The document discusses mechanical comparators used in metrology and measurements. It describes the basic components and working of dial indicators and Johansson Mikrokator comparators. Dial indicators use a gear train mechanism to amplify small displacements of a contact point and indicate them on a graduated dial. Johansson Mikrokator comparators use a twisted metal strip to provide high magnification of 5000x. The document also briefly covers Sigma comparators and lists advantages and disadvantages of mechanical comparators compared to other measurement devices.
The document discusses mechanical comparators used in metrology and measurements. It describes the basic components and working of dial indicators and Johansson Mikrokator comparators. Dial indicators use a gear train mechanism to amplify small displacements of a contact point and indicate them on a graduated dial. Johansson Mikrokator comparators use a twisted metal strip to provide high magnification of 5000x. The document also briefly covers Sigma comparators and lists advantages and disadvantages of mechanical comparators compared to other measurement devices.
The document discusses mechanical comparators used in metrology and measurements. It describes the basic components and working of dial indicators and Johansson Mikrokator comparators. Dial indicators use a gear train mechanism to amplify small displacements of a contact point and indicate them on a graduated dial. Johansson Mikrokator comparators use a twisted metal strip to provide high magnification of 5000x. The document also briefly covers Sigma comparators and lists advantages and disadvantages of mechanical comparators compared to other measurement devices.
The document discusses mechanical comparators used in metrology and measurements. It describes the basic components and working of dial indicators and Johansson Mikrokator comparators. Dial indicators use a gear train mechanism to amplify small displacements of a contact point and indicate them on a graduated dial. Johansson Mikrokator comparators use a twisted metal strip to provide high magnification of 5000x. The document also briefly covers Sigma comparators and lists advantages and disadvantages of mechanical comparators compared to other measurement devices.
K. S. R. Varun Teja Department of Mechanical Engineering NIT Trichy Dial Indicator It is primarily used to compare workpieces against a master. The basic features of a dial gauge consist of a • Body with a circular graduated dial. • A contact point connected to a gear train. • An indicating hand that directly indicates the linear displacement of the contact point.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy • Dial gauges is are used along with V-blocks in a metrology laboratory to check the roundness of components. • A dial gauge is also part of standard measuring devices such as • Bore gauges • Depth gauges
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy Video Source: https://youtu.be/8sry-KiKKcU K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Working Mechanism of Dial Indicator • The spindle attached to the bottom of the rack is the basic sensing element. • A coil spring resists the measurement movement and thereby applies the necessary gauging pressure. • The plunger carries a rack, which meshes with a gear (marked gear A in the figure). A rack guide prevents the rotation of the plunger about its own axis. • A small movement of the plunger causes the rack to turn gear F through connected gears A, B, C, D and E.
• The overall magnification obtained in the gear train A–B–C–D–E is
given by TD/TE × TB/TC, where TD, TE, TB, and TC are the number of teeth on the gears D, E, B, and C, respectively. • The magnification is further enhanced at the tip of the pointer, depending on the length of the pointer.
• A hair spring loads all the gears in the train against the direction of gauging movement. This eliminates backlash that would be caused by gear wear.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy Video Source: https://youtu.be/Ew7KmAMcyxA K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Contact Points Used for Dial Indicator
The standard or spherical
contact point is the most A tapered point is convenient preferred one because it for component surfaces that presents point contact to the cannot be accessed by either standard or flat contact points. mating surface irrespective of whether it is flat or cylindrical.
The use of contact points on
A button-type contact point spherical surfaces presents can be used if light contact some problems. Only a flat pressure on smaller point is suitable in such cases. components is required. It gives reliable readings for cylindrical surfaces too.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy The following guidelines are recommended for the proper use of dial indicators:
1. A dial indicator is a delicate instrument as the slender spindle can be damaged easily. The user should avoid sudden contact with the workpiece surface, over-tightening of contact points, and side pressure. 2. Any sharp fall or blow can damage the contact points or upset the alignment of bearings, and hence should be avoided. 3. Standard reference surfaces should be used. It is not recommended to use non-standard attachments or accessories for reference surfaces. 4. The dial indicator should be cleaned thoroughly before and after use. This is very important because unwanted dust, oil, and cutting fluid may seep inside the instrument and cause havoc to the maze of moving parts. 5. Periodic calibration of the dial gauge is a must. K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Johansson Mikrokator • The basic element in this type of comparator is a light pointer made of glass fixed to a thin twisted metal strip.
• This type of comparator was developed by the
Johansson Ltd Company of USA.
• The comparator works on the magnification provided
by a twisted loop metal strip attached with a glass pointer.
• Whenever the loop is pulled outwards, the string
unwinds, thereby spinning the strip at high speed.
• The magnification is of the order of 5000.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy • The deviation in the bell crank lever enables the expansion of the thin twisted metal strip, thus rotating the glass pointer.
• A small movement in the
contact point pushes the plunger thus making the bell crack lever to deviate. • The plunger bearing the contact point is connected to a bell crank lever.
• Slit washer to arrest the
• The plunger having the rotation of the plunger about contact point passes through its axis and give frictionless the slit washer. linear movement K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Video Source: https://youtu.be/_VfXMs4iIYk K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Sigma Comparator
• It is a simple but ingenious mechanical
comparator developed by the Sigma Instrument Company, USA.
• A linear displacement of a plunger is translated
into the movement of a pointer over a calibrated scale.
• The instrument is available with vertical
capacities of 150 mm, 300 mm and 600 mm and a magnification of 500, 100, 1500, 3000 and 5000.
• The least count is of the order of 0.25 microns
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Cross Strip Hinge
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy Video Source: https://youtu.be/39YJzk3-Jrc K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Advantages and Disadvantages of Mechanical Comparators Advantages of Mechanical Comparators Disadvantages of Mechanical Comparators 1.Mechanical comparators are cheaper as compared 1.The mechanical comparators have more moving parts, due to to other amplifying devices. which the friction, wear and tear are a high and low 2.These comparators don’t require any external inaccuracy. supply of electricity or air. 2.Any negligence in moving parts reduces accuracy. 3.These comparators have a linear scale, for easy 3.The mechanism has more inertia, which causes the inference of readings. instrument to be sensitive to vibrations. 4.They are robust, compact and easy to handle. 4.The range of the instrument is limited as the pointer moves 5.They are suitable for ordinary workshop over a fixed scale. conditions and are portable. 5.Parallax error is high as the pointer moves over a fixed scale. 6.Highly difficult to incorporate arrangement for adjusting the magnification. K. S. R. Varun Teja, Department of Mechanical Engineering, NIT Trichy Thank You
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
