UNIT3

FORM MEASUREMENT
Measurementofscrewthreads-Threadgauges,floatingcarriagemicrometer-measurement
of gear-tooth thickness-constant chord and base tangent method-Gleason gear testing
machine (radius measurements-surface finish, straightness, flatness and roundness
measurements-these topics not included in topics so you study by your own)
Important topics are highlighted
ScrewThreadsTerminology:

Screwthread.Ascrewthreadisthehelicalridgeproducedbyformingacontinuous
helicalgrooveofuniformsectionontheexternalorinternalsurfaceofacylinderor
cone.Ascrewthreadformedonacylinderisknownasstraightorparallelscrew
thread,whiletheoneformedonaconeorfrustumofaconeisknownastapered
screwthread.
2 Externalthread.Athreadformedontheoutsideofaworkpieceiscalledexternal
threade.g.,onbolts orstudsetc.
3. Internalthread.A threadformedontheinsideofa workpiece is calledinternal
threade.g.onanut orfemalescrewgauge.
4. Multiplestartscrewthread.Thisisproducedby
formingtwoormorehelical
grooves,equallyspacedandsimilarlyformedinanaxialsectionon a cylinder.This
gives a quick traverse without sacrificing core strength.
Axisofathread. Thisisimaginarylinerunninglongitudinallythroughthecentre ofthe
screw.
6 Hand(Rightorlefthandthreads).Supposeascrewisheldsuchthattheobserver
islookingalongtheaxis.Ifapoint movesalongthethread inclockwise direction
andthusmovesawayfromtheobserver,thethreadisright hand;andif itmoves
towardstheobserver,thethread islefthand.
7 Form,ofthread.Thisistheshapeofthecontourofonecompletethreadas.seenin
axialsection.
Crestofthread.Thisisdefinedastheprominentpartofthread,whetheritbeexternalor
internal.
1

12

14

16
17

19

Rootofthread.Thisisdefinedasthebottomofthegroovebetweenthetwoflanksofthe
thread,whetheritbeexternalorinternal.
10. Flanksofthread.Thesearestraightedgeswhichconnect the crestwiththe
root.
11. Angleofthread{Includedangle).Thisistheanglebetween the flanksorslope
ofthethreadmeasuredinanaxialplane.
Flank angle. The flank angles are the angles between individual flanks and the
perpendiculartotheaxisofthethreadwhichpassesthroughthevertexofthe
fundamentaltriangle.Theflankangleofasymmetricalthreadiscommonlytermed
asthehalfangleofthread.
13 Pitch. Thepitchofathreadisthedistance,measuredparalleltotheaxisofthe
thread,betweencorrespondingpointsonadjacentthreadformsinthesameaxial
planeandonthesamesideofaxis.Thebasicpitchisequaltotheleaddividedby
thenumberofthreadstarts.Ondrawingsofthreadsections,thepitchisshownas
thedistancefromthecentreofonethreadcresttothecentreofthenext,andthis
representationiscorrectforsinglestartaswellasmultistartthreads.
Lead.Leadistheaxialdistancemovedbythethreadedpart,whenitisgivenonecomplete
revolutionaboutitsaxiswithrespecttoafixedmatingthread.Itis
necessarytodistinguishbetweenmeasurementsofleadfrommeasurementofpitch,
asuniformityofpitchmeasurementdoesnotassureuniformityoflead.Variationsin
eitherleadorpitchcausethefunctionalorvirtualdiameterofthreadtodifferfrom
thepitchdiameter.
15 Threadperinch.Thisisthereciprocalofthepitchininches.
Leadangle.Onastraightthread,leadangleistheanglemadebythehelixofthethreadat
thepitchlinewithplaneperpendiculartotheaxis.Theangleis
measuredinanaxialplane.
Helixangle.Onstraightthread,thehelixangleistheanglemadebythehelixofthethread
atthepitchlinewiththeaxis.Theangleismeasuredinanaxialplane.
18 Depthofthread.Thisisthedistancefromthecrestortipofthethreadtotherootof
thethreadmeasuredperpendiculartothelongitudinalaxisorthiscouldbedefinedas
thedistancemeasuredradiallybetweenthemajorandminorcylinders.
Axial thickness. This is the distance between the opposite faces of the same thread
measuredonthepitchcylinderinadirectionparalleltotheaxisofthread.
20 Fundamentaltriangle.Thisisfoundbyextendingtheflanksandjoiningthepoints
BandC.ThusinFig.13.2,triangleABCisreferredtoasfundamentaltriangle.
Here BC=pitch and the vertical height of the triangle is called the angular or
theoreticaldepth.ThepointAistheapexofthetriangleABC.
21 Truncation. Athreadissometimestruncatedatthecrestorattherootoratboth
crestandroot.Thetruncationatthecrestistheradialdistancefromthecresttothe
nearestapexofthefundamentaltriangle.Similarlythetruncationattherootisthe
radialdistancefromtheroottothenearestapex.
22 Addendum.Foranexternalthread,thisisdefinedastheradialdistancebetweenthe
majorandpitchcylinders.Foraninternalthreadthisistheradialdistancebetween
theminorandpitchcylinders.
Measurementofscrewthreadsprinciplesoffloatingcarriagemicrometer,

Itconsistsofthreemainunits.Abasecastingcarriesapairofcentres,onwhichthe
threadedworkpieceismounted.Anothercarriageismountedonitandisexactlyat90toit.
Onthisisprovidedanothercarriagecapableofmovingtowardsthecentres.Onthiscarriageone
headhavingalargethimbleenablingreadingupto0.002mmisprovided.Justoppositeto
itisafixedanvilwhichisspringloadedanditszeropositionisindicatedbyafiducial
indicator.Thusthemicrometerelementsareexactlyperpendiculartotheaxisofthecentres
as the twocarriagesare located perpendicular to each other. On the fixedcarriage the
centresaresupportedintwobracketsfittedoneitherend.Thedistancebetweenthetwo
centrescanbeadjusteddependinguponthelengthoftiethreadedjob.Afterjobisfitted
betweenthecentresthesecondcarriageisadjustedincorrectpositiontotakemeasurements
andislocatedinposition,Thethirdcarriageisthenmovedtillthefiducialindicatoris
againstthesetpoint.Thereadingsarenotedfromthethimblehead.Itisnowobviousthat
theaxisoftheindicatorandmicrometerheadspindleissameandisperpendiculartothe
lineoftwocentres.Theindicatorisspeciallydesignedforthisclassofworkandhasonly
one index line, against which the pointer is always to be set. This ensures constant
measuringpressureforallreadings.Sufficientfrictionisprovidedbytheconicalpegsto
restrainthemovementofcarriagealongthelineofcentres.Theuppercarriageisfreeto
floatonballsandenablesmicrometerreadingstobetakenonadiameterwithoutrestraint.
Squarenessofthemicrometertothelineofcentrecanbeadjustedbyrotatingthepegsin
thefirstcarriagewhichismadeeccentricinitsmounting.

Abovethemicrometercarriage,twosupportsareprovidedforsupportingthewiresand
Veepiecesformeasurementofeffectivediameteretc.
(i)MeasurementofMajorDiameter.
Forthemeasurementofmajordiameterofexternalthreads,agoodqualityhand
micrometerisquitesuitable.Intakingreadings,alightpressuremustbeusedastheanvils
makecontactwiththegaugeatpointsonlyandotherwisetheerrorsduetocompressioncan
be introduced. It is, however, also desirable to check the micrometer reading on a
cylindricalstandardofapproximatelythesamesize,sothatthezeroerroretc.,mightnot
comeintopicture.
Forgreateraccuracyandconvenience,themajordiameterismeasuredbybench
micrometer.ThisinstrumentwasdesignedbyN.P.L.toestimatesomedeficienciesinherent
inthenormalhandmicrometer.Itusesconstantmeasuringpressureandwiththismachine
the error due to pitch error in the micrometer thread is avoided. In order that all
measurementsbemadeatthesamepressure,afiducialindicatorisusedinplaceofthefixed
anvil.Inthismachinethereisnoprovisionformountingtheworkpiecebetweenthecentres
anditistobeheldinhand.Thisisso,because,generallythecentresoftheworkpieceare
nottruewithitsdiameter.Thismachineisusedasacomparatorinordertoavoidanypitch
errorsofmicrometers,zeroerrorsettingetc.Acalibratedsettingcylinderisusedasthe
settingstandard.
Theadvantageofusingcylinderassettingstandardandnotslipgaugesetc.,isthatit
givesgreatersimilarityofcontactattheanvils.Thediameterofthesettingcylindermustbe
nearlysameasthemajordiameter.Thecylinderisheldandthereadingofthemicrometeris
noteddown.Thisisthenreplacedbythreadedworkpieceandagainmicrometerreadingis
notedforthesamereadingoffiducialindicator.Thus,ifthesizeofcylinderisapproaching,
thatofmajordiameter,thenforagivenreadingthemicrometerthreadisusedoverashort
lengthoftravelandanypitcherrorsitcontainsarevirtuallyeliminated.

Thenmajordiameter=D1+(R2R1).
Inorderto determine the amount of taper, the readings should be taken at various
positionsalongthethreadandtodetecttheovality,twoorthreereadingsmustbetakenat
oneplaneinangularpositions.
ii

MeasurementofMinorDiameter
ThisisalsomeasuredbyacomparativeprocessusingsmallVeepieceswhichmake
contact with arootof thethread.The Veepieces are available inseveral sizeshaving
suitableradiiattheedges.TheincludedangleofVeepiecesislessthantheangleofthe
threadtobecheckedsothatitcaneasilyprobetotherootofthethread.Tomeasurethe
minordiameterbyVeepiecesissuitableforonlyWhitworthandB.A.threadswhichhavea
definiteradiusattherootofthethread.Forotherthreads,theminordiameterismeasured
bytheprojectorormicroscope.

Themeasurementiscarriedoutonafloatingcarriagediametermeasuringmachine
inwhichthethreadedworkpieceismountedbetweencentresandabenchmicrometeris
constrainedtomoveatrightanglestotheaxisofthecentrebyaVeeballslide.Themethod
oftheapplicationofVeepiecesinthemachineisshowndiagrammaticallyinFig..The
dimensionsofVeepiecesplaynoimportantfunctionastheyareinterposedbetweenthe
micrometerfacesandthecylindricalstandardwhenstandardreadingistaken.
Itisimportantwhiletakingreadings,toensurethatthemicrometerbelocatedat
rightanglestotheaxisofthescrewbeingmeasured.TheselectedVeesareplacedoneach
sideofthescrewwiththeirbasesagainstthemicrometerfaces.Themicrometerheadisthen
advanceduntilthepointeroftheindicatorisoppositethezeromark,andnotebeingmade
ofthereading.Thescrewisthenreplacedbystandardreferencediscoraplaincylindrical
standardpluggaugeofapproximatelythecorediameterofthescrewtobemeasuredand
secondreadingofthemicrometeristaken.
IfreadingonsettingcylinderwithVeepiecesin
position=R1andreadingonthread=R2
anddiameterofsettingcylinder=D1
Thenminordiameter=D1+(R2R1)
Readingsmaybetakenatvariouspositionsinordertodeterminethetaperandovality.
iii EffectiveDiameterMeasurements.
Theeffectivediameterorthepitchdiametercanbemeasuredby.anyoneofthe

followingmethods:
i Themicrometermethod
ii Theonewire,twowire,orthreewireorrodmethod.
TwoWireMethod.
Theeffectivediameterofascrewthreadmaybeascertainedbyplacingtwowiresor
rodsofidenticaldiameterbetweentheflanksofthethread,asshowninFig.13.15,and
measuringthedistanceovertheoutsideofthesewires.TheeffectivediameterEIsthen
calculatedas
E=T+P
WhereT=Dimensionunderthewires=M
2d
M=dimensionoverthewires,d=diameterofeachwire

Fig(a)

Fig(b)

Thewiresusedaremadeofhardenedsteeltosustainthewearandtearinuse.These
aregivenahighdegreeofaccuracyandfinishbylappingtosuitdifferentpitches.
DimensionTcanalsobedeterminedbyplacingwiresoverastandardcylinderofdiameter
greaterthanthediameterunderthewiresandnotingthereadingR 1andthentakingreading
withoverthegauge,sayR2.ThenT=S(R1R2).
P=Itisavaluewhichdependsuponthediaofwireandpitchofthethread.
If
P=pitchofthethread,then
P=0.9605p1.1657d (for Whitworth thread).
P=0.866pd(formetricthread).
ActuallyPisaconstantValuewhichhastobeaddedtothediameterunderthewires
togivetheeffectivediameter.TheexpressionforthevalueofPintermsofp(pitch),d
(diameterofwire)andx(threadangle)canbederivedasfollows:
InFig.13.15(b),

sinceBCliesontheeffectivediameterline

BC=pitch=p
OP=dcosecx/22
PA=d(cosecx21)2
PQ=QCcotx2=p4 cot x2
AQ=PQAP=p cot x24 d(cosecx2 1)2
AQishalfthevalueofP

..

Pvalue=2AQ
=p2 cot x2 d (cosecx21)

Two wire method can be carried out only on the diameter measuring machine
describedformeasuringtheminordiameter,becausealignmentisnotpossibleby2wires
andcanbeprovidedonlybythefloatingcarriagemachine.Inthecaseofthreewiremethod,
2wire,ononesidehelpinaligningthemicrometersquaretothethreadwhilethethird
placedontheothersidepermitstakingofreadings.
ThreeWireMethod.
Thismethodofmeasuringtheeffectivediameterisanaccuratemethod.Inthisthree
wiresorrodsofknowndiameterareused;oneononesideandtwoontheotherside{Fig.
13.17(a)and(&)].Thismethodensuresthealignmentofmicrometeranvilfacesparallelto
thethreadaxis.Thewiresmaybeeitherheldinhandorhungfromastandsoastoensure
freedomtothewirestoadjustthemselvesundermicrometerpressure.

M=distanceoverwires
E=effectivediameter
r=radiusofthewires
d=diameterofwires
h=heightofthecentreorthewireorrodfromthe
effectivex=angleofthread.

Fig(a)

Fromfig.(b),
AD=ABcosecx2=rcosecx2
H=DEcotx2=p2 cot x2
CD=H=p4 cot x2
H=ADCD
r=cosecx2 p4cotx2
Distanceoverwires=M=E+2h+2r
=

E+2(rcosecx2 p4cotx2)+2r

E+2r(l+cosecx2 ) p2 cot x2
or M=E+d(1+cosecx2) p2 cot x2
(since2r=0)
(i)IncaseofWhitworththread:

Fig(b)

X=55,depthofthread=0.64p,sothat
E=D0.64pandcosecx2 =2.1657
Cotx2=1.921
M=E+d(1l+cosecx2) p2 cotx2
=

D0.64p+d(1+2.1657)p2(1.921)

D+3.1657d1.6005p
M=D+3.1657d1.6p
whereD=outsidedia.

(ii)Incaseofmetricthreads:
Depthofthread=0.6495p
so,

E=D0.6495p.

x=60,cosecx2=2;cotx2 = 1.732
M=D0.6495 p+d(l+2)p2 (1.732)
=

D+3d(0.6495+0.866)p

D+3d1.5155p.
WecanmeasurethevalueofMpracticallyandthencomparewiththetheoretical
valueswiththehelpofformulaederivedabove.AfterfindingthecorrectvalueofMand
knowingd,Ecanbefoundout.
IfthetheoreticalandpracticalvaluesofM(i.e.measuredoverwires)differ,then
thiserrorisduetooneormoreofthequantitiesappearingintheformula.
Effectofleadangleonmeasurementby3wiremethod.Iftheleadangleislarge(aswith
worms; quick traversing lead screw,etc .) then error in measurement is about 00125 mm
whenleadangleis41for60singlethreadseries.
Forleadanglesabove4,thecompensationforrakeandcompressionmustalsobe
takenintoaccount.

ThereisnorecommendationforB.S.W.threads.
RakeCorrectioninU.S.Standard:
2
E=M+cotx22n x(1 +cosec x2+s 2 cosx2 cot x2)
where
x2 =half the included angle of threads.
E=effectivediameter
M=actuallymeasureddiameterover
wires:n=numberofthreads/inch.
d=diameterofwire.
S=tangentofthehelixangleinthread.
BestsizewireMethod.
Thiswireisofsuchdiameterthatitmakescontactwiththeflanksofthethreadonthe
effectivediameterorpitchline.Theeffectivediametercanbemeasuredwithanydiameter
wirewhichmakescontactonthetrueflankofthethread,butthevaluessoobtainedwill
differ from those obtained with best size wires if there is any error in angle or form of

thread.tisrecommendedthatformeasuringtheeffectivediameter,alwaysthebestsize
wireshouldbeusedandforthisconditionthewiretouchestheflankatmeandiameterline
within1/5offlanklength

Letthethreadangle

TheninleOAP,SinPOA= AP /OP
0

Orsin(90

( )
2 )=AP/OP

( )
/2 )=APsec /2
OP=AP/sin(90 2 )=AP/(cos
0

Since,OP=r=APsec / 2
Andwirediameter=Db=2r=2APsec

/ 2

SinceAPliesonthepitchline
AP=p/4where,pisthepitchofthethread
/ 2
/2
Therefore,Db=2p/4 sec
=p/2sec
ToolMakersMicroscope:
Thetoolmaker'smicroscopeisanopticalmeasuringmachineequippedforexternaland
internal length measurements as well as measurements on screw threads, profiles,
curvatures and angles. For these purposes, the microscope is provide with several
measuringattachmentssuchas
1 Centrestageformountingofcylindricalcomponents,
2 Revolvingandanglemeasuringoculars,
3 Doubleimageocular,
4 Opticalfeeder,and
5 Projectionscreen.
Theapplicationsoftheinstrumentmaybesummarizedlows:broadlyasfollows.
1 ThedeterminationoftherelativepositionofvariousPointsonworkbymeasuringthe
travelnecessarytobringasecondpointtothepositionpreviouslyoccupiedbythefirst,
andsoon..
2 Measurementofanglesbyusingaprotractoreyepiece.
3 Comparison of thread forms with master profiles engraved in the eyepiece and

measurementofpitchandeffectivediameter.
Comparisonofanenlarged,projectedimagewithascaletracingfixedtotheprojection
screen.

Figureshowsatoolmaker'smicroscope.Themainpartsoftheinstrumentare:
1 Rotatabletable
2 Swingablehead
3 Projectionscreen
4 Objectivelens
5 Measuringstage
6 Ocular
7 Micrometers
8 Prism.
Construction:
Themicroscopeconsistsofarigidstandonwhichaswingableheadismounted.The
measuring stage moves on ball guideways by actuating two measuring micrometers
arrangedperpendiculartoeachotherinthelength.andthecrosssections.Themeasuring
rangeofeachmicrometeris25mmandthemeasuringcapacitycanbeincreasedusingslip
gauges.Arotatabletableisprovidedoverthestage,onwhichtheworkpiececanbefixed
eitherdirectlyorbetweencenters.Thistablecanberotatedthough3600andtheangular
rotationcanbereadbyafixedverniertoascalevalueof3'.
Working:
Thecomponentbeingmeasuredisilluminatedbythethroughlightmethod.Aparallelbeam
oflightilluminatesthelowersideofworkpiecewhichisthenreceivedbytheobjectivelens
initswaytoaprismthatdeflectsthelightraysinthedirectionofthemeasuringocularand
theprojectionscreen.Incidentilluminationcanalsobeprovidedbyanextraattachment.
Exchangeableobjectivelenshavingmagnification1X,1.5X,3Xand5Xareavailablesothat
atotalmagnificationofl0X,15X,30Xand50Xcanbeachievedwithanocularofl0X.The
directionofilluminationcanbetiltedwithrespecttotheworkpiecebytiltingthemeasuring
headandthewholeopticalsystem.Thisinclinedilluminationisnecessaryinsomecasesas
inscrewthreadmeasurements.
Thescalevalueofthismicroscope:
0.01mmforlengthmeasurement.
3'foranglemeasurementwithrotatabletable.
Applications
Theapplicationsoftheinstrumentmaybesummarizedbroadlyasfollows.
1 ThedeterminationoftherelativepositionofvariousPointsonworkbymeasuring
thetravelnecessarytobringasecondpointtothepositionpreviouslyoccupiedby
thefirst,andsoon.
2 Measurementofanglesbyusingaprotractoreyepiece.
3 Comparison of thread forms with master profiles engraved in the eyepiece and
measurementofpitchandeffectivediameter.
4 Comparison of an enlarged, projected image with a scale tracing fixed to the
projectionscreen.
GearMeasurement
Gearsisamechanicaldrivewhichtransmitspowerthroughtoothedwheel.Inthisgear
drive,thedrivingwheelisindirectcontactwithdrivenwheel.Theaccuracyofgearingis
the very important factor when gears are manufactured. The transmission efficiency is
almost99ingears.Soitisveryimportanttotestandmeasurethegearsprecisely.
Forproperinspectionofgear,itisveryimportanttoconcentrateontherawmaterials,

whichareusedtomanufacturethegears,alsoveryimportanttocheckthemachiningthe
blanks,heattreatmentandthefinishingofteeth.
Thegearblankshouldbetestedfordimensionalaccuracy(facewidth,bore,hub,length,
andoutsidediameter),andeccentricity.Asoutsidediameterformsthedatumfromwhere
thetooththicknessismeasured,itformsanimportantitemtobecontrolled.Concentricity
oftheblanksisalsoessentialandthesidefacesshouldbetruetothebore.Onveryprecise
gearsdetailsliketipradius,shapeofrootprovidedandsurfacefinisharealsomeasured.
Themostcommonlyusedformsofgearteethare
1 Involute
2 Cycloidal
Theinvolutegearsalsocalledasstraighttoothorspurgears.
Thecycloidalgearsareusedinheavyandimpactloads.
Theinvoluterackhasstraightteeth.
Theinvolutepressureangleiseither20or14.5
Typesofgears
1Spurgear:
Cylindricalgearwhosetoothtracesisstraightline.
Theseareusedfortransmittingpowerbetweenparallelshafts.
2Spiralgear:
Thetoothofthegeartracescurvedlines.
3Helicalgears:
Thesegearsusedtotransmitthepowerbetweenparallelshaftsaswellas
nonparallelandnonintersectingshafts.
Itisacylindricalgearwhosetoothtracesisstraightline.
4Bevelgears:
Thetoothtracesarestraightlinegeneratorsofcone.
Theteetharecutontheconicalsurface.Itisusedtoconnecttheshaftsatrightangles.
5WormandWormwheel:
Itisusedtoconnecttheshaftswhoseaxesarenonparallelandnonintersecting.
6RackandPinion:
Rackgearsarestraightspurgearswithinfiniteradius.

1Toothprofile:
Itistheshapeofanysideofgeartoothinitscrosssection.

2Basecircle:
Itisthecircleofgearfromwhichtheinvoluteprofileisderived.
BasecirclediameterPitchcirclediameterxCosineofpressureangleofgear
3Pitchcirclediameter(PCD):
Thediameterofacirclewhichwillproducethesamemotionasthetoothed
gearwheel
4Pitchcircle
Itistheimaginarycircleofgearthatrollswithoutslippingoverthecircleofits
matinggear.
5Addendumcircle:
Thecirclecoincideswiththecrests(or)topsofteeth.
6Dedendumcircle(or)Rootcircle:
Thiscirclecoincideswiththeroots(or)bottomonteeth.
7.Pressureangle(a):
Itistheanglemakingbythelineofactionwiththecommontangenttothepitch
circlesofmatinggears.
8.Module(m):
Itistheratioofpitchcirclediametertothetotalnumberofteeth.
Where,
d=Pitchcircle
diameter.
n=Numberfteeth
9Circularpitch
Itisthedistancealongthepitchcirclebetweencorrespondingpointsofadjacentteeth

10 Addendum:
Radialdistancebetweentipcircleandpitchcircle.Addendumvalue=1module.
11 Dedendum:
Radialdistancebetweenitchcircleandrootcircle,Dedendumvalue=1.25module.
12 Clearance(C):
Amountofdistancemadebythetipofonegearwiththerootof
mating gear. Clearance = Difference between Dedendum and
addendumvalues
13 Blankdiameter:
Thediameteroftheblankfromwhichgearisout.Blankdiameter=PCD+2m
14 Face:
Partofthetoothintheaxialplanelyingbetweentipcircleandpitchcircle.
15 Flank:
Partofthetoothlyingbetweenpitchcircleandrootcircle.
16 Topland:

 Topsurfaceofatooth
17 Leadangle:
Theanglebetweenthetangenttothehelixandplaneperpendiculartotheaxisof
cylinder.
18 Backlash:
Thedifferencebetweenthetooththicknessandthespaceintowhichitmeshes.
GearToothCaliper
Ingeartoothverniermethodthethicknessismeasuredatthepitchline.Geartooth
thicknessvariesfromthetipofthebasecircleofthetooth,andtheinstrumentiscapableof
measuringthethicknessataspecifiedpositiononthetooth.Thetoothverniercaliperconsistsof
vernierscaleandtwoperpendiculararms.Inthetwoperpendiculararmsonearmisusedto
measurethethicknessandotherarmisusedtomeasurethedepth.Horizontalvernierscale
readinggiveschordalthickness(W)andverticalvernierscalegivesthechordaladdendum.
Finallythetwovaluesecompared.The theoretical values of W and d can be found out by
consideringonetoothinthegearanditcanbeverified.

InfignotethatwisachordADBandtooththicknessisspecifiedbyAEB.The
distancedisnotedandadjustedoninstrumentanditisslightlygreaterthanaddendumCE
Therefore, W is chordal thickness andd is named as chordal addendum.

So,W=AB=2AD
And angle, AOD = =
Where,

n=numberofteeth
W = 2AD = 2 x AO sin
=2Rsin360/4n

Where,

R=Pitchcircleradius

Module,m=pitchcircledia/noofteeth=2R/n
Therefore,R=nm/2
And OD = R Cos = nm/2 cos (90/n)
OD== nm/2 cos (90/n)
Alsofromthefigure,
d=OCOD

Addendumistheradialdistancefromthepitchcircletothetipofthetooth.Its
valueisequaltoonemodule
But OC=OE+Addendum=R+m=nm/2+m
And
OD = R cos
= nm/2 cos (90/n)
Therefore d= (nm/2) +(nm/2 cos(90/n))
Verniermethodlikethechordalthicknessandchordaladdendumaredependsupon
thenumberofteeth.Duetothisformeasuringlargenumberofgearsdifferentcalculationsare
tobemadeforeachgear.Sothesedifficultiesareavoidedbythisconstantchordmethod.

Base Tangent Method

Tool Makers Microscope:

TOOL-MAKERS MICROSCOPE Tool makers microscope is based on the Principle of
optics. The microscope consists of a heavy-duty hallow-duty hallow base, which
accommodates the illuminating unit underneath, and above this on the top surface of the
base, the work table carriage is supported on ball and controlled by micrometer screws.
Projecting up from the rear of the base is a column, which carries the microscope unit
and various interchangeable eyepieces. Uses: The chief applications of the tool room
microscope are as follows 1. The determination of relative position of various points on
work. 2. Measurement of angle by using a protractor eyepiece. 3. Comparison of thread

forms with master profiles engraved in the eyepiece, measurement of pitch and effective
diameter.

CONSTRUCITON OF MICROSCOPE

Base: The study base rest on three support two of which are adjustable for leveling the
instrument. The base has built in all electrical transformers and their control panel and
transmitted illuminator with green filter. The course focusing movement provided in the
microscope tube separately. The coarse motion is knurled knob on both side of the tube
and ha as the total travel of 200mm. Its also lock any position by lever, this movement is
characterized by its exceptionally smooth and accurate precision. The vertical travel or
measurement up to 10mm, thickness can be read by the depth dial gauge. The thickness
is being measured with the difference of two different focusing of object. The least
count of gauge is 0.01. Fig. Tool makers microscope Eyepiece Protractor This unique
protractor head graduated 0 to 360 degree with adjustable vernier reading to 6 minutes
cross line incorporated in the protractor head rotating in the optical axis of the
microscope the cross line graticule is replaceable with many other measuring graticules.
Measuring Stage The stage plate is of 150 X 150 mm having very smooth and precise
movements in both axis with special ball racers arrangements. The travel of the stage is
25mm. in both direction with precise imported micrometer head, least count 0.01 or
0.005mm. The stage has two T-slots for mounting accessories like rotary stage, center
holding device attachment and V-block etc. Rotary Stage A rotating stage is fixed in Tslots of square plate having 360 degree graduations on its periphery with vernier reading

to6 minute, and lock screw. All types of horizontal angular measurements can be done
with this stage. Illuminating System Two possible range of illuminating system are
provided with standard equipment to meet every application, operated through 6 volts
solid state variable light control built in transformer. 1. Sub-stage transmitted light from
a bottom source providing collimated green filter halogen light for viewing contours and
transparent objects. 2. Surface incident illuminator for shadow free lighting, for high
power examination of opaque objects.
Measurement of screw thread pitch :
1. The image of the thread profile is set so that some of the profile coincides with the
cross hair as seen on the ground- glass screen.
2. The reading on thimble of the longitudinal micrometer screw is noted down.
3. Then the part is traversed by the micrometer screw until a corresponding point on the
profile of the next thread coincides with the cross hairs.
4. The reading on thimble is again noted and the difference in two readings gives the
actual pitch of the screw.
Measurement of angle of thread :
1. It is determined by rotating the screen until a line on the screen coincides with one
flank of the thread profile
2. The angle of screen rotation is noted and then the screen is further rotated till the
same line coincides with the other flank of thread.
3. The difference in two angular readings gives the actual angel of thread on the
screw.
Parkinson Gear Tester or Gleason gear testing machine
It works on the principle of measurement of the mis-run of the smooth running of the
precisely meshing gears (when rotated with respect to each other) with any variation in
the geometry of the gear tooth profile due to the wear and tear by the periodic use or the
faulty manufacturing
Its special features are:
It applies the accuracy up to 1 micron.
It is light in weight and hence it is portable.
Weight of machine is 30 kg.(approx.)
It requires very low maintenance.
Its setting time is less
. It requires very low floor space area
. Its manufacturing cost is also very low.
No separate arrangement of drawing sketch is required.
It requires low power for its operations hence it can be excited using d.c.
Power and d.c. motor (also to be used in remote areas also).
It is compact. Total length of machine is 1200 mm.

Parkinson gear tester

Gear test rig is such arrangement which simplifies the measurement and saves the
labourtime and labour cost with greater accuracy. In gear test rig all the gears will be
mounted on a plate which may be fixed or stationary as per the requirement of the
measurement. While measuring the one gear remaining will act as a master gear. This
will help in finding the composite error. This test rig can be used in shop floor as it
requires less space and operatorcan use it as per need without wasting much time. The
test rig can be developed for different parameter as per measurement requirement. There
are various test rigs which can be used for that particular designed condition
To operate the testing machine, electric motor (prime mover), which is torque motor
having 20 N-m torque capacity, is used to rotate the master gear against the gear to be
tested. Also an another motor of the same capacity is used to rotate the paper rolling
drum to pass the recording paper against the vibrating pen and stylus due to the
improper tooth geometry provided. The gear to be tested is installed on the trolley gear
shaft using the fasteners as the nut and bolts. The trolley being spring loaded is in
continuous close contact with the master gear. The master gear shaft is extended and is
coupled with the driving torque motor using a coupling. When the pair of master gear
and the gear to be tested is rotating and if there is any mis-run of the gear to be tested
then the stylus and pen arrangement will deflect and the appropriate amount of variation
in the graph which is recorded on the moving paper is being recorded. Thus the
operation of gear testing machine is done.

Straightness Measurement
Set-up:
Autocollimator with double micrometer, collimator reticle S115 (crossline) and eyepiece
reticle S127 (double crossline)
or
ELCOMAT (electronic autocollimator) and
Base mirror Straight edge Tripod
Adjustable holder
Measurement
Set mirror on slide. Adjust autocollimator to the mirror. Move the slide and observe the
autocollimation image. Each tilting of the mirror in the guiding direction effects a ydisplacement of the autocollimation image from the zero-position. A tilting vertical to the
guide can be tested by a rectangular prism instead of a mirror. Move the mirror by the base
length of the mirror (100 mm or 50 mm) and read out each difference y or y0 to the previously
recorded value. The local slope m of the slide is determined by:
0

m = 2f 0

or m = tan

yy

Where:
: local slope of the slide over the base length of the mirror y : angular reading of
autocollimators with angular graduation y0 : distance in the autocollimation image plane
f 0 : focal length of the autocollimator
The height difference from the mirror position to the previous position is:
h=m b
Where:
h: Height difference between the supporting points of the base mirror
b : Base length (distance between the supporting points) of the base mirror
The height profile h(l) can be calculated by accumulation of the height deviation in each
measurement position. With the ELCOMAT 3000 or ELCOMAT vario the measurement can
be carried out with higher accuracy and in shorter time compared to visual autocollimators