Faculty of Engineering, Architecture and Science

Department of Mechanical and Industrial Engineering

Program: Mechanical Engineering/Industrial Engineering

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Introduction

The objective of this lab was to aid participating students in learning how to use optical
measuring tools. The lab consisted of 3 parts:
Part A - Optical Projector
Part B- Toolmakers microscope
Part C: Measurement Using Optical Flats
The optical projector works by projecting an image of the vertical pin (object used for
measurement) on its screen, where different scales are used to measure diameters and pitches.
Toolmakers microscopes are often used for making linear measurements on very small parts. In
this case, diameters of holes on a watch plate were measured. Optical flats are mainly used for
testing the flatness of surfaces with monochromatic light and a pattern of interference fringes. In
this case, a helium light source was used to measure the diameter of a cylindrical plug gage.

Procedure

Calibration
1) Align the Zero mark of the Vernier protractor on the screen with the scale.
2) Use the vertical and horizontal pins to calibrate the machine further. Move the table accordingly
to align the pins with the horizontal marker on the screen to complete the calibration.
1)
2)
3)
4)

1)
2)
3)
4)

Magnification
To measure magnification, align the vertical pin with the centre cross hair on the screen
using a ruler, measure the magnifies diameter of the pin on the screen (end to end)
Then, using Vernier calipers, measure the diameter of the actual pin
Divide the magnified value by the actual value to get magnification number
Part A: Optical projector
(Note: Divide all measurements by 50 to get unmagnified value)
Setup the object given to measure between the fixed pins on the table and move the table so the
threads of the object are visible on the screen
To calculate the major diameter, measure the length of the threads from the top end to bottom
end (Refer to figure 1)
To calculate the minor diameter, measure the length from the inner end on top to the inner end on
the bottom (Refer to figure 1).
To find the average pitch, measure the horizontal distance from the top point of one thread to a
thread 4 spaces away. Divide the number by 4 to find pitch.

Figure 1
5) Find the major and minor diameters and the pitch values again using the micrometer on the
projector.
Part B: Toolmakers microscope
1) Calibrate the microscope by aligning the protractor scale with the 0 (Figure 2). Place a ruler or a
straight object under the microscope and while looking under the scope, see if the horizontal
dotted line runs parallel to the straight object.
2) When calibrated, place the watch plate (Figure 3) under the scope such that the pins centre line is
parallel to the horizontal cross line on the eye piece.
3) Measure the diameter of the holes on the watch plate by measuring the outer edge and then then
inner edge.

4) Record values and subtract one from the other.

5) Repeat for hole two.

Figure 2

Figure 3

Part C: Measurement Using Optical Flats

1) Place optical flat on cylindrical plug gage.
2) Moved the optical plate to get a resolution.
3) Measured diameter of the cylindrical plug gage within the resolution with the monochromatic
helium light source (=23.2 in) and other dimensions given (Figure 4).

Figure 4

Results

Figure 5

Part A
Part 2
There was a measured value of 6.25in with a ruler that had a resolution of 0.01. After factoring the
magnification of 50X the actual diameter was determined to be 0.1251*10 -4in.
Analysis of Pin diameter [table 1]
Measured diameter
6.255*10-3in

Magnification
50X

Actual diameter
0.1251*10-4in

Part 3
The major and minor diameters were measured with a ruler with a resolution of 0.00001.
davg=(dmin+dmaj)/2, davg was then converted to the actual diameter by multiplying it by the magnification of
50.
Analysis of Screw diameter [table 2]
Major diameter
9.531255*10-6in

Minor diameter
7.343755*10-6in

Average diameter
8.43755*10-6in

Magnification
50X

Actual diameter
0.14875
1*10-7in

4 pitches were measured with a ruler with a resolution of 0.0001. This value was divided by four to
determine the average pitch. After factoring the magnification of 50X the actual pitch was found.
Pitch(4)/4=pitchavg
50*pitchavg=pitchactual
Analysis of Pitch [table 3]
4 Pitches
6.28155*10-5in

Average Pitch
1.57045*10-5in

Magnification
50X

Actual Pitch
0.0314071*10-6in

Part 4
Two peaks and a pitch diameter were found using a micrometer with resolution of 0.0001. The distance
between the two peaks was the pitch. The pitch diameter and pitch formed a right angle tringle where the
pitch diameter was adjacent to the lead angle and the pitch was opposite. Therefor tan -1(pitch/pitch
diameter)=lead angle
Analysis of Pitch with a micrometer [table 4]
Peak 1
0.1250
5*10-5in

Part B

Peak 2
0.1561
5*10-5in

Pitch
0.0311
5*10-5in

Pitch Diameter
0.1688
5*10-5in

Lead angle
10.440.01o

Two opposite points, Rn and Rn+1, of a hole were measured with a microscope with a resolution of
0.0001. the distance between these points was the diameter. This was repeated for 2 other holes.
Left hole dimensions [table 5]
R1
0.96085*10-5in

R2
0.91405*10-5in

Diameter
0.04685*10-5in

Right hole dimensions [table 6]

R3
0.65065*10-5in

R4
0.63055*10-5in

Diameter
0.02015*10-5in

Center hole dimensions [table 7]

R5
0.69905*10-5in

R6
0.76055*10-5in

Diameter
0.06155*10-5in

Part C
The equation below was used to find the plug gage diameter
[N* ()/2]/0.95=(D/2)/(0.95+0.734+0.9420/2) where n=22 (the amount of light fringes), =23.2 *10-6in
and D was the diameter of the plug gage diameter.
(1/n)/M= 0.0001 was used to find M the magnification
Plug Gage Analysis [table 8]
n(number of lines)

Magnification

(wavelength)

22

454

23.2*10-6in

Analysis of Results

Plug Gage
Diameter
1.1578*10-3in

Actual
Diameter
0.5257in

Part A
During part A of the experiment a micrometer and a ruler were used to measure values. When
measuring the diameter the ruler could have been inaccurate do to the experimenter having to
line up the ruler. To accurately measure the diameter the ruler must be held from one point to the
part of the circle that is the greatest possible distance away. It may have been difficult for the
experimenters to line this up properly.
Part B
During part B of the experiment a microscope was used. The vernier protractor had to be
manually lined up with the holes by the experimenter. This would allow errors to occur because
of a humans limited ability to line it up.
Part C
During part C of the experiment an optical flat was used. The experimenters had to count the
amount of bright fringes on the optical flat. The light waves could have travelled a greater
distance than the measured n value but only the bright fringes (lines). The true value of n could
have been as much as 0.5 greater than what it was measured to be.

Conclusion and Discussion

In conclusion, this experiment familiarized the experimenters with measuring tools that use
optical methods. The measuring tools used include an optical comparator, a toolmakers
microscope, and an optical flat. The optical comparator was used to measure the magnification of
a pin by mathematically comparing the actual value of the pin with the magnified value of the
pin. This magnification was maintained as the tool was used to measure various dimensions on a
screw. The measured values of the screw include its major diameter, minor diameter, average
pitch, pitch diameter, and lead angle. There were many possible errors that could have occurred
during the experiment. To decrease the sources of error, certain precautions must be taken. The
thread must have been cleaned from all contaminates such as oil and dust. This will ensure
accuracy of each reading. The person who is reading the values should be the same person and
read from the same spot to avoid parallax error and keep data precise. This procedure helped us
familiarize us with the optical projector to measure the profiles of a thread by ourselves. We were
successfully able to measure all the essential measurements of a common thread. Tools such as
the optical projector are usually used to inspect manufactured parts in the industry.
The toolmakers microscope was used to measure the centre distance of the pins as well as the
diameter of the hole on the watch plate. There have been many errors which could have led to
insufficient results. For future procedures, it would be more practical to measure one edge of a
circle to the other edge, instead of center to center because there is a lot of visual judgment
required. Also, the same person should be adjusting and reading the values to maintain precision.
We accurately learned how to use the toolmakers microscope and we were able to successfully
measure the diameter and the distances between two holes. This tool is usually used to measure
minute details and is commonly used in the automotive and electronic industry.
Finally, the optical flat was used to view the light bands and count the number of bright fringes
that were displayed. The wavelength of the monochromatic helium light, the dimensions of the
setup, and the number of total fringes were values used in order to calculate the diameter of the
cylindrical plug gage. The fringe sharpness and the reflective properties of the flat may have
contributed to parallax errors. Using a more accurate and well maintained flat will improved the
accuracy of the results. This tool is usually used to calibrate metal parts.

Lab Questions
1. Errors in the measurement of the major diameter could be created due to multiple reasons.
There could be an issue with the calibration of the projector, or a malfunction during use. There
could be errors in the measurement due to environmental effects changing the dimensions on the
screw, like the pressure applied from the clamps. Additionally, errors could be created due to
parallax or a poor understanding on how the micrometer scale works. The errors to do with
calibration, parallax, environmental effects and understanding of the micrometer scale would be
systematic error. Errors due to the optical projector malfunctioning would be a random error.
The errors could be reduced by making sure that the device is properly calibrated before using it,
that the people using the device understand how to read its measurements and that the users take
the average of multiple measurements.
2. Errors in the measurement of the pin using the toolmakers microscope could be created due to
mistakes in orienting the pin with the cross-lines on the eyepiece, issues with reading the vernier
scale and vibrations changing the position of the pin. The errors to do with calibration and
knowledge of the vernier scale are systematic errors, whereas the error to do with vibration
would be a random error. The errors could be reduced by making sure that the people using the
device understand the vernier scale and that they have practice orienting the pin. The errors
could also be reduced by having larger knobs on the microscope to give the user more fine tuning
and by making sure that the microscope is located in an area with little vibration.
3. The optical projector and toolmakers microscope could have broken lines instead of solid lines
because it makes it easier to ensure that the object you are measuring is actually level with the
line. If the line were solid, you would not be able to notice if the edge of the object was slightly
slanted because the slant would be covered up by the solid, opaque line.

References
(n.d.). Retrieved February 2, 2015, from http://glink.hu/kezikonyv/menetek_images/thread.gif

(n.d.). Retrieved February 2, 2015, from https://courses.ryerson.ca/bbcswebdav/pid-2897598-dtcontent-rid-4611110_2/courses/mec322_w14_01/metrology_lab_w2014.pdf

(n.d.). Retrieved February 2, 2015, from http://www.nist.gov/calibrations/upload/75-975.pdf

MM-200 Toolmakers Microscope | Measuring Microscopes | Video & Microscope Measuring |
Products | Nikon Metrology. (n.d.). Retrieved February 2, 2015, from
http://www.nikonmetrology.com/en_US/Products/Video-MicroscopeMeasuring/Measuring-Microscopes/MM-200-Toolmakers-Microscope