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. 1
Determination 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. Main Scale Vernier Scale C= L.C. X VSR Total Reading = MSR – C
No. Reading (MSR) Reading (VSR)
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.

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. 2
Machine 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:-
 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. 3
Study and Measurement of parameters using
Tool Maker’s Microscope.
1. Construction and Working Principle of Tool Maker’s microscope
2. Screw thread measurement.
3. Gear measurement
4. Tool wear measurement
5. Linear dimensions measurement
6. 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:-

Dimension Main Scale Vernier C= Total Difference

s Reading Scale L.C. X VSR Reading = between
(MSR) Reading (mm) MSR + C initial and
(VSR) (mm) final
Pitch Initial
Final
Major Initial
Final
Diameter
Minor Initial
Final
Diameter

Result:-
 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. 4
Exercise 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
 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. 5
Study 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 Vernier C= L.C. X Total Difference

Reading Scale VSR Reading = between
MSR Reading (mm) MSR + C Initial &
(mm) VSR (mm) Final
(mm) (mm)
Pitch Initial
Final
Major Initial
Diameter
Final
 Minor Initial
Diameter
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

 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. 6
Interferometry:
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: -
 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. 7
Surface 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: -
 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. 8
Assignment 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

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. 9
Measurement of Screw Parameters using
Floating Carriage Micrometer.
1. Screw Thread Terminology
2. Measurement of various elements of threads
a. Measurement of Major Diameter, External / Internal
b. Measurement of Minor Diameter, External / Internal
c. Effective Diameter Measurement
Thread Micrometer Method
• One Wire Method
• Two Wire Method
• Three Wire Method
d. Best Wire Size
Aim: - 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. Pitch (p) Wire Std. MSR CSR VSR Dimensio Dimensio Effective
no. (mm) Dia. Cyl. n over n under dia
(d) Size wire wire E =T + P
(mm) (mm) (mm) (mm) (mm) M T (mm)
(mm) (mm)
1
2
3
4
5

Result: -

1. Effective Diameter of Screw Thread = mm

2. Major Diameter of screw thread = mm

 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. 10
Precision Angular Measurement.
1. Sine Principle & Sine Bar
2. Characteristics of Sine Bar
3. Use of Sine Bar
4. Sine Centre
5. Vernier Bevel Protractor
6. 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 Angular Measure(θ)

position (H) = sin-1 (H / L)

Result: -

Angular Measurement of given component = Degrees.