Alignment & Testing Methods – Detailed Notes for GATE
(Mechanical – Metrology)
Complete study of Alignment and Testing Methods in Metrology as per GATE syllabus. Includes instruments, least
counts, detailed notes and solved numericals.
1. Alignment vs. Testing
• Alignment = checking whether axes/surfaces properly located (parallel, perpendicular, colinear). • Testing =
systematic checking of machine tool geometry and performance. Two categories: (a) Geometrical tests – without
cutting. (b) Practical tests – with cutting (test piece).
2. Instruments Used (with Typical Least Counts)
Instrument Use Typical Least Count
Dial Indicator Run-out, straightness, parallelism 0.01 mm (some up to 0.001 mm)
Precision Spirit Level Checking level of machine beds 0.02 mm per metre
Autocollimator Small angular deviation 0.5 arc-second
Sine Bar Setting/Checking angles Uses slip gauges; accuracy ~seconds of arc
Slip Gauges Reference for dimension Up to 0.001 mm
Optical Flat Flatness testing with fringes Resolution ~0.3 µm per fringe
Test Mandrel/Bar Spindle alignment Straight within microns over length
3. Machine Tool Testing – Key Checks
Lathe: • Bed Straightness. • Headstock Spindle Alignment. • Tailstock Alignment. • Cross Slide Perpendicularity.
Milling Machine: • Spindle Perpendicularity to Table. • Table Movement Parallelism. • Overarm/Arbor Alignment.
Drilling Machine: • Spindle Perpendicularity to Table. • Spindle Run-out. Grinding Machine: • Spindle Axis Parallel
to Table Movement. • Table Movement Straightness. • Wheel Spindle Alignment.
4. Performing Tests
Straightness – Dial indicator along surface. Flatness – Optical flat or surface plate + dial indicator. Parallelism –
Dial indicator across surfaces. Squareness – Dial indicator + reference square. Spindle Alignment – Test mandrel
+ dial indicator. Leveling – Precision spirit level.
5. Typical Solved Numericals
Q1. A dial indicator shows 0.02 mm deviation over 300 mm travel while checking bed straightness.
Find the angular misalignment in radians and mm per metre.
Solution: Slope = 0.02/300 = 0.000067 rad. Error per metre = 0.067 mm per metre.
Q2. A test bar turned between centres has diameters 50.000 mm and 49.800 mm over a length of 200
mm. Calculate taper per unit length and approximate half-angle.
Solution: Taper per mm = 0.001000 mm/mm. Half-angle = 0.029°.
Q3. A precision level indicates a difference of 0.03 mm over 500 mm. Express the slope per metre and
angle in radians.
Solution: Error per metre = 0.060 mm per metre. Angle ≈ 6.000000e-05 rad.
Remember: GATE mainly tests conceptual understanding and basic calculations, not full BIS tables.
