Professional Documents
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By S K Mondal
Linear measurements
Some of the instruments used for the linear
measurements are:
Rules
Vernier
Micrometer
Height gauge
Bore gauge
Dial indicator
Slip gauges or gauge blocks
Vernier Caliper
A vernier scale is an auxiliary scale that slides along the main
scale.
The vernier scale is that a certain number n of divisions on
the vernier scale is equal in length to a different number
(usually one less) of main-scale divisions.
nV = (n −1)S
where n = number of divisions on the vernier scale
V = The length of one division on the vernier scale
and S = Length of the smallest main-scale division
Least count is applied to the smallest value that can be read
directly by use of a vernier scale.
Least count = S − V = 1 S
n
Vernier Caliper
Metric Micrometer
A micrometer allows a measurement of the size of a
body. It is one of the most accurate mechanical devices
in common use.
Method of Measurement
checking dimensions
GATE – 2008 S-1
A displacement sensor (a dial indicator) measures the
lateral displacement of a mandrel mounted on the taper
hole inside a drill spindle. The mandrel axis is an
extension of the drill spindle taper hole axis and the
protruding portion of the mandrel surface is perfectly
cylindrical. Measurements are taken with the sensor
placed at two positions P and Q as shown in the figure.
The readings are recorded as Rx = maximum deflection
minus minimum deflection, corresponding to sensor
position at X, over one rotation.
GATE – 2008 contd… from S-1
If Rp= RQ>0, which one of the
following would be consistent with the
observation?
(A) The drill spindle rotational axis is
coincident with the drill spindle taper
hole axis
(B) The drill spindle rotational axis
intersects the drill spindle taper hole
axis at point P
(C) The drill spindle rotational axis is
parallel to the drill spindle taper hole
axis
(D) The drill spindle rotational axis
intersects the drill spindle taper hole
axis at point Q
Slip Gauges or Gauge blocks
These are small blocks of alloy steel.
Used in the manufacturing shops as length standards.
Not to be used for regular and continuous
measurement.
Rectangular blocks with thickness representing the
dimension of the block. The cross-section of the block
is usually 32 mm x 9 mm.
Are hardened and finished to size. The measuring
surfaces of the gauge blocks are finished to a very high
degree of finish, flatness and accuracy.
Come in sets with different number of pieces in a given
set to suit the requirements of measurements.
A typical set consisting of 88 pieces for metric units is
shown in.
To build any given dimension, it is necessary to
identify a set of blocks, which are to be put together.
Number of blocks used should always be the smallest.
Generally the top and bottom Slip Gauges in the pile
are 2 mm wear gauges. This is so that they will be the
only ones that will wear down, and it is much cheaper
to replace two gauges than a whole set.
To make up a Slip Gauge pile to 41.125 mm
A Slip Gauge pile is set up with the use of simple
maths.
Decide what height you want to set up, in this
case 41.125mm.
Take away the thickness of the two wear gauges,
and then use the gauges in the set to remove
each place of decimal in turn, starting with the
lowest.
To make up a Slip Gauge pile to 41.125 mm
41.125
-4.000
______
37.125
-1.005
_______
36.120
-1.020
_______
35.100
-1.100
_______
34.000
-4.000
_______
30.000
-30.000
_______
0.000
A Metric slip gauge set (88 Pieces)
Slip gauges size or Increment, mm Number of
range, mm Pieces
1.005 - 1
1.001 to 1.009 0.001 9
1.010 to 1.490 0.010 49
0.500 to 9.500 0.500 19
10 to 100 10.000 10
Comparators
Comparator is another form of linear measuring
method, which is quick and more convenient for
checking large number of identical dimensions.
During the measurement, a comparator is able to give
the deviation of the dimension from the set dimension.
Cannot measure absolute dimension but can only
compare two dimensions.
Highly reliable.
To magnify the deviation, a number of principles are
used such as mechanical, optical, pneumatic and
electrical.
Fig. Principle of a comparator
GATE – 2007 (PI)
Which one of the following instruments is a
comparator ?
(a) Tool Maker’s Microscope
(b) GO/NO GO gauge
(c) Optical Interferometer
(d) Dial Gauge
Feeler Gauge
PSU
A feeler gauge is used to check the
the scales
Bevel protractor
Sine bar
Bevel Protractor
Is part of the machinist's combination square.
L
1 1
Ra y ( x) dx
L0 N
y i
The other parameter that is used sometimes is the root
mean square value of the deviation in place of the
arithmetic average , This in expression form is
1
RRMS
N
2
yi
2
Optical flat as a comparator
n l
h
2
Where l separation of edges
n number of fringes / cm
h The difference of height between gauges
wevlength of monochomatic light
GATE - 2003
Two slip gauges of 10 mm width measuring 1.000 mm
and 1.002 mm are kept side by side in contact with each
other lengthwise. An optical flat is kept resting on the
slip gauges as shown in the figure. Monochromatic light
of wavelength 0.0058928 mm is used in the inspection.
The total number of straight fringes that can be observed
on both slip gauges is
(a) 2 (b) 6
(c) 8 (d) 13
GATE – 2011 (PI)
Observation of a slip gauge on a flatness
interferometer produced fringe counts numbering
10 and 14 for two readings. The second reading is
taken by rotating the set-up by 180o. Assume that
both faces of the slip gauge are flat and the
wavelength of the radiation is 0.5086 µm. The
parallelism error (in µm) between the two faces of
the slip gauge is
(a) 0.2543 (b) 1.172
(c) 0.5086 (d) 0.1272
Talysurf
It is based upon measuring the generated noise due to
dry friction of a metallic blade which travels over the
surface under consideration.
If the frictional force is made small enough to excite
the blade, and not the entire system, then the noise
will be proportional to surface roughness, and
independent of the measured specimen size and
material.
The specimen surface roughness was measured by a
widely used commercial instrument (Talysurf 10), and
the prototype transducer.
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Ans. (d)