Metrology and Quality Control

Experiment No. 1

Experiment No. 1
1.0 TITLE:
Study of basic measuring instruments (surface plate, angle plate, v-block, spirit level, combination set, straight edge, feeler gauge, screw pitch gauge, radius gauge)

2.0

PRIOR CONCEPT:
1. 2. 3. Principles of linear measurement Methods of measurement Basic units of measurement

3.0

NEW CONCEPT:
Surface plate, angle plate, v-block, spirit level, combination set, straight edge, feeler gauge, screw pitch gauge, radius gauge. 4.1 Proposition: Surface plate, angle plate, v-block, spirit level, combination set, straight edge, feeler gauge, screw pitch gauge, radius gauge are basic instruments used for engineering measurements. 4.2 Concept structure:

4.0

LEARNING OBJECTIVES:
After the study of all the basic instruments the students will acquire

4.1 Intellectual skills

Understand the construction and use of the instruments. Select the appropriate instrument for the given task of measurement.

4.2 Motor skill

Manipulate different basic measuring instruments.

5.0

APPARATUS:
Instruments for use: 1. Surface plate, angle plate, v-block, spirit level, combination set, straight edge, feeler gauge, screw pitch gauge, radius gauge 2. At least 4-6 industrial jobs.

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Experiment No. 1

Metrology and Quality Control

6.0

PROCEDURE:
6.1 Brief theory:

1.

Surface Plate:

Surface plates are mostly rectangular having 4:3 length to width ratio. These plates are rigid in design & generally ribbed at the bottom to carry heavy load without deflection. The top surface of the plate is scraped to true flatness. For big surface plates, four leveling screws are provided for adjusting their top surface truly horizontal. The standard available sizes of the plates vary from 100 x 100 mm to 2000 x 1000 mm in about 13 ranges. The four edges of the plates are finished, straight & are square to each other. According to IS-2285-1963, the CI surface plates are classified into two grades as GRADE I & GRADE II. Surface plate is used to provide datum or a reference surface for measurement in workshop & laboratories. It is also used to check flatness of any surface.

Fig. 1.1 SURFACE PLATE

2.

Angle plate:

The two working surfaces of the angle plate are truly perpendicular to each other & these surfaces are scraped. Generally, no sharp edges are allowed in the plate. They are used along with surface plate in workshop & laboratories for measurement. Angle plates are manufactured from cast iron and cast steel. The angle plates are available in two grades depending upon the accuracy (IS 2554 1963). Grade I: either grinding or hand scraping operation finishes all exterior & interior faces and edges. Grade II: planning or milling operations finishes all exterior faces.

Fig. 1.2 ANGLE PLATE

3.

V-block:

V-block is a supporting device for cylindrical work-pieces for marking center accurately and for checking out of roundness. The angle of V in V-block is 90 degree. All the working surfaces of the V-block are polished. Clamps are also provided for holding round bars. According to IS-2949-1964, V-blocks are available in two grades, Grade A & Grade B. While using V-block, it is essential that the cylindrical work piece should rest firmly on the

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Metrology and Quality Control

Experiment No. 1

slides of the vee & not on the edges of the vee.

Fig. 1.3 V-BLOCK

4.

Spirit level:

Spirit level consists of a sealed glass tube mounted on a base. The inside surface of the tube is ground to a convex barrel shape having large radius. A scale is engraved on the glass at the top of the tube. The tube is nearly filled with Ether or Alcohol except a small air or vapor bubble. The bubble always tries to remain at the highest point of the tube. If the base is placed on horizontal surface, then the bubble rests at the center of the scale. If the spirit level is tilted through small angle, the bubble moves & tries to remain at the highest point of the tube. They are used for leveling of machines, for measuring small angle or inclination and for checking straightness & flatness of surface.

5.

Combination set:

The combination set consists of a scale, square head, protractor head, center head and spirit level. Groove is made along the length of the scale. Square head can slide in this groove. It can be locked at any place by a locking nut & bolt. One surface of square head is always perpendicular to the scale. The square head consist of a spirit level for checking parallelism. The square head can be used for height & depth measurements. The center head attachment with scale is used to locate the center of a cylindrical bar. The protractor head consists of a semi-circular disc graduated from 0-90 degree on either side of center. Correct angle can be found out with the help of protractor. Combination set is used in workshops for marking centers, checking squareness and angular measurements.

FIG. 1.4 COMBINATION SET

6.

Straight Edge:

Straight edge is rectangular or I shaped in section with beveled edge. Steel straight edges are available up to 2 meter length & CI straight edges are available up to 3 meter length & are widely used for testing machine tool slide ways. It is used in conjunction with surface plate & spirit level for measurement of straightness and flatness of parts. For checking the straightness of the part, the straight edge is placed along the full length of the surface against the bright light. The absence of the light between straight & surface indicates the straightness of the element. Similarly the flatness of the surface can be tested by placing the straight edge in different directions at different places on the surface. By using

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Experiment No. 1

Metrology and Quality Control

Prussian blue & straight edge, the irregularities on the surface can also be found out. According to IS-2220-1962, straight edges are provided into two grades. Grade A for inspection purpose Grade B for workshop purpose Stepwise procedure: 1. Put the straight edge on surface under test 2. Observe the gap between the straight edge and surface under test 3. If there is no gap, the surface is straight.

7.

Feeler Gauge:

Feeler gauge is a narrow strip of steel sheet made up of required thickness. The complete set consists of number of gauging blades of different thickness. Its working is based on the sense of feel & hence it is called as feeler gauge. If necessary, two blades can be joined together to check dimensions. They are available from 0.03 to 1 mm size. Each blade is permanently marked with the nominal thickness & grade. It is used to measure the gap between two parallel flat faces, to measure clearance between piston & cylinder, spark plug gap and setting tappet clearance. Stepwise procedure: 1. Take the job to measure the gap 2. By trial & error method insert the leaf of feeler gauge in the gap. The leaf of feeler gauge that matches exactly with the gap is the gap distance. The dimension is written on each leaf of feeler gauge.

8.

Screw pitch gauge:

In this gauge, one edge of the blade is notched to various pitches & contours of specific threads. The blades are stamped with the pitch size. These gauges are available for metric, British and American form of threads. By matching these gauges with the job to be measured, the pitch of the job can be found easily. Stepwise procedure: 1. Take the threaded job to measure the pitch. 2. By trial and error method match the leaf of pitch screw gauge with the threads. 3. The leaf that exactly matches with the thread form gives the pitch of the thread, which is engraved on the leaf of the gauge.

Fig 1.6 PITCH SCREW GAUGE 4

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Metrology and Quality Control

Experiment No. 1

9.

Radius gauge:

Radius gauge is used for determining radius of a fillet. Radius gauge consist of set of blades on each of which the corresponding radius is marked. By placing the correct gauge & by observing the light source with eyes the correct radius can be checked. Stepwise procedure: 1. Take the job to measure the radius. 2. By trial and error method match one of the leaves of the radius gauge with the job radius. 3. The leaf that matches exactly with the radius of the job gives the radius of the job that is engraved on the leaf of the gauge.

7.0

Questions: (Attempt 3-5 questions as directed by teacher)

1. Write at least two industrial applications of following instruments. i. Feeler gauge: ii. Screw pitch gauge: iii. Radius gauge: iv. V-block: v. Surface plate: Measure the gap of a spark plug using the available set of feeler gauges. Measure the pitch of at least two threaded components by using the available set of screw pitch gauge. Measure the fillet radius of a given component using available set of radius gauges. State the precaution to be taken while using V- block. Give the sizes of the blades in the recommended set of Indian Standard thickness gauge. State reasons for a. Ribs provided under the surface of the surface plate. b. Artificial aging of the surface plate. c. Slot provided along the sides of the V-block. d. Leveling of the surface plate before measurement. e. Inside surface of the spirit level glass tube ground to a convex form with a large radius. Space for writing answers

2. 3. 4. 5. 6. 7.

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Experiment No. 1

Metrology and Quality Control

Space for writing answers

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