Lab Report 3

Metrology and Quality Assurance Lab

Submitted by:
Awais Shahbaz 2015-IM-05

Zahid Ishfaq 2015-IM-06

Muhammad Umar Farooq 2015-IM-07

Farrukh Waheed 2015-IM-17

Submitted to:

Dr. Muhammad Qaiser Saleem

Department of Industrial and Manufacturing Engineering

University of Engineering and Technology, Lahore
Contents
Table of figures: .............................................................................................................................. 3
Objective: ........................................................................................................................................ 4
Problem Statement: ......................................................................................................................... 4
Apparatus: ....................................................................................................................................... 4
Theory: ............................................................................................................................................ 4
Vernier height gauge: .................................................................................................................. 4
Usage:.......................................................................................................................................... 5
Trigonometric Relations: ............................................................................................................ 6
Apex Angle: ............................................................................................................................ 6
Similar Triangle Properties: .................................................................................................... 6
Pin/Round gauges: ...................................................................................................................... 8
Procedure: ....................................................................................................................................... 9
Observations & Calculations: ......................................................................................................... 9
Comments: .................................................................................................................................... 10
References: .................................................................................................................................... 10
Table of figures:
Figure 1:Vernier height Gauge[1] ................................................................................................... 5
Figure 2: Reading of height gauge [1] ............................................................................................ 5
Figure 3:Apex Angle Representation .............................................................................................. 6
Figure 4: similar triangle representation [3] ................................................................................... 6
Figure 5: Measurement of the tapered plug gauge .......................................................................... 7
Figure 6: Triangle representation .................................................................................................... 7
Figure 7: (a) Precision Roller Gauge Set (b) Precision Pin Gauge Set [4-5] .................................. 8
Objective:
To determine the taper angle and specified diameter of taper plug gauge using precision pin/roller
gauge and micrometer screw gauge.

Problem Statement:
The physical limitations of certain specimens may make it difficult for traditional instruments to make
measurements directly, thus necessitating the use of trigonometric functions for determination of certain
dimensions. The taper angle and specified diameters of taper plug gauge are required to be determined.

Apparatus:
 Micrometer screw gauge
 Pin or roller gauge set
 Block gauge set
 Vernier height gauge

Theory:
Vernier height gauge:
A height gauge is a measuring device used either for determining the height of objects, or for
marking of items to be worked on.
These measuring tools are used in metalworking or metrology to either set or measure vertical
distances; the pointer is sharpened to allow it to act as a scriber and assist in marking out work
pieces.
Devices similar in concept, with lower resolutions, are used in health care settings (health clinics,
surgeries) to find the height of people, in which context they are called audiometers.
Height gauges may also be used to measure the height of an object by using the underside of the
scriber as the datum. The datum may be permanently fixed or the height gauge may have provision
to adjust the scale, this is done by sliding the scale vertically along the body of the height gauge
by turning a fine feed screw at the top of the gauge; then with the scriber set to the same level as
the base, the scale can be matched to it. This adjustment allows different scribers or probes to be
used, as well as adjusting for any errors in a damaged or sharpened probe.
In the tool room, the distinction between a height gauge and a surface gauge is that a height gauge
has a measuring head (whether Vernier, fine rack and pinion with dial, or linear encoder with
digital display), whereas a surface gauge has only a scriber point. Both are typically used on a
surface plate and have a heavy base with an accurately flat, smooth underside.[1]
Usage:

Figure 1:Vernier height Gauge[1]

1. Loosen the scribe clamp screw and insert the holder arm into the scribe
2. clamp in place of the scribe.
3. Remove any contamination and clean the surface plate, gauge base, and scribe reference
surface.
4. Lower the scribe and bring the reference plane into good contact with the surface plate.
5. As with Vernier calipers, the scale is read off the main scale and off the Vernier scale at
the point where the lines match.

Figure 2: Reading of height gauge [1]

Trigonometric Relations:
Apex Angle:
The vertex of an isosceles triangle having angle different from the two equal angles is called the
apex of the isosceles triangle. The common polygon vertex at the top of a pyramid or the vertex
of a cone is also called an apex.

Figure 3:Apex Angle Representation

Isosceles triangle is a triangle having two lengths equal.

Similar Triangle Properties:

Triangles are similar if they have the same shape but can be different sizes. They are still similar
even if one is rotated, or one is a mirror image of the other.

Figure 4: similar triangle representation [3]

• Corresponding angles are congruent (same measure)

So angle between two triangles is similar because they are similar triangles.
• The ratio of corresponding sides of two similar triangles are equal. [3]
Trigonometric functions:
𝑝𝑟𝑒𝑝𝑒𝑛𝑑𝑖𝑐𝑢𝑙𝑎𝑟
Tan𝜃= 𝑏𝑎𝑠𝑒
For below figure:

𝐵𝐶
Tan𝜃= ℎ
where
Bc=(M2-M1)/2

𝑝𝑟𝑒𝑝𝑒𝑛𝑑𝑖𝑐𝑢𝑙𝑎𝑟
Sinθ= ℎ𝑦𝑝𝑜𝑡𝑒𝑛𝑢𝑠𝑒
𝐵𝑎𝑠𝑒
Cosθ=ℎ𝑦𝑝𝑜𝑡𝑒𝑛𝑢𝑠𝑒
 Figure 5: Measurement of the tapered plug gauge

For the measurement of minimum and maximum diameter we just used the trigonometric or
arithmetic calculation.
For above figure:
As the round gauges are used so for the calculation we just take the triangle of KFG so:

Figure 6: Triangle representation

𝑟
Tan∅=𝑥
90−𝜃
Where: 𝜑= 2

By Arithmetic means:
As the M1 is the distance of bottom (also including roller gauges) so by just subtracting the
double of x and double of radius we can calculate the Ds
 Ds=M1-2x-2r
Dmax=Ds+2Htanθ
Dmin=Ds+2(H-S)tanθ

Pin/Round gauges:
Gauge blocks (also known as gage blocks, Johansson gauges, slip gauges, or Jo blocks) are a
system for producing precision lengths. The individual gauge block is a metal or ceramic block
that has been precision ground and lapped to a specific thickness. Gauge blocks come in sets of
blocks with a range of standard lengths. In use, the blocks are stacked to make up a desired length.

A gauge block is a block of metal or ceramic with two opposing faces ground precisely flat and
parallel, a precise distance apart. Standard grade blocks are made of a hardened steel alloy, while
calibration grade blocks are often made of tungsten carbide or chromium carbide because it is
harder and wears less.

In use, the blocks are removed from the set, cleaned of their protective coating (petroleum jelly or
oil) and wrung together to form a stack of the required dimension. Gauge blocks are calibrated to
be accurate at 68 °F (20 °C) and should be kept at this temperature when taking measurements.
This mitigates the effects of thermal expansion. The wear blocks, made of a harder substance like
tungsten carbide, are included at each end of the stack, whenever possible, to protect the gauge
blocks from being damaged in use. [2]

Figure 7: (a) Precision Roller Gauge Set (b) Precision Pin Gauge Set [4-5]
Procedure:
• Note down the height (H) of the workpiece (taper plug gauge)
• Place the taper gauge (workpiece) on a surface plate. Place the precision roller
gauges or pin gauges so that they touch the sides of the taper gauge (at both sides)
as shown in figure.
• Take micrometer screw gauge reading at outside of these rollers/pins. This will be
M1 as per the labeling shown in the figure.
• Place two gauges blocks of known dimension and take another measurement after
placing the precision roller/pin gauges on top of the gauge blocks. This will be M2
as per the labeling shown in the figure.
• Carryout the required calculations to find the taper angle and the specified
diameters of the workpiece.

Observations & Calculations:

Height of taper plug gauge block = 80.98mm

Diameter of the roller gauge/pin gauge used = 12.7mm

Micrometer screw gauge reading taken at the base of taper plug gauge “M1” = 45.46mm
Height of block gauges used = 50mm

Micrometer screw gauge reading taken at a certain height (at top of gauge block) “M2” = 48.01mm
For triangle ABC:

BC =(M2-M1)/2
48.01−45.46
BC = 2

BC =1.275mm
𝐵𝐶
Tanθ = ℎ
1.2715
Tanθ = 50

Θ =1.4607250
90−𝜃 𝑟
Tan( )=
2 𝑥

For triangle KFG:

 90−1.460725 6.35
Tan( )=
2 𝑥

x= 6.513989mm
Ds= M1-2x-2r
Ds= 45.46-2(6.513989)-2(6.35)
Ds-=19.732mm
Dmax = Ds+2Htanθ
Dmax =19.732+2(80.98) (tan 1.460725)
Dmax = 23.8969mm
Dmin = Ds+2(H-S)tanθ
Dmin =19.732+2(80.67)( (tan 1.460725)
Dmin = 23.8461mm

Comments:
• In mathematical calculation we just take answer up to four decimal places and not
considered the higher decimal which produce error in calculation.
• We must use the digital Vernier height gauge to reduce visualization error.
• While using Vernier Gauge the flat surface must be ensured for correct reference point.
• The gauges must be properly cleaned and free from dust particles so that height gauge
properly attach with surface.

References:
1. "Vernier height gauge" [Online]. Available:
"https://en.wikipedia.org/w/index.php?title=Heightgauge& oldid=818895784"
[Accessed 16 Oct. 2018].

2. "Round gauge," [Online]. Available:

“http://www.craftsmanspace.com/knowledge/round guage.html”.
[Accessed 16 Oct. 2018].
3. T. K. C. J. Althin, The Master of Measurement, Johansson Corporation.
4. https://picclick.com.uk/Vintage-hoffmann-Precision-Roller-Gauge-Set-1-4-
22238382794.html
5. http://www.starrett.com/metrology/product-detail/S4003-