Study of Sine Bar

Lab Session: 3
To measure the small external taper of given specimen using Sine Bar.
Objective:
Main objective of this experiment is to understand how we can measure small tapers by using
sine principles. In this experiment, we also get awareness of dial indicators.
Problem statement:
Precise measurement of angles is an important factor in workshops and tool rooms. The parts
produced are useless if they are not according to the dimensions provided by the consumer.
Proper care of tools and instruments is required for accurate measurements.
Apparatus:
 Sine bar.  Vernier calipers.
 Shapes of different sizes.  Gauge Blocks.
Theory:
Sine bar:
A sine bar is used in conjunction with slip gauge blocks for precise angular measurement. A
sine bar is used either to measure an angle very accurately or face locate any work to a given
angle. Sine bars are made from a high chromium corrosion resistant steel, and is hardened,
precision ground, and stabilized.
Figure 3.1: Sine Bar
Two cylinders of equal diameter are placed at the ends of the bar. The axes of these two
cylinders are mutually parallel to each other, and are also parallel to, and at equal distance from,
the upper surface of the sine bar. Accuracy up to 0.01mm/m of length of the sine bar can be
obtained. A sine bar is generally used with slip gauge blocks. The sine bar forms the
hypotenuse of a right triangle, while the slip gauge blocks from the opposite side.
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Types of Available Sine Bars:
Sine bars are available in different forms and sizes, according to the purpose of its use and
method of application. In design (a), the plugs project about 12 mm from the front face of the
bar and in design (b) and (c), the ends of the bar are stepped and the plugs are secured into each
step by screw. Sine bar is also available in inches.
Figure 3.2: Types of Sine Bar
Construction of the Sine Bar:

 Sine Bar is made up of High Carbon steel, High Chromium (Corrosion resistance),
and Hardened.
 It contains Two rollers with the Steel Bar.
 The two rollers are very accurate and Highly precise and truly equal in Diameters.
 When we place the Sine bar on the truly flat surface, the axes of the two rollers are
parallel to each other and also parallel to the upper face of the Sine bar.
 There is the presence of relief holes in the steel bar. (To handle the sine bar easily
and also reduces the overall weight.
Figure 3.3: Parts of Sine Bar
 The normal distance between the two rollers usually available in 100mm, 200mm
or 300mm.
 There are two grades in sine bars. A grade, B grade.
 A grade sine bar is having the accuracy of 0.01mm/m length, B grade sine bar is
having the accuracy of 0.02mm/m length.
Sine Bar Principles:

 As you can see, one Roller is placed on the surface plate and the other one is placed
at a height h with the help of slip gauges.
 Where L is the distance between the two setting rollers of the Sine bar.
 From the above trigonometric formulas Sine θ = Opposite /Diagonal = h/L
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 From this, we can write θ = Sin-1(h/L).
 This is the formula for sine bar to calculate the angle or to set the workpiece at a
required angle. Pretty simple, isn’t it?
 This is the reason why this device called “The Sine Bar’’. (We use Sinθ formula
from Trigonometry)
Figure 3.4:Basic Principle
How to achieve accurate measurements with the Sine Bar?

 The axes of the Setting rollers must be parallel to each other and parallel to the
upper surface of the Bar.
 The distance between the two rollers must be known value. (Size of the sine bar is
determined by this distance only).
 The flatness of the upper surface of the bar should be truly flat. And it should be
parallel to the surface which is contacted to the two setting rollers.
 The two setting rollers must be equal in diameter and round within very close
tolerances.
Accuracy requirement:
The accuracy of the angle set by a sine bar depends on the errors in its important dimensions
such as error in distance between roller centers, error in combination of the slip gauges used
for setting, error in parallelism between gauging surface and plane of roller axes etc.
The slip gauge combination (h) required to set angle (ϴ) is given by,
h = L sin(α)
The effect of error in spacing of roller centers (dL) or errors in combination of slip gauges
(dh) on angular setting accuracy can be obtained by partial differentiation of the above
equation.
dh/dα = (sinα) (dL/dα) + L cosα
dh = (sinα) dL + (L cosα) dα
dα = tanα ((dh/h) - (dL/L))
From the above equation, we can see that, the effect of error in roller spacing or slip gauge
combination is a function of angle α. As the angle α increases, the error (dα) in the angular
measurement increases and above 45
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The graph for dα vs. α is similar to that of exponential curve which steeps at around 45°.
Uses of Sine Bar:

 Sine-bar is used to set or locate the workpiece at a given angle.
 To check the measuring of unknown angles in the workpiece
 Check the unknown angles on the heavier components.
 Some specially designed Sine bars are used to mount the workpiece to do the conical
shape machining for the workpiece.
Limitations of Sine bar:
 Any unknown projections present in the component will cause to induce errors in the
angle measured.
 For the building of the slip gauges, there is no scientific approach available and it is to
be built on the trial and error basis and it is a time-consuming process.
 During measurement of an angle by using sine bar, the length of the sine bar should
be greater than or equal to a length of the component to be inspected.
Sin(θ) = h/L
 If the length of the component Inspected is very long then there is no sine bar
available which is longer than the Component. In such cases, the sine bar will be used
in association with Height Gauge for measurement of the angles.
Sin(θ) = (h2 -h1)/L
Dial indicator:
The Dial indicator is a mechanical mean, having gears and pinions or levers for magnification
system. They can responses to linear measurements even when they are too small. The Dial
Indicators can be used as comparators. Basically, comparators are the precession measuring
instruments used to compare the workpiece measurements with the standard measurements.
When this Dial Indicator is used in any measuring equipment for comparison purpose then this
equipment is called Dial Gauges. A Dial Indicator must be mounted on any other
base/Equipment, otherwise, it will be useless. The accuracy of the dial indicator is up to 0.001
mm are available
Figure 3.5: Dial Indicator
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Main Parts of Dial Indicator:
 Dial with the main scale
 Indicator (Needle)
 The plunger (spindle)
 Mini dial (to represent the number of
revolutions of the indicator.)
 Locking screw
 Magnification Mechanism (Lever/Gear and
Pinion)
Figure 3.6: Parts of Dial Indicator
Procedure:
 The component being checked is placed over the surface of a sine bar as shown.
 A dial gauge is mounted upon a suitable stand such as universal surface gauge.
 It is moved over the component throughout its length. If there is a variation in
parallelism of the upper surface of the component and the surface plate, it is indicated
by the deflection of pointer.
 Now, we tried to adjust the slip gauges height so that the dial indicator reads zero
position.
Observation and calculations:
Where, θ = is the angel to be measure
h = height of the slip gauges.
L = Length of the sine bar (between centers)= 254mm
Difference between 2 end points x Lenght of sine bar

Theoratical Height is given by =
Length of woekpiece
Shape 1:
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5.05x254
Theoratical Height = = 12.50mm
102.6
Thoratical Height 12.50
Sinθ = = = 0.0492
Lenght of sine bar 254
θ = Sine inverse (0.0492)
𝛉 = 𝟐. 𝟖𝟐𝟎°
Shape 2:
5.66x254
Theoratical Height = = 13.998mm
102.6
Thoratical Height 13.998
Sinθ = = = 0.05511
Lenght of sine bar 254
θ = Sine inverse (0.05511)
𝛉 = 𝟑. 𝟏𝟓𝟗°
Comments:
While using sine bar, first we have to ensure the accuracy of sine bar to avoid any errors in
readings. Sine bar is an indirect method to find angles and more accurate than protractors.
These are always used to measure angle between 0-45 degree.
This experiment helps us to understand the importance of trigonometry and its applications.
Moreover, it also shows that how trigonometry can be used for indirect measurement of
angles.
References:
 https://extrudesign.com/sine-bar-construction-working-principle/
 https://extrudesign.com/sine-bar-construction-working-principle/
 https://mechanicalstudents.com/sine-bar-principle-formula-construction-limitations-
factors-influencing-the-angle/
 https://extrudesign.com/dial-indicator-dial-gauge/
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Lab Session: 3

Figure 3.1: Sine Bar

Figure 3.2: Types of Sine Bar

Construction of the Sine Bar:

Figure 3.3: Parts of Sine Bar

Sine Bar Principles:

Figure 3.4:Basic Principle

How to achieve accurate measurements with the Sine Bar?

Uses of Sine Bar:

Sin(θ) = (h2 -h1)/L

Figure 3.5: Dial Indicator

Observation and calculations:

Where, θ = is the angel to be measure

h = height of the slip gauges.

L = Length of the sine bar (between centers)= 254mm

Difference between 2 end points x Lenght of sine bar

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