Metrology

by

P.Venkateswara Rao
Professor in Mechanical Engg.
IIT Delhi

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 Inspection by Measurement
 Direct Measurement
◦ Vernier Caliper, Vernier Height
gauge, Verneir Depth gauge
◦ Outside Micrometer, Inside
Micrometer, Depth Micrometer,
◦ Slip gauges (gauge blocks), length
bars,etc.
 Indirect Measurement
◦ Comparators
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Slip gauge Box

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 Comparators
 Comparing the manufactured part to the
master part envisaged by the designer
 Dimensional variation from the master
part can be amplified and measured so as
to get the deviation and the instruments
for doing that are called comparators
◦ Mechanical Comparators
◦ Optical Comparators
◦ Pneumatic Comparators

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 Design Considerations
 The instrument must be sufficiently
robust
 The system response should be faster
 The contact plunger should be provided
with a hardened steel or diamond to
minimize wear & tear
 Means should be provided for easy lifting
of the plunger

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 Design Considerations
 Magnification should be as high as
possible, but it should also be capable of
measuring the wide range
 The recording scale should be linear
 The system should have good
repeatability
 Comparator should be versatile

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Mechanical Comparators
Dial Indicators

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Johansson Mikrokator

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Sigma Comparator

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Optical Comparator

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Zeiss Ultra optimeter

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Pneumatic comparator

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 Angular Measurements
 Angle Measuring Devices: Bevel Protractors & Angle
Gauges measure the angle between the surfaces of a part
or assembly

 Bevel Protractor: It normally can read about 5 minutes of a

degree. It consists of a sliding blade which can be set at
some with respect to the stock. The reading can be
obtained with the help of main scale and Vernier scale.

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 Angle Gauges
 A series of fixed angles are used for comparative
assessment of angle between two surfaces

 By making use of different permutations &

combinations, we could set an angle nearest to 3”.
The dimensions of the angle gauges are 75 mm length
&& 16 mm width.

 The set consists of 10, 30, 90, 270 & 410

1’, 3’, 9’, 27’ and 3”, 6”, 18”, 30”.

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Angular Gauges

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 Sine Bar
 A sine bar is a high precision angle measuring
instrument. It is used in conjunction with other
accessories such as slip gauges, angle gauges, etc.

 It consists of a bar carrying two rollers set at a

known centre distance. The options are 100 mm, 250
mm, etc.

 They are available in several designs.

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Sine Bar

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Sine Centre

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 Autocollimator
 Autocollimators are used to detect small
misalignments
 If a parallel beam of light is projected from the
collimating lens and if a plane reflector R is set up
normal to the direction of the beam, light will be
reflected back along the same path and light will be
brought back to focus exactly at the position of the
light source

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 Autocollimator contd..
 If the reflector is tilted through a small angle (q), the
parallel beam will be reflected through twice the
angle (2q) and would be brought to focus in the
same plane as the light source but to one side of it.
The image will not coincide but there will be a
distance equal to focal length times the angle of
reflection (2f q) where f is the focal length of the
collimating lens.

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 Autocollimator contd..
 The distance between the reflector and the lens has
no effect on the separation between the source and
the image.
 For high sensitivity, a long focal length is required
 Although the distance of the reflector does not
effect the reading, if it is moved too far back,
reflected rays will miss the lens completely and no
image will be formed.

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 Types of Gear Inspection
 Element by Element Inspection of Gear:
Laborious, useful in error analysis, can’t be
used by the gear manufacturers.
◦ Tooth thickness measurement
◦ Base pitch measurement
 Composite Error Checking: Used in Gear
Inspection by conducting only one test
 Parkinson Gear Tester

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Gear Tooth Vernier

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Base Pitch Measuring Instrument

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Involute Property

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Parkinson Gear Tester

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 Thread Inspection - Terminology
 Pitch: It is the distance measured parallel to
the axis between the corresponding points on
adjacent surfaces in the same axial plane.
 Lead: It is the axial distance advanced by the
thread in one revolution. Lead is equal to the
same multiples of pitches as the number of
starts.

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 Thread Terminology Contd..
 Included angle: It is the angle between the flanks of
the thread measured in an axial plane.

 Pitch diameter: It is the diameter of tee imaginary

coaxial cylinder which intersects the surface of the
thread in such a manner that the intercept on the
generator of the cylinder is equal to half the pitch.

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 Thread Terminology Contd..
 Major Diameter: It is the diameter of
imaginary coaxial cylinder that just touches
the crests
 Minor Diameter: It is the diameter of
imaginary coaxial cylinder that just touches
the roots
 Helix Angle (q):
tan q = p/p d

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 Thread Inspection
 Measurement of Major Diameter: Bench micrometer
is normally used for this measurement.

 It has measuring anvils so that the thread can be held

between them.

 It has fiducial indicator so that the required pressure

can be applied for all the measurements

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Bench Micrometer

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 Thread Inspection
 Measurement of Minor Diameter: Bench
micrometer can not be used for Minor
Diameter. So, another one, Floating Carriage
micrometer is normally used for this
measurement.

 In this instrument, the thread is held between

the centres so that the influence of helix
angle can be nullified in this arrangement.
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 Thread Inspection
 Measurement of Pitch (effective) Diameter: Again
Floating Carriage micrometer is normally used for
this measurement.

 Here, the prisms used in the measurement of minor

diameter are replaced by the steel wires whose size
is chosen such that they pitch at the effective
diameter.

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 Thread Inspection
 Diameter of the best wires: If the wires used
make contact exactly at the pitch diameter,
then such wire is called the best wire. The
diameter of such wire can be estimated from
the formula.

 Compression & Rake correction.

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Measurement of Internal Threads
 Measurement of Major Diameter: The major
diameter of internal thread is normally measured
using horizontal comparator fitted with ball end styli
of radius less than the root radius of the thread to
be measured.
 When the thread is mounted on a comparator, it
aligns itself with the axis of the machine and
measurement would be done along the helix of the
thread as indicated above.

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Measurement of Int. Threads

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Measurement of Internal Threads
 Measurement of Minor Diameter: Calibrated
rollers and slip gauges are used for this
measurement as shown below.

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Measurement of Internal Threads
 Measurement of Effective Diameter: The effective
diameter of internal thread is measured using the
horizontal comparator using ball ended styli of the
best size wire.
 Measurement of Flank angle: The semi cast of the
thread form may be made using dental plaster and
measurement is obtained as done for external
thread.

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 Thread Gauges
 Thread inspection can also be carried out
using gauges designed according to the
Taylors Principles:
 Limit gauges for Internal threads:
◦ Full form Go Gauge
◦ Truncated Effective Diameter NOGO gauge
◦ Minor Diameter NOGO gauge

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Go & NoGo Gauges

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Thread Gauges
 Limit gauges for External threads:
◦ This is usually carried out using caliper type
gauges
◦ Full form Go Gauge
◦ Truncated Effective Diameter NOGO gauge
◦ Major Diameter NOGO gauge

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Limit gauges for External threads

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Limit gauge for Major Diameter

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