = 39.975 mm
LLS = 40 − e = 40 − 0.064 = 39.936 mm
Shaft tolerance = 39.975 − 39.936 = 0.039 mm
Gauge tolerance = 0.0039 mm (assumed 10% of shaft tolerance)
WA = 0.00039 mm (assumed 10% of gauge tolerance)
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ULS - WA = 39.975 − 0.00039 = 39.9746 mm

No go end = LLS
.
= 39.936
Go end = (ULS − WA) mm
= 39.9746 . mm

Numerical 4:
Compute the limiting dimension for the hole and shaft pair 52 H7/d10. State the type of fit. Compute
the minimum and maximum allowance.
Given data
52 mm falls in the diameter steps of 50 − 65 mm
Fundamental deviation for a type of shaft = −16D .
i.e. 0.453 √D − 0.01D
IT7 = 16i
IT10 = 64i

Solution:
Fit 52H7/d10
Basic size = 52 mm
D = √50 × 65 = 57 mm
i = 0.453√57 + 0.001D
= 0.0453 √57 + 0.001 × 57 = 1.8 micron
= 0.0018 mm
For hole
LLH = 52 mm; ULH = 52 + IT7
IT7 = 16i = 0.029 mm
∴ ULH = 52.029 mm
Hole tolerance = 0.029 mm
Gauge tolerance = 0.0029 mm
WA = 0.00029 mm
No go end= (52.029) . mm
.
Go end = (52 + 0.0029) mm
.
= (52.0029) mm

For shaft
Fundamental deviation,
e = −16D . = −16 × 57 .

= −94.8 micron
= −0.095 mm

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= 52 − 0.095 = 51.905
10 = 64 = 0.115
= − = −0.095 − 0.115 = −0.21
= 52 − 0.21 = 51.79
ℎ = 51.905 − 51.79 = 0.115
= 0.0115
= 0.00115
− = 51.905 − 0.00115
= 51.904

No go end= (LLS) . mm
.
= (51.79) . mm
Go end = (ULS − WA) mm
.
= (51.904) . mm

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EXPERIMENT NO: 03
Determination of geometry and dimensions of given
composite object / single point tool, by using Optical
Projector / Tool makers’ Microscope.

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EXPER
RIMENT NO : 03

Title: Dettermination of geom metry and dimension ns of givenn compositte object / single
point tooll, by using Optical Pro
ojector / To
ool makerss’ Microsco
ope.

Aim: To study
s Deteermination of
o geometry & dimensio ns of given ccomposite o object using
profile pro
ojector and measuremen
m nt of variouss angles of siingle point ccutting tool u
using tool
maker’s miicroscope.

us:
Apparatu

Sr. No. Instru

ument
1 Toool Makers Microscope
M e
2 Prrofile Projecctor, templaate of threadded compon
nent, trace p
paper, penciil

Theory:
1. Tool Ma akers Microscope:
The toolm maker’s micrroscope is a versatile instrumentt that measu ure by optiical means wwith no
pressure being
b involv
ved, thus very useful for measuremment on smaall and deliccate parts.
It is design
ned for:
a) Measu urement on parts of co omplex form m e.g. - proofile of extternal threaad, tool, tem
mplates,
gauges, etcc.
b) Measuring centre to centre distance of holes in any plane.

Fig.
F 1 Tool Makers
M Miccroscope

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Tool maker’s microscope is shown in Figure 1. The optical head can be moved up or down the
vertical column and can be clamped at any height by means of clamping screw. The table, which
is mounted on the base of the instrument, can be moved in two mutually perpendicular
horizontal directions (longitudinal and lateral) by means of accurate micrometer screw having
thimble scale and venires.

Principle of Measurement:
A ray of light from a light source Figure 2. b is reflected by a mirror through 90’ It then passes
through a transparent glass plate (on which flat parts may be placed). A shadow image of the
outline or counter of the workspaces passes through the objective of the optical head and is
projected by a system of three prisms to a ground glass screen. Observations are made through
an eyepiece. Measurements are made by means of cross lines engraved on the ground glass
screen. The screen can be rotated through 360’; the angle of rotation is read through an
auxiliary eyepiece.

Fig. 2 Principle of Measurement

A) Pitch Measurement:
a. Take the screw pitch gauge and mount on the moving table of tool maker’s Microscope in
horizontal position.
b. Focus the microscope on the screw pitch gauge.
c. Make the cross line in the microscope coincided with one of the edge of the screw pitch
gauge.
d. Take a reading on ground glass screen, this is the initial reading.
e. The table is again moved until the next edge of the screw pitch gauge
coincides with the cross-line on the screen and the final reading takes.
f. The difference between initial and final reading gives pitch of the screw pitch gauge.

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B) Teeth Angle:
a. Place the single point cutting tool on the table in same position.
b. Rotate the screen until a line on the angle of screen rotation is noted.
c. Take the angular reading, the initial one.
d. Again rotate the screen until the same line coincides with the other side of the tool.
e. Take the final angular reading.
f. The tool angle of single point cutting tool is the difference between the two angular
readings.

Observation Table:
Component: Screw Pitch gauge
Sr. Dimensions to Initial Final Difference
No. be Measured Reading Reading
1 Pitch
2 Tooth Angle

2. Profile Projector:
Profile projector (refer Fig.3) displays the magnified image of the components which are
difficult to be measured by other methods. The magnified image can be compared with some
standard for its dimensions, form etc.
• The Profile projector consists of:
• A projector having light source, a condenser or collimating lens.
• Work Holding table.
• Projection system having mirrors and lenses.
• Screen on which image of the workpiece is projected.
• Measuring devices.
The light source is a tungsten lamp, filament lamp or high-pressure mercury lamp. A strong
beam of light consisting of concentrated bundle of parallel right rays is produced by optical
means. The two common arrangements of light sources used in optical projectors are shadow
contour diascopic and surface (episcopic). The image of the object may be produced either on
horizontal or vertical screen. Surface illumination produces a reflecting image of the object on
the screen. The objects to be tested are placed on the work table. The lenses are used to obtain
desired magnification and mirrors to direct the beam of light on the screen. Normally 10x, 20x,
50x, 100x magnification is done.
Screens usually made of acrylic plain glass used for measurement. The work table is provided
with means for measurement like micrometer. Angles can be measured by rotating the screen.
The screen is divided into 360º with 90º cross line marking.

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Procedurre:
a. Switchh on the profile projecto
or.
b. Place the
t clean wo orkpiece on the glass off the table.
c. Focus it properly by movingg focusing wheel
w and mmoving the work tablee to obtain correct
magniffied image of
o the objectt.
d. Horizoontal (x axiis) measureement can be taken b by right haand side miicrometer aand the
verticaal measurem
ment can be taken from m front side m micrometerr.
e. To meaasure pitch take the distance betw ween two si milar pointts on adjaceent flank or crest to
crest or
o root to root on ad djacent threeads, parall el to the aaxis of the screw threead. For
achieving this adjjust the refference linee on the proojector to tthe corresp
ponding points and
note thhe micrometer readings between these
t pointss.
f. For meeasurementt of thread angle match the refereence line between flan nks and notte down
the anggle.
g. Image of the comp ponent can beb compareed with masster templatte or chart.

Fig.3 Profile Pro

ojector

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Observation Table:
Component: Screw Pitch gauge
Sr. Dimensions to be Initial Final Reading Difference
No. Measured Reading
Pitch
Tool Angle

Conclusion: Thus dimensions of given component i.e. single point cutting tool is measured by tool
maker’s microscope and profile projector.

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EXPERIMENT NO: 04
Surface roughness measurement of a given sample
using surface tester.

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EXPERIIMENT NO:: 04
Title: Surfface roughn
ness measu
urement of a given sam
mple using ssurface tester.

Aim: To sttudy surfacee roughness using surfacce roughnesss tester.

SURFACE FINISH ME
EASUREMEN
NT METHO
OD
Surface finish testing g of small--diameter stainless
s steeel tubing measures roughness, or the
texture, off a given su
urface. It is quantified by the verttical deviatiions of a reeal surface ffrom its
ideal form
m. If these deviations
d are
a large, th he surface iis rough; if they are sm mall, the su
urface is
smooth. Roughness
R plays
p an impportant rolee in determiining how a real object will interaact with
its environ
nment. Alth hough rough hness is usu
ually undesiirable, it can n be difficullt and expennsive to
control duuring the manufacturin
m ng process. Decreasingg the rough hness of a surface will usually
increase manufacturi
m ing costs, an
nd this ofteen results in
n a trade-offf between the manufaacturing
cost of a component
c and its perfformance inn applicatioon. It is of uttmost impo ortance to cconsider
the end usse of the pro
oduct prior tot determin ning the dessired surfacee finish valuue.

Example : MEASURE
EMENT PRO
OCESS

K-Tube usses a contact surface prrofilometer to measuree OD/ID surrface finish for parts w with ID >
.017 inch. This methood involves dragging a measurem ment stylus aacross the ssurface of th he tube.
The surfacce features are measurred relativee to the drivve unit referrence surfaace. This acccurately
measures waviness and finely sttepped featu ures in addiition to surfface roughn
ness. The callibrated
profilometter reports the results in Rq, Ra an
nd Rz (desccription and d formulas b below). “The series
is equippeed with Rq calibration n and step calibration n methods ffor detector calibratio on (gain
adjustmennt). In both calibration
n methods only
o the callibrated vallue of the pprecision sppecimen
needs to be
b entered.”1 No other operations
o are required to calibraate the testeer.

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Procedurre for Samp ple Prepara ation & Testing Using Surftest
a. A 6 inch
h sample is randomly
r seelected from
m productioon.
b. A one in
nch window w is ground into
i the OD surface so tthat the ID iis visible.
c. Any dirtt and metal shavings arre removed from the su urface with compressed air.
d. Test sammple is placeed on flat suurface and secured
s from
m movemen nt during teesting.
e. Contactting stylus iss placed direectly over thhe center off test samplle.
f. Stylus iss gradually lowered
l until it comes in contact wwith the tubbe surface.
g. Stylus profiles
p the surface
s of th
he tube, measuring rou ughness oveer a distancee of 3/16 inch in
the longgitudinal dirrection.

Conclusio on: Hence we have sttudied abou ut surface flatness ussing optica l flat for diifferent
surfaces we
w got diffferent pattterns as sh hown in T Table 1. A And also m measured surface
roughness for the saame.
*In order to determinne whetherr the surfacee is convex or concavee, it must bee pressed w with the
finger tip at the centtre of the rings.
r If thee colour fri nges move away from m the cen ntre, it
indicates convexity;
c and
a if they move
m in tow
wards the ce ntre, the su
urface is con
ncave.

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EXPERIMENT NO: 05
Verification of dimensions and geometry of given
components using Electric /Mechanical /Optical
/Pneumatic comparator in context of manufacturing

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EXPERIMENT NO: 05
Title: Verification of dimensions and geometry of given components using Electric
/Mechanical /Optical /Pneumatic comparator in context of manufacturing.

Aim: To study Verification of dimensions & geometry of given components using Mechanical &
Pneumatic comparator.
Apparatus:
Sr. No. Instrument
Mechanical comparator-with Dial indicator and Work piece-Any 5 jobs
1
of size within the range of comparator and master jobs, slip gauges.

Theory:
A comparator is a device used to get dimensional variation between unknown Dimensions of a
part and same standard or master setting (slip gauge).

The comparator is a device, which takes a dimension of standard job as reference dimension,
and Gives a reading to a pointer on a scale, the variation in such dimension of the job to be
compared Upper end of the vertical beam, and an adjusting screw is provided for final zero
setting of the scale.

A new-patented feature is shown at K. This is a magnetic counter balance which serves to

neutralism the positive 'rate' of spring reaching on the measuring tip. In this way a constant
pressure over the whole scale range is achieved. The instrument is available with vertical
capacities of 6‟, 12', and 24,' and magnification of 500, 1000, 500, 3000 and 5000.

The scales are graduated both in English and Metric systems. The least count is of order of 10R
Inch. A worktable on the base of this comparator stand is used to keep the job on. Special
attachments are used for typical jobs like screw thread effective/outside diameter.

Dial indicator type of mechanical comparator consists of a sensitive dial indicator mounted on a
Horizontal arm on a stand. The arm is capable of coarse and fine adjustment movements in the
Vertical direction for initial setting of the Instrument. The base is heavy so that stability and
rigidity of the instrument is ensured.

Based on principle used for magnification:

1. Mechanical comparators.
a. Dial-indicator
b. Johnson mikrokator
c. Read-type mech. Comparators
d. Sigma comparators
2. Mechanical-Optical comparators
3. Electrical and Electronic comparators
4. Pneumatic comparators
5. Fluid displacement comparators

Types of comparator:
1. Mechanical comparator
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Principle – It works ono the principle of con nverting lin

near momen nt into angu
ular using rrack and
pinion. It uses
u the geaar train for magnificatio
m on & scale p
pointer as in
ndicating deevice.
2. Pneum matic comp parator

Principle –Pneumatic
– c comparato or works on n the principle of back k pressure. A simple p pressure
regulator which
w may control the pressure off air from th he normal supply line iis provided in Solex
gauge by passing thee high pressure air aftter filteringg through a flow valvee. Here is a tank in
which water is filled d up to a ceertain level and a dip tube is im mmersed intto it up to a depth
correspon nding to air pressure reequired. Sin nce air is seent at higheer pressure than requirred one,
some air will
w leak ou ut from dip p tube and bubbled ou ut of water,, and the air moving ttowards
control orrifice will bee at desired
d constant pressure
p H. The air at reduced pressure than n passes
thought th he control orifice
o and escape
e from
m the measuring jets. Th he back preessure in thee circuit
is indicateed by a headd of water diisplaced in the
t manometer tube.
The tube is i graduated linearly to show chaanges in preessure resullting from cchanges in internal
diameter of o the work measured.

Advantag ges of Pneumatic Comparators

a. The gaauging mem mber does notn come in to contact with the paart to be measured and hence
particuularly no weear takes plaace on the gauging
g memmber.
b. It has usually verry small nu umber of moving
m partss and hencce some casses none. T
Thus the
accuraacy is more due to less friction and less inerttia. Measuriing pressure is very sm mall and
the jet of air helpss in cleaningg the dust, iff any, from tthe part to b
be measured.
c. It is po
ossible to haave very higgh magnificaation.
d. The ind dicating insstrument can be remotee from the m measuring u unit.
e. It is very
v suitable device fo or measurin ng diamete r of holes where the diameter iis small
Compaared with a length.
f. It is probably thee best meth hod for dettermining th he ovality and tapern
ness of the circular
bores.

Disadvantages of Pn neumatic Co omparatorrs:-

a. It requ
uires elaboraate auxiliaryy equipmen nt such as acccurate presssure regulaator.
b. The scaale is generally not uniform.
c. When indicating device
d is th
he glass tubbe, then higgh magnificaation is neccessary in o
order to
avoid the
t meniscu us errors.
d. The appparatus is not
n easily po ortable and is rather ellaborate forr many indu
ustrial appliccations.
e. Differeent gauging heads are required
r forr different d
dimensions.
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EXPERIMENTATION:
Mechanical comparator:-
Instruments used:
a. Dial gauge indicator
b. “V” block
c. Slip gauges
Construction:-
It consist of dial gauge indicator which indicates rack & pinion springs , gear, plunger, guide
way, printer, scale, support with helical gear. It has six gear meshing together as A, B, C, D, E & F.
Pointer shows reading. Coil H is used for avoiding backlash.

Working:-
When plunger „P‟ moves up with rack R‟, Gear A rotates as shown in figure. Linear movement is
converted into angular movement. As A & B rotates D also rotates, which is meshed with C gear
rotates. To the centre of E pointer Po is attached. The pointer Po shows reading on the scale.
Gear H is used for support whereas spring coil H is used for avoiding backlash. Guide way G is
used for support plunger. The spring is used to maintain pointer at O position when plunger
movement is zero. It is self-control & no power or any other form of energy required to it. It
employs mechanical stylus for magnifying the small of movement of measurement. The
Movement mechanism of the instrument is housed in metal case for its protection from any
damages.

Procedure:
A) Checking the flatness of given object –
a. Fix the dial gauge indicator to the stand.
b. Measure the height of given object.
c. Take the slip gauge of same height.
d. Set the slip gauges below the plunger & set to the dial gauge pointer to Zero level.
e. Remove the slip gauges.
f. Now adjust the given component below the plunger of dial gauge indicator & give some
movement to the component.
g. If components having some irregularities the pointer will give some deflection

B) Checking of roundness of given objects:-

a. Fix the dial gauge indicator to the stand.
b. For the measurement of roundness of given object take a V block.
c. Put the object on V block & set it below plunger of dial gauge indicator.
d. Rotate it in clockwise or anticlockwise direction.
e. More deflection of pointer will indicate the ovality of roundness.

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Observation Table:
Work Standard
Comparator Reading
piece. dimensions
A 55 55.3 55.1 55.5

B 85 85.8 85.2 85.4

Conclusion:
From above observation table we conclude that, work piece comparing with standard
dimensions there is slight deflection in the comparator reading due to surface roughness.

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EXPERIMENT NO: 06
Experimentation by using Gear Tooth Vernier
Caliper

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EXPERIIMENT NO:: 06

Title: Experimentatioon by usingg Gear Tooth Vernier C Caliper.

Aim: To sttudy Measurrement of sp
pur gear parrameters usiing Gear Too
oth Vernier, Span, Gear R
Rolling
Tester.

Apparatu
us:

Sr.
Instru
ument
No.
1 Gear Tootth Vernier ccaliper
2 Bench vicce

Theory:
1. Gear Toooth Vernier Caliper: It is used to o measure tthe thicknesss of gear teeeth at the p
pitch line
or chordall thickness of
o teeth and oth to the cchord. The thickness
d the distance from thee top of a too
ddendum iss measured by an adjustable tonggue, each of which is
of a tooth at pitch line and the ad
adjusted independently by adjussting screw w on graduaated bars. The effect off zero errorrs should
nto considerations. (Reefer Fig. 1)
be taken in

Fig. 1 Gear Tooth

T Vern
nier Caliperr

2. Termin
nology of Ge
ear Tooth:

1. Pitch ciircle diameeter (PCD):: It is the diaameter of a circle, whicch by pure rrolling action
would pro oduce the saame motion on the tootthed gear w wheel.
It is equal to
x
=
( + 2)

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Genba S
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oze College off Engineering
g, Balewadi Measurem
ment Labora
atory Manua
al

Where,
OD = outside d iameter.
T = number oof teeth

e: It is defineed as the len

2. Module ngth of the pitch circlee diameter p
per truth, an
nd is expresssed in mm.
Module
M m=D D/T

Circular Pitch
P (CP) : It is the arcc distance measured
m arround the p
pitch circle from the flaank of one
tooth to a similar flan
nk in the nexxt tooth.
Addendumm: This is the
t radial distance
d from
m the pitch he tip of the truth. It is equal to
h circle to th
one module.

3. Clearannce: This is the radial distance

d from
m the tip off a tooth to the bottom of the matiing
tooth spacce when thee teeth are symmetrical
s lly engaged
d. Its standarrd value is 0
0.157m or 0
0.25m.

4. Dedendum: This is
i the radiall distance frrom the pitcch circle to tthe bottom of tooth spaace.

dum = Addeendum +Cleearance = m +0.157m = 1.157m.=1

5. Dedend 1.25m (metrric gearing
system)

= Addendum + Clea rance

m + 0.157m
m = 1.157m. = 1.25m

6. Tooth Thickness:
T This is the arc
a distancee measured along the p pitch from th
he intercepts with
one flank to
t the intercepts with the
t other flaank of the saame tooth.

Fig. 2 Termin
nology of G
Gear Tooth

3. Procedure:
For finding PCD, module, addend dum, dedend
dum and cleearance:
a. First fin
nd the blank
k diameter, OD
O by a vernier caliperr and also co
ount the number of teeeth T
of the sppur gear.
b. Next callculate pitch
h circle diam
meter
c. Find addendum, cleearance, pittch, module and Deden dum as perr the formulae given in the theory.

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Genba S
Sopanrao Mo
oze College off Engineering
g, Balewadi Measurem
ment Labora
atory Manua
al

FOR CHOR
RDAL TOOT
TH THICKN
NESS (using
g gear tooth
h caliper):

a. Set the chordal

c dep
pth (addenddum) on thee vertical sli de of the geear tooth Veernier and tthen
insert th he instrumeent on the tooth to be m
he jaws of th measured.
b. Adjust the
t horizonttal Vernier slide
s by the fine adjustiing screw so that the jaaws just
touch thhe tooth.
c. Read the horizontaal Vernier slide and notte the readinng. It gives tthe chordal thickness oof tooth.
d. Repeat the
t observaations for th
he different teeth.
e. Comparre the values of differen
nt characterristics with the standarrd value and d set the
percenttage error.

4. Observvations:
a. Least co
ount of calip
per= 0.02 mm.
m
b. Numberr of teeth= 40
4

T
Table for Se
etting Gearr Tooth Caliiper For Sp
pur Gear

Fig.3
F Chord
dal Tooth T
Thickness

Chordal Th
hickness:

Sr No. M.S.R V.S.R Ch

hordal Thicckness Verificattion (Digita
al
(M
M.S.R+V.S.R
R*L.C) Vernier CCaliper)

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Tooth Height:

Sr No. M.S.R V.S.R Chordal Thickness Verification

(M.S.R+V.S.R*L.C) (Digital Vernier
Caliper)

4. Calculations:

a. Pitch circle diameter

b. module
c. Addendum
d. Dedendum= m + 0.157m = 1.157m. = 1.25m

Conclusion: Hence, we have various gear parameters of gear using gear tooth Vernier caliper and Span
micrometer.

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EXPERIMENT NO: 07
Fundamentals of measurements and Calibration
process by using Dead weight Tester/Strain Gauges

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Title: Fundamentals of measurements and Calibration process by using Dead weight

Tester/Strain Gauges/Pressure Gauge/Dial calibration Tester.

Aim: Study of Dial Gauge using Dial Calibration Tester

Apparatus:

Sr.
Instrument
No.
1 Dial Calibration Tester

Theory:
Dial indicators, also known as dial gauges and probe indicators, are Instruments used to accurately
measure small linear distances, and are frequently used in industrial and mechanical processes. They
are named so because the measurement results are displayed in a magnified way by means of a dial.

Dial indicators may be used to check the variation in tolerance during the inspection process of a
machined part, measure the deflection of a beam or ring under laboratory conditions, as well as many
other situations where a small measurement needs to be registered or indicated. Dial indicators
typically measure ranges from 0.25 mm to 300 mm (0.015 in to 12.0 in), with graduations of 0.001
mm to 0.01 mm (metric) or 0.00005 in to 0.001 in (imperial)

Applications:
a. To check for run out when fitting a new disc to an automotive disc brake. Run out can rapidly
ruin the disc if it exceeds the specified tolerance (typically 0.05 mm or less).
b. In a quality environment to check for consistency and accuracy in the manufacturing process.
c. On the workshop floor to initially set up or calibrate a machine, prior to a production run.
d. Dial indicators help users measure the distance between two plates, but the readings given by
the tool could be faulty.

Procedure:
a. Wipe the surface plate, the gauge blocks and the tip of the dial indicator's plunger to remove
any dirt or debris. Lock the dial indicator in place on its stand, resting the indicator high
enough to allow the plunger to travel its full length and still be able to touch off against the
surface plate.
b. Rest the tip of the plunger directly on the surface plate. Rotate the indicator's face until the "0"
marking aligns with the dial.
c. Raise the plunger and slip a 0.020-inch gauge block underneath. Lower the plunger onto the
surface of the gauge block. Check that the indicator reads 0.020-inch. Raise and lower the
plunger two more times to check that the dial indicator gives the same measurement in the
same spot repeatedly.
d. Repeat the process with 0.025-inch, 0.050-inch, 0.100-inch, 0.250-inch, 0.400-inch and 1- inch
gauge blocks. Check each block three times to ensure the dial indicator's repeatability. If the
indicator's plunger reaches a 2-inch depth, stack the blocks to check the dial indicator at
1.025-inch, 1.050-inch,

Electronic Dial Gauge Tester:

[l.C: 0.0001 mm] in association with sylvan, Switzerland. It meets the Iso 9000 requirements for
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periodic calibrations of one micron least count dial gauges [l.C: 0.001].
The equipment is useful for periodic calibration of plunger type dial gauge and lever types dial
gauges and bore gauges. It includes rigid stand having dial gauge fitting arrangement on upper
holder and micro screw with probe in the holder below the same.

The dial gauge holding system is having mechanism of fine adjustment for setting the dial gauge.
This is the specialty of the design. The digital unit indicates movement of probe that is fitted in
micro screw.
The digital indication unit is having a required operating switch for setting different modes that
consists of change of resolution either 0.0001, 0.001, or 0.01 mm.

Conclusion: Hence, we have studied Dial gauge calibration.

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EXPERIMENT NO: 08
Applications of Open Education Resources like
Scilab in measurement / Students should develop
any online calculator

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