Metrology and Quality Assurance Laboratory
SE
Experiment No: 8
Title: Limit Gauges: Concepts, uses and applications of Go –No Go Gauges, Taylor’s principle and
Design of gauges (Numerical and student activity)
Aim : Study of Limit Gauges and auto Gauging Systems
Theory:
“Limit gauging is a method of checking dimensions in which a fixed gauge is applied to the work
in order to determine whether a given component lies within its limits.” Gauges are inspection tools
of rigid design, without a scale, which used to check the dimensions of manufactured components.
Gauges do not indicate the actual value of the dimensions of the component. Theyare only used
to check whether the inspected part has been made within the specified limits.
Thus, a limit gauge, unlike a conventional measuring tool, simply determines whether, the part is
inside or outside the tolerance zone. The gauge neither measures a value of dimensions, nor shows
the value of error evolved in the component. It simply checks that part is correct or not.
Fig. Limit gauges
These are also called “GO” and “NO GO” gauges. These are made to the limit sizes of the work
to be measured. One of the sides or ends of the gauge is made to correspond to maximum and the
other end to the minimum permissible size. The function of limit gauges is to determine whether the
actual dimensions of the work are within or outside the specified limits. A limit gauge may be either
double end or progressive. A double end gauge has the “go‟ member at one end and “no go” member
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 1
Metrology and Quality Assurance Laboratory
SE
at the other end. The “go‟ member must pass into or over an acceptable piece but the “no go”
member should not. The progressive gauge has “no go‟ members next to each other and is applied
to a work piece with one movement. Some gauges are fixed for only one set of limits and are said
to be solid gauges. Others are adjustable for various ranges.
Fig. Plug gauge Fig. Ring gauge
Fig. Threaded plug gauge Fig. GO-NO GO Snap gauge
ADVANTAGES OF LIMIT GAUGES:
1. Quicker Inspection Method:
It is quicker than direct measurement. The time to inspect on shop-floor is minimized.
2. Used In-Mass Production:
Limit gauges are conveniently used in mass production for checking and controlling various
dimensions.
3. Ensure Interchangeability:
A Limit gauge ensures interchangeability and hence components can be assembled without
difficulty.
4. Need Semiskilled Operator:
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 2
Metrology and Quality Assurance Laboratory
SE
Limit gauges can easily be used by semi-skilled operators.
5. Check both Linear and Geometric Features:
A proper designed limits gauge can check both linear and geometric features simultaneously.
6. Economical:
Limit gauges are economical in their own cost as well as in inspection cost.
LIMITATIONS OR DISADVANTAGES OF LIMIT GAUGES:
1. Do not Indicate Exact Size:
Limit gauges do not indicate exact size of the component. They only indicated whether the
component is within the tolerance zone or not.
2. Errors due to Wear:
Limit gauges are subjected to errors due to wear of gauges during use.
3. Difficulty in Checking of Finer Tolerance:
It is generally uneconomical to manufacture a limit gauge with 0-0.0013 mm tolerance, to check the
work tolerance of about 0.013mm. Such fine limit gauges are also difficult to use in shop- floor, due
to wear.
Taylor’s principle:
Taylor’s principle states that the “GO” gauge should always be designed so that it will cover the
maximum metal condition (MMC) of as many dimensions as possible in the same limit gauge,
whereas a “NOT GO” gauge should cover the maximum metal condition of one dimension only.
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 3
Metrology and Quality Assurance Laboratory
SE
For example, let us assume that a bushing is to be inspected. The bush to mate a shaft. The shaft, therefore, opposed the
part in relation to the bushing. Therefore, the form of “GO” plug gauge should exactly coincide with the form of the
shaft. For this purpose, the “GO” plug gauge must be of adequate length not less than the length of the future
association of bushing and shaft. If this condition is not satisfied, part inspection with the gauge may prove to be
defective or even entirelythat the bush being inspected has a curved axis and a short “GO” plug gauge is employed.
Design of gauges (Numerical and student activity):
Note: Solve numerical in practical slot.
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 4
Metrology and Quality Assurance Laboratory
SE
Experiment No: 3
Title: Surface roughness measurement of a given sample using surface tester. Students should
also plot of flow chart of its usage.
Aim: Identification of roughness measurement using talysurf.
Prerequisites: Principle of Roughness measurement methods.
Apparatus: Roughness tester, Master specimen. etc.
Theory:
Roughness Measurement
Theory:
Taylor-Hobson Talysurf is a stylus and skid type of instrument working on carrier modulating
principle. Its response is more rapid and accurate as compared to Tomlinson Surface Meter. The
measuring head of this instrument consists of a sharply pointed diamond stylus of about 0.002
mm tip radius and skid or shoe which is drawn across the surface by means of a motorized driving
unit. In this instrument the stylus is made to trace the profile of the surface irregularities, and the
oscillatory movement of the stylus is converted into changes in electric current by the arrangement
as shown in Figure.
Fig. Talysurf
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 5
Metrology and Quality Assurance Laboratory
SE
The arm carrying the stylus forms an armature which pivots about the centre piece of E-shaped
stamping. On two legs of (outer pole pieces)'the E-shaped stamping there are coils carrying an
A.C. current. These two coils with other two resistances form an oscillator. As the armature is
pivoted about the central leg, any movement ofthe stylus causes the air gap to vary and thus the
amplitude of the original A.C. current flowing in the coils is modulated. The output of the bridge
thus consists of modulation only as shown in figure.
Surface finish refers to the process of altering a metal’s surface that involves removing, adding,
or reshaping. It is a measure of the complete texture of a product’s surface that is defined by three
characteristics of surface roughness, waviness, and lay.
Ra – Average Surface Roughness
While most people refer to Ra as Center Line Average or Arithmetic Average, it is the average
roughness between a roughness profile and the mean line. This is the most commonly used parameter
for surface finish. The Ra surface finish chart is also one of the most used for absolute values.
Rz – Average Maximum Height of the Profile
Unlike Ra, Rz measures the average values of the five largest differences between peaks and valleys.
The measurement is done using five sampling lengths, and it helps to eliminate error since Ra is
quite insensitive to some extremes.
Rq (RMS) is calculated as the Root Mean Square of a surfaces measured microscopic peaks and
valleys.
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 6
Metrology and Quality Assurance Laboratory
SE
Fig. Mitutoyo Roughness tester
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 7
Metrology and Quality Assurance Laboratory
SE
PRECAUTIONS:
• The surface to be tested should be cleaned properly.
• The tester should be fixed to the height properly so that the movement of the probe is exactly
parallel to the surface of work.
• Make sure that the probe gently touches the work
PROCEDURE:
1. The finished component is placed on the surface plate.
2. Talysurf tester is fixed to the vernier height gauge using adopter at a convenient height.
3. Make sure that the stylus probe touches the work piece.
4. Fix the sampling length in the tester.
5. Then the power button is pressed so that the probe moves on the surface to and fro.
6. Take the readings of the surface roughness directly from the instrument.
7. Repeat the above process for the remaining specimen and tabulate the readings
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 8
Metrology and Quality Assurance Laboratory
SE
Observations-
Process performed on Ra value in Rq value in microns Rz value in microns
surface microns
Conclusion: -
Ra:
Rq:
Rz:
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 9
Metrology and Quality Assurance Laboratory
SE
Experiment No: 6
Title: Determination of geometry and dimensions of given composite object / single point tool,
by using Optical Projector / Tool makers’ Microscope and differentiate between its usefulness
in real life.
Aim: - Study and Experiment on Profile Projector.
Objective:- To measure different parameter of given composite object using profile project &
Tool maker microscope.
Prerequisites: - Optical Principle, work piece parameters, micrometer scale.
Theory: –
Profile projectors becomes an indispensable in modern laboratories because of its versatility and
easy in using profile projector it is possible to measure those components which are difficult to
measure by other method due to typical size, material composition or dimensional characteristic
It display the magnified image of the object. The magnified image serves as an aid to more precise
measurement of dimension from etc. The projector has following parts.
1. A projector having light sources a condenser collimating lens system to direct the light past
the part and into optical system
2. Suitable work holding table, which may be fixed on movable
3. Screen where the image of the work piece is projected and where measurement and comparison
are made
4. Projection optics including tooth mirror and lenses.
5. Measuring devices, a good optical projector must have a precise optical system and means for
precise mechanical measurement.
An optical projector displays a two dimensional projector of part. It may be noted that all parts not
ideally suited to optical gauging because of the accuracy of the magnified image and the contrast
in image. A beam of light produces the image of the test piece. The last sources commonly used
are tungsten lamp, high pressure measuring lamp.
Work Table: –
The objects to be tested are placed on the work table. The focal clearance or the working distance
of the optical systems devices have the space in which the parts can be staged. The
Department of Robotics and Automation Engineering
Page 10
ZES’s ZCOER, Pune-411041
Metrology and Quality Assurance Laboratory
SE
sectional contour or maximum size of an object that can be normally being projected to the screen
is the counter lining in the focal plane. The projector table may be either stationary typeor
moving type. It may have facilities for measurement for movement. Some tables are also equipped
with an angular adjustment for positioning the helix threads and worms. Micrometers in
connections with dial gauge indicators are fitted as measuring attachments to simplify the
determination of angular measurement.
Fig. Profile Projector
Projection System: –
The beam of light after passing through the object is to be projected losses into the projector
system. Comprising of lenses and mirrors which must be held in accurate alignments or rigid
supports. Lenses are used to obtain the beam of light on the image produced is not defined as with
low magnification. Sources are usually made of glass with the surface facing the operator ground
to a very fine grain.
Techniques employed in projector In Statement for Measurement –
1. Measurement by comparison-
In this method the 2D screen image are produced to the desired magnification by keeping the
Department of Robotics and Automation Engineering
Page 11
ZES’s ZCOER, Pune-411041
Metrology and Quality Assurance Laboratory
SE
object in the focal plane of the optical system. The counter characteristics such asirregular
curves, chamfers can be all in speeded in a single stretch without restarting to the other
inspection method.
2. Measurement by movement-
The projector should have table travel and measuring facilities. In this method the
center cross line on the screen provides the reference.
3. Measurement by translation-
In such measurement a tracer that is one at the one pantograph is applied one arm of the
pantograph is a styles which faces freely over the part contour and not restricted by the
part size magnification is a glass reticule.
Tool Maker microscope:
The general method and small model tool maker’s microscope giving its design and optical
systems which is commonly available. This is designed for measurement and complex parts like
external threads, tools, template and gauges. It is also used for measuring center to center distance
system. The toolmakers microscopes essentially consist of cast base, the main lighting unit, the
upright with carrying arm and sighting microscope. The rigid base is resting on 3 foot screw by
means of which m\c can be Lavelle with ref. to build in box level the base carries the coordinate
measuring table consist of two measuring table sliding in x and y direction and rotary circular table
provided with glass plate. The slides are running on precision balls in hardened guide ways. Two
micrometer screws each of them measuring range 0-25 mm permit the measuring table to be
displaced in x-y direction. The range of the moment of carries can be winded up to 150mm.
Construction-
It consists of the optical head, which can be adjusted vertically along the ways of supporting beam
the optical head can be damped in any direction by screw. The working table on which the parts
to be inspected are place. The working table is screwed on heavy hollow base. The working has
compound side by means of which the measured parts can have longitudinal and lateral movements
are controlled by accurate micrometer screw having thimble scale and vernier. At the
Department of Robotics and Automation Engineering
Page 12
ZES’s ZCOER, Pune-411041
Metrology and Quality Assurance Laboratory
SE
back of base is arranged with light sources, which provides a horizontal beam of light which
reflects from mirror 90 upward the table. The beam of light passes through transparent glass on
which flat parts are to be checked are placed. A shadow head and is projected through the system
of 3 prism to a ground Glass.
Fig. Tool Maker’s Microscopy
Observations are made through optical head. The measurements are made by cross line. The angle
of rotation of screen can be read through an eye piece provided. An optical head view of field
contains an illuminated circular scale with division value of 1 mm. The optical head tube is
adjusted in ht. for focusing purpose till sharp image of the projected contour is seen on the ground
glass screen.
Fig. Tool geometry
Department of Robotics and Automation Engineering
Page 13
ZES’s ZCOER, Pune-411041
Metrology and Quality Assurance Laboratory
SE
Observation Table: -
Profile Projector:
Specimen :
Sr. Parameter Initial Reading Final Reading Actual
No. (mm) (mm) Reading (mm)
1 Major Diameter
2 Minor Diameter
3 Pitch
4 Angle
Tool makers microscope:
Specimen:
Sr. Parameter Initial Reading Final Reading Actual
No. (mm) A (mm) B Reading (mm)
B-A
1 Side Cutting Edge length
2 Side Cutting Edge Angle
3 Nose Angle
Conclusion: -
Questions:
1. Explain the principle of working of profile projector.
2. What is least count of micrometer scale used in profile projector?
3. What is least count of angular measurement scale used in profile projector?
4. What are various applications of the profile projector?
5.Explain the principle of working of tool maker’s microscope.
6.What is least count of micrometer scale used in tool maker’s microscope?
7.What is least count of angular measurement scale used in tool maker’s microscope?
8.What are various applications of the tool maker’s microscope?
Department of Robotics and Automation Engineering
Page 14
ZES’s ZCOER, Pune-411041
Metrology and Quality Assurance Laboratory
SE
Experiment No.7
Title: Verification of dimensions and geometry of given components using Mechanical /Pneumatic
comparator in context of manufacturing.
Aim: Study and Experiment on any type Comparator ( Mechanical / Pneumaticcomparator)
Apparatus: Dial indicator, slip gauges, specimen, surface plate.
Fig. Dial Indicator
Theory:
Principle of Mechanical Comparator:-
It is one of the most widely used mechanical comparator. It consists of a dial connected to plunger
projecting at its bottom. The plunger moves upward when a very slight upward pressure as applied. The
mechanism has a system connected to the toothed rack. A compound gear is provided to connect toothed
rack to pointer. A helical spring is used to bring back the plunger to its original position. When pressure
is released the pointer moves. The indicator is adjusted to zero by rotating dial rim. The minimum reading
of dial is 0.01mm. A revolution counter in form of a small dial is provided to indicate the total travel by
stem.
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 15
Metrology and Quality Assurance Laboratory
SE
Procedure:
1. First decide the dimension of specimen to be compared against the standard.
2. Get the standard (desired) value of that dimension from design manual.
3. Build up a slip gauge bar of standard value by wringing.
4. Place the slip gauge bar, specimen and dial indicator on the surface plate.
5. The pointer of dial indicator is made to touch the top surface of slip gauge bar.
6. Adjust the dial indicator to zero reading.
7. Then pointer is made to touch the top surface of specimen.
8. Note the dial reading, it gives the deviation of specimen dimension from standard value.
9. Repeat the same procedure for different workpieces.
Sr Mechanical Comparator Reading
No. Standard Dimension
Dimension Geometry
Conclusion :
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 16
Metrology and Quality Assurance Laboratory
SE
Experiment No: 7
Title: Experimentation by using Gear Tooth Vernier Caliper
Aim: Measurement of Gear Parameters
Prerequisites: Gears and its type, Cycloidal and involute forms of gears, Gear terminology
Objectives: Selection of tool and techniques for determining dimensions of gears.
Apparatus: Gear tooth Vernier caliper, bench vice.
Theory:
Brief description of different characteristics of measuring of tooth thickness by gear truth Vernier
is given. It consists of a horizontal and a vertical Vernier scale. It is based on the principle of
Vernier scale. The thickness of a tooth at pitch line and the addendum is measured by an
independent tongue each of which is adjusted independently by adjusting the slide screws on
graduated beams.
TERMINOLOGY OF GEAR TOOTH
1. Pitch circle diameter (PCD) : It is the diameter of a circle which by pure rolling action would
produce the same motion on the toothed gear wheel. It is equal to D = (T X OD)/(T+2)OD =
outside diameter T = number of teeth
2. MODULE: It is defined as the length of the pitch circle diameter per truth. Module
m=D/T and is expressed in mm.
3. CIRCULAR PITCH (CP) : It is the arc distance measured around the pitch circle from the
flank of one truth to a similar flank in the next tooth
CP==ΠD/T=Πm.
4. ADDENDUM: This is the radial distance from the pitch circle to the tip of the truth. It is
equal to one module.
5. Clearance: This is the radial distance from the tip of a tooth to the bottom of the mating
tooth space when the teeth are symmetrically engaged. Its standard value is 0.157m or 0.25m.
6. DEDENDUM: This is the radial distance from the pitch circle to the bottom of tooth space.
Dedendum = Addendum +Clearance = m +0.157m =1 .157m. =1.25m
7. TOOTH THICKNESS: This is the arc distance measured along the pitch from the intercepts
with one flank to the intercepts with the other flank of the same tooth.
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 40
Metrology and Quality Assurance Laboratory
SE
Diagram:
Fig: Gear terminology
Fig: Gear Tooth Vernier Caliper
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 41
Metrology and Quality Assurance Laboratory
SE
Fig. Gear tooth measurement
Procedure:
For finding PCD, module, addendum, Dedendum and clearance:
1. First find the blank diameter, OD by a Vernier caliper and also count the Number of teeth
T of the spur gear.
2. Next calculate pitch circle diameter D= (TxOD)/(T+2)
3. Find addendum, clearance, pitch, module and Dedendum as per the formulae given in the
theory.
FOR CHORDAL TOOTH THICKNESS (using gear tooth caliper):
1. Set the Chordal depth (addendum) on the vertical slide of the gear tooth Vernier and
then insert the jaws of the instrument on the tooth to be measured.
2. Adjust the horizontal Vernier slide by the fine adjusting screw so that the jaws just
touch the tooth.
3. Read the horizontal Vernier slide and note the reading. It gives the Chordal thickness of
tooth.
4. Repeat the observations for the different teeth.
5. Compare the values of different characteristics with the standard value and set the
percentage error.
OBSERVATION:
Gear tooth vernier (LC 0.02 mm)
Module = OD/ (T+2)
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 42
Metrology and Quality Assurance Laboratory
SE
Vertical setting d = mT [ 1+(2/T) – cos(90/T) ]
Tooth Vertical MSR On VSR On Tooth thickness Avg.Tooth
no. setting Horizontal scale Horizontal w (mm) thickness
d (mm) (mm) scale MSR +(VSR x 0.02) (mm)
1
Theoretical tooth thickness w= mT sin(90/T)
Actual tooth thickness= mm
Error in tooth thickness measurement = Theoretical tooth thickness - Actual
tooth thickness
Conclusion:
Questions:
1. Define pitch circle.
2. What is module?
3. What is Addendum?
4. What is Dedendum?
5. Define tooth thickness.
6. Which are the different types of gear profile?
7. What are the advantages of involute profile over Cycloidal profile of gear?
8. What is interference in gear? How it can be avoided?
9. Explain the different types of gear?
10. What is gear ratio?
Department of Robotics and Automation Engineering
ZES’s ZCOER, Pune-411041 Page 43
