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Linear and Angular Measurements: Unit - 2

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LINEAR AND ANGULAR

MEASUREMENTS

UNIT -2
METROLOGY
METROLOGY is defined as a measurement of length and
angles and other such quantities which are expressed in
linear and angular measurement.
• ENGINEERING METROLOGY is the measurement of
dimensions: length, thickness, diameter, taper,
angle,flatness, profiles, and others.

• Traditionally: Post process inspection


• Current Trend: In-process, on-line, real-time inspection
• Inspection: Check dimensions of what have been produced or
what is being produced whether it conforms with the specified
dimensional accuracy.
• Dimensional Tolerances: Permissible variation in dimensions of a
part
• Instruments: tools for measurements
IMPORTANTCE OF METROLOGY

• IMPORTANTCE OF METROLOGY
• To achieve quality control in production
• To achieve up to date production, knowledge of The
measurement require.
• To reduce rejection with the help of quality control.
• To develop inspection procedure .
• To calibrate measuring instrument time to time
TERMS USED IN METROLOGY

• SPECIFICATION:
Every product and part have some certain
characteristics .It gives certain thoughts of that
particular product. Its called specification. It gives
easy to understand production method.
• STANDARD :
Standard is define as , it is a physical quantity
which is established by higher authority or
organization .This standard is reliable and acceptable
to measure physical quantity. Ex. METER
LENGTH STANDARD

THERE ARE TWO STNDARD SYSTEM TO


MEASURE LENGTH
1.BRITISH SYSTEM: INCH,FOOT,YARD

2.METRIC SYSTEM: MM,CM,METER


UNITS

UNIT OF LINEAR MEASUREMENT:


1.British system : mile
yard
foot (‘)
inch (“)
2.metric system: kilometer
meter
decimeter
centimeter
millimeter
3.S.I. System : meter
CONVERSION

BRITISH SYSTEM: 12 inch=1 foot


36 inch=1 yard
3 foot=1 yard
1760 yard=1mile
METRIC SYSTEM:1000micron=1mm
10mm=1cm
10cm =1decimeter
10decm=1meter
1000meter=1kilometer
S.I.SYSTEM

As per S.I.System fundamental unit of length is METER


1.METER=1000MM
1CENTIMETER=10MM
1MILIMETER=1000MICRON
1MICRON=0.001MM
Standards of Linear Measurement
• According to the instrument design the length
can be measured by using following standards
• Line Standard. E.g. Yard, Meter
• End Standard. E.g. Slip Gauges, End Bars etc.
• Wavelength Standard E.g.Interferometers
Line Standard
• Distance is measured between two lines
• A scale is quick and easy to employ
• Scale marking are not subject to wear. However
significant wear on leading edge leads to under sizing
• A scale does not possess a built in datum
• Scales are subjected to parallax effect
• Not convenient for close tolerance measurement
• Less accurate compared to end standard.
End Standard
• Distance is measured between two surfaces.
• Highly accurate and well suited for close
tolerance(0.005) measurement.
• Time consuming and prove one dimension at a
time
• Subjected to wear on their measuring faces
• Have built in datum.
• Free from parallax.
Wavelength Standard
• Orange radiation of Kr86 in hot cathode discharge lamp
maintained at 68C. According this standard meter is defined
as 1650763.73 wavelength.
• It is not a material standard and hence not influenced by the
effects of variation of environmental temperature, pressure,
humidity and ageing.
• It need not stored under security and thus there is no fear of
its being destroyed as in the case of meter and yard.
• There are problems of transferring this standard to other
standards as in the case of meter and yard.
• Easily available to all standardizing houses, laboratories and
industries.
• Easily reproducible and thus identical standard are available
with all.
• Can be used for comparative measurements of a much higher
accuracy.
Linear and Angular Measurement

• The Linear Measurement includes


measurements of length, diameters, heights
and thickness
• The Angular measurement includes the
measurement of angles or tapers
LINEAR MEASUREMENTS INSTRUMNETS
CLASSIFICATION
INSTRUMENTS
FOR LINEAR
MEASUREMENTS

DIRECT INDIRECT
MEASURING MEASURING
INSTRUMENTS INSTRUMENTS

GRADUATED NON-GRADUATED

PRECISION NON -PRECISION PRECISION NON - PRECISION


Dimensions
• A very common measurement is that of
dimensions, i.e., length, width, height of an
object
• Dimensions of the measuring instruments are
classified as follows
– Low resolution devices (up to 0.25mm)
– Medium resolution devices (up to 0.0025mm)
– High resolution devices (less than microns)
TYPES OF LINEAR MEASURERMNT
INSTRUMNETS
• STEEL RULE FIRM JOINT
• CALLIPERS CALLIPERS
SPRING

OUTSIDE

INSIDE
CALLIPERS
TRANSFER

ODD LEG
TYPES OF LINEAR MEASURERMNT
INSTRUMNETS
• SURFACE PLATE
• SPIRIT LEVELS
• COMBINATION SET
• UNIVERSAL SURFACE GAUGE
• ENGINEER’S SQUARE
• ENGINEER’S PARALLEL’S
• PLANER GAUGE
• FEELER GAUGE
TYPES OF LINEAR MEASURERMNT
INSTRUMNETS
• SCREW PITCH GAUGE
• RADIUS GAUGE
• WIRE GAUGE
• VERNIER CALLIPERS
• VERNIER HEIGHT GAUGE
• VERNIER DEPTH GAUGE
• SLIP GAUGES
TYPES OF LINEAR MEASURERMNT
INSTRUMNETS
• MICROMETERS
• TELESCOPIC GAUGE OUTSIDE

INSIDE
MICROMETERS
SCREW
THREAD

DEPTH GAUGE
STEEL RULE
CALLIPERS
CALLIPERS
CALLIPERS
SURFACE PLATE
• Surface plates are a very common tool in the
manufacturing industry and are often
permanently attached to robotic type
inspection devices such as a coordinate-
measuring machine.
• Material Granite, CI, Glass
SURFACE PLATE
SPIRIT LEVELS
COMBINATION SET
• This is a commonly used
versatile, non –precision
instrument. It is used in
layout and inspection
work.
• It consists of:
1. Protractor head
2. Square head
3. Center head
4. Steel rule
SURFACE GAUGE &
ENGINEERS SQUARE
SURFACE GAUGE &
ENGINEERS SQUARE
ENGINEER’S PARALLELS
• These are generally used in tool room for setting the work pieces at
desired distances in milling, grinding, and shaper vices or for checking
purpose on the surface plate.
ENGINEER’S PARALLELS
PLANER GAUGE
• This is a convenient and quick way of securing variable height above the
surface plate.
• It consists of two triangular shaped blocks with sloping sides which can be
clamped.
FEELER GAUGE
• A feeler gauge (also
known as a thickness
gauge) is an accurately
manufactured strip of
metal that is used to
determine the gap or
clearance between two
components.
FEELER GAUGES
FEELER GAUGE
• A feeler gauge can be
used to check the
following:
– Piston ring gap
– Piston ring side clearance
– Connecting rod side
clearance
RADIUS GAUGES
• A radius gauge is a tool used to measure the
radius of an object.
RADIUS GAUGES
THREAD PITCH GAUGE
• It used to quickly determine the pitch of
various threads by matching the teeth on the
leaves with teeth on the work.
WIRE GAUGE
• These are used to find the diameters of wires by inserting the
wire in the notches provided and finding out which it fits.
VERNIER CALLIPERS
• These are employed for both internal and
external measurements.
• Vernier calipers are available in size of 150 mm,
225 mm, 900 mm and 1200 mm. The selection of
the size depends on the measurements to be
taken. Vernier calipers are precision instruments,
and extreme care should be taken while handing
them.
VERNIER CALLIPERS
VERNIER CALLIPERS
In the Vernier caliper shown in fig the main scale division (9mm) are divided
in to 10 equal parts in the Vernier scale.
i.e. one main scale division (MSD) =1mm

one Vernier scale division (VSD) =9/10mm


Least count is 1 mm =1/10mm
The difference between one MSD and one VSD=0.1mm
VERNIER DEPTH GAUGE
•Base ,Graduated beam ,
Clamping screw , Fine
adjustment mechanism
and Vernier scale .
VERNIER DEPTH GAUGE
VERNIER HEIGHT GAUGE

The main parts of a Vernier height gauge and


their function are given.
1.base
2. beam
3.Vernier slide
4. fine setting device
5. Vernier plate
6. locking screws
7. scriber
ELECTRONIC DIGITAL READ OUT’S
MICROMETERS
• Micrometers are one of the most common
and most popular forms of measuring
instrument for precise measurement with 0.01
mm accuracy.
• Micrometers with 0.001mm accuracy are also
available.
• The accuracy of vernier callipers is 0.02 mm.
MICROMETERS
• Classification: The Micrometers are classified
as follows :
1. Outside Micrometer
2. Inside Micrometer
3. Screw Thread Micrometer
4. Depth gauge Micrometer
OUTSIDE MICROMETERS
• Principle of working: The micrometer works
on the principle of screw and nut .The
longitudinal movement of the spindle during
one rotation is equal to the pitch of the screw.
The movement of the spindle to the distance
of the pitch or its fractions can be accurately
measured on the barrel and thimble.
OUTSIDE MICROMETER

A micro meter is a
precision instrument
used to measure a job,
generally within an
accuracy of
0.01mm.Micrometer
used to take the outside
measurements are
know as outside
micrometer
OUTSIDE MICROMETERS
Various Parts are:
1. U-shaped steel frame.
2. Anvil & Spindle
3. Lock nut
4. Sleeve or Barrel
5. Thimble
6. Ratchet or Friction
Thimble
OUTSIDE MICROMETERS
OUTSIDE MICROMETER

• In metric micrometer the pitch of the spindle thread is 0.5mm.


Thereby ,in one rotation of the thimble, the spindle advances by
0.5 mm.
On the barrel a 25 mm long datum line is mar-ked. This line
is further graduated to millimeters and half millimeters (i.e. 1
mm& 0.5 mm).
L.C of Micrometer = Pitch of the spindle screw/Number of divisions on the
spindle
OUTSIDE MICROMETER

• RANGES OF O.S. MICROMETER: Outside micrometer are available in


ranges of 0 to 25mm, 25 to 50mm, 50 to75mm, 75 to
100mm,100to125mm, 125 to 150mm. For all range of micrometer, the
graduations marked on the barrel is only 0-25 mm
OUTSIDE MICROMETER ERRORS
• Possible sources of errors in outside micrometers are :
1. Lack of flatness anvil surfaces
2. Lack of parallelism of the anvils at some parts or all parts of the
scale.
3. In accurate setting of the zero reading.
4. In accurate reading following the zero position.
5. In accurate raedings shown by fractional divisions on the thimble.
6. Applying too much pressure on the thimble or not using ratchet.
7. Wear of anvil surfaces threads on spindle due to constant or
incorrect use.
8. Wear of ratchet stop mechanism , locking arrangement etc.
DEPTH MICROMETERS
•Depth micrometers are
special micrometers used to
measure the depth of holes,
the depth of grooves and
recesses, the heights of
shoulders or projections.
•Ithas a shoulder which acts
as a reference surface.
•The scale of the depth
micrometer is calibrated in
reverse direction.
DEPTH MICROMETERS
INSIDE MICROMETERS
• These are used for measuring larger internal
dimensions.
• It consists of the following parts:
1. Measuring Head (micrometer unit)
2. Extension rods
3. Spacing collars
4. Handle
INSIDE MICROMETERS
SCREW THREAD MICROMETER
• This type of micrometer uses differential screw principle and
hence is more accurate than ordinary micrometer.
TELESCOPIC GAUGE

•Used for measuring


cylinder bores,
housing bores
•Screw pitches
same as outside
micrometer
•One inch of travel
•Used more often
with ‘transfer’
measurements
SLIP GAUGES
• Slip gauges or gauge blocks are universally accepted end standard
of length in industry.
• These were introduced by Johanson, a Swedish engineer, and are
also called as Johanson Gauges.
• These are rectangular blocks of high grade steel with exceptionally
close tolerances.
• These blocks are suitably hardened through out to ensure
maximum resistance to wear.
• They are then stabilized by heating and cooling successively in
stages so that the hardening stresses are removed.
• After being hardened they are carefully finished by high grade
lapping to a high degree of finish, flatness and accuracy.
SLIP GAUGES or JO BLOCKS – ISO 3650
Come in sets to 150 mm with 88
blocks
Minimum step 1 μm
Make up any dimension by wringing
blocks together
Sets come in several grades, typical
for shop use is grade AS-1 with
thinner blocks good to sub-
microns
Sets include two wear blocks to be
mounted to either end of stack to
protect the measurement blocks
from wear
SLIP GAUGES
• Slip gauges are rectangular blocks of steel
having a cross-section of about 30 by 10 mm
• Normal set
Range Step Pieces
1.001 to 1.009 0.001 9
1.01 to 1.09 0.01 9
1.1 to 1.9 0.1 9
1 to 9 1 9
10 to 90 10 9
Total 45
SLIP GAUGES
• Special Set
Range Step Pieces
1.001 to 1.009 0.001 9
1.01 to 1.49 0.01 49
1.5 to 9.5 0.5 19
10 to 90 10 9
Total 86
CLASSIFICATION

• AA slip gauges

• A slip gauges and

• B slip gauges
SLIP GAUGES
• AA slip gauges
– Master slip gauges
– Accurate to plus or minus two microns per meter
• A slip gauges
– Reference purpose
– Type A is guaranteed accurate up to plus or minus four
microns per meter
• B slip gauges
– Working slip gauges
– Type 'B' for plus or minus eight microns per meter
SLIP GAUGES CLASSES

• Grade II

• Grade I

• Grade 0
• Grade 00
• Calibration grade
GRADE 2

• This is the workshop grade

• Typical uses include setting up machine tools,


positioning milling cutters and checking
mechanical width.
GRADE 1

•  Used for more precise work, -tool room.

• Typical uses include setting up


– Sine bars and sine tables

– Checking gap gauges and


– Setting dial test indicators to zero
GRADE 0

•  This is more commonly known as the


Inspection grade
• Inspection Department only have access to
this grade of slips
GRADE 00

•  This grade would be kept in the Standard


Room and would be kept for work of the
highest precision only.
• Determination of any errors present in the
workshop or Grade II slips.
CALIBRATION GRADE
• Calibration grade are used for calibration of
slip gauges, other measuring instruments
SLIP GAUGES USAGE
Gauge blocks are used for:

• Direct precision measurement where accuracy is required.


• For checking accuracy of vernier callipers, micrometers etc.
• Setting up a comparator to a specific dimension.
• For measuring angle of work piece and for angular setting.
• The distances of plugs, spigots etc. on fixtures and
measured with slip gauges.
• To check the gap between parallel locations such as gap
gauges or between any two mating parts.
SLIP GAUGES WRINGING
• The success of precision measurement by slip gauges depends on the
phenomenon of wringing.
• The slip gauges are wrung by hand through a combined sliding and
twisting motion.
• The gap between two wrung slips is only of the order of 0.00635 microns
i.e. 6.35*10¯⁴ mm which is negligible.
• When two gauges are wrung in this manner is exactly the sum of their
individual dimensions.
DIAL INDICATORS
• These are basically used for making and checking linear
measurements.
• They are also used as comparators. This is a simplest
type of mechanical comparator.
• This measures the displacement of its plunger or a
stylus on a circular dial by means of a rotating pointer.
• These are very sensitive and versatile instruments.
• They require little skill in their use than other precision
instruments, such as micrometer, vernier callipers,
gauges etc.
DIAL INDICATORS
DIAL INDICATORS USES
• By mounting a dial indicator on any suitable base and with
various attachments, it can be used for variety of purposes as
follows:
1. Determining errors in geometrical forms.
2. Determining positional errors of surfaces
3. Taking accurate measurements of deformation in tension and
compression testing of materials.
4. Comparing two heights or distances between narrow limits.
5. To check trueness of milling machine arbours.
6. To check –parallelism of the shaper ram with table surface or
like.
DIAL INDICATORS REQUIREMENTS
• Requirements of good dial indicator are:
1. It should be robust in design and construction.
2. Pointer movement should be properly damped so that
it will not oscillate when readings are not taken.
3. Operating pressure must remain constant over whole
range.
4. To avoid damage of the instrument the plunger
movements of the plunger must be controlled.
5. The plunger movements should not affect the accuracy.
DIAL INDICATORS ADVANTAGES
• Advantages of dial indicators are:
1. The instrument can be easily used and read even by unskilled
worker.
2. Contact pressure is low and uniform.
3. It is not subjected to problems such as wear , temperature
variation etc.
4. It is best suited in mass production foe precision dimensional
control.
5. It can detect small dimensional variations that are beyond the
range of conventional gauges.
6. The instrument is accurate and economical.
7. It is portable, easy to handle and can be set very quickly.
DIAL INDICATORS CLASSIFICATION
• Dial indicators may be classified according to their shape as
i. Sector Shaped
ii. Circular
• The circular types are more commonly used.
• These can also be classified as:
1. Player Type - a) back plunger
b) plunger parallel to the plane of dial
2. Lever Type
• Mostly used is the lever type of dial indicator.
DIAL INDICATORS
GEAR AND PINION MECHANISM

• Parts are :
1. A – PINION (P1)
2. B- GEAR (G1)
3. C- PINION (P2)
4. D – GEAR (G2)
5. E – PINION (P3)
6. F – GEAR (G3)
7. H – HAIR SPRING
8. S – COIL SPRING
9. G – RACK GUIDE
10. PLUNGER
11. RACK
DIAL INDICATORS
GEAR AND PINION MECHANISM
DIAL INDICATORS
GEAR AND PINION MECHANISM
• There is a plunger which is a perfect sliding fit in its own bearings.
• This carries a rack which accurately meshes with a pinion A. The rotation
of the plunger about its own axis is prevented by a pin attached to it,
which is located in a slot in a rack guide G.
• In order to keep the plunger in an extended or normal position a light coil
spring S is employed.
• The spring exerts a pressure .
• A small movement of the contact point causes the rack to turn the pinion
A with which it is meshed.
• A large gear B is attached to the same spindle as pinion A.
• The gear B is further meshed with a pinion C, which thus magnifies the
movement of pinion A.
• Attached to the second pinion C is another gear D which meshes with a
third pinion E mounted on the same spindle as the indicator pointer
DIAL INDICATORS
GEAR AND PINION MECHANISM
• Magnification = NG2 * NG1/(NP3*NP2)
NGI, NG2,NP2, NP3 are number of teeth of gears G1 & G2 AND pinion P2 &
P3.
• This magnification is further enlarged at the tip of the pointer by an
amount dependent upon its length.
• The overall magnification for any dial gauge may be thus calculated by
measuring the distance between division on the scale and dividing this
dimension by the equivalent movement of the measuring plunger.
• In order to take up the backlash, a light hair spring H is always fitted to
the dial gauge gear trains by meshing a gear F to pinion E and attaching
spring if with F.
• In order to prevent gear backlash, the gears are precision cut and the
movement assembly resembles that of high-grade
DIAL INDICATORS LIMITATIONS
• Draw backs (limitations) of Dial Indicators are:
1. Wear of plunger bearing surfaces, gear bearing
points etc. causes an error in the measurement.
2. Accuracy of the instrument is reduced due to
backlash in gear and pinion or gear train.
3. As the plunger moves inside, the contact
pressure of the plunger increases. The variations
in the plunger contact pressure also introduces
error in the measurements.
ANGULAR MEASUREMENTS
• Angular measurements are frequently necessary for the
manufacturing of interchangeable parts.
• Precise angular measuring devices can be used in astronomy to
determine the relation of the stars and their approximate distances.
• The angle is defined as the opening between two lines which meet at
a point.
• If a circle is divided into 360 parts, then each part is called a degree
(°).
• The basic unit for angular measurements id degree(°).
1° = 60’ (minutes) & 1’ = 60’’(seconds)
• An alternate method of defining the angle is radian.
2π radians = 360° & 1 radian = 57.2958°
ANGULAR MEASUREMENT INSTRUMENTS

There are many instruments which are used for angular


measurements.
• Vernier bevel protractor
• Optical bevel protractor
• Universal bevel protractor
• Sinebar
• Angle gauges
• Clinometer
• Angle dekkor
• Auto collimator etc.
VERNIER BEVEL POTRACTOR
• This is the simplest angle measuring instrument.
• The flatness of the body is tested by checking the
squareness of blade with respect to base plate.
• It consists of :
– Main body
– Base plate stock
– Adjustable blade
– Circular plate containing Vernier scale
– Acute angle attachment
VERNIER BEVEL POTRACTOR
VERNIER BEVEL POTRACTOR
• The base plate is attached to the main body and an adjustable blade is
attached to the circular plate containing Vernier scale.
• The adjustable blade is capable of sliding freely along the groove provided
on it and can be clamped at any convenient length.
• The adjustable blade along with the circular plate containing the Vernier
can rotate freely about the center of the main scale engraved on the body
of the instrument and can be locked in any position with the help of a
clamping knob.
• An acute angle attachment is provided at the top for measuring acute
angles.
• The base of the base plate is made flat so that it could be laid flat upon
the work and any type of angle measured.
VERNIER BEVEL POTRACTOR
• The main scale is graduated in degrees.
• The Vernier scale has 12 divisions on either side of
the center zero.
• They are marked 0-60 minutes of arc, so that
each division is 1/12th of 60 minutes, i.e. 5
minutes.
• These 12 divisions occupy same arc space as 23
degrees on the main scale, such that each division
of the Vernier = (1/12)*23 = 1(11/12) degrees.
READING A VERNIER PROTRACTOR
• Note number of whole degrees between zero
on main scale and zero on Vernier scale
• Proceeding in same direction, note which
Vernier line coincides with main scale line
• Multiply number by 5' and addFourth
to
degrees on protractor dial

50º
4 x 5'= 20'

Reading =
50º 20'
VERNIER BEVEL POTRACTOR USES
The bevel protractor is used for several measurements as follows:
• Use of bevel protractor for checking inside beveled face of a ground
surface.
• Use of bevel protractor for checking “V” block.
• Use of Vernier protractor for measuring the acute angle.
UNIVERSAL BEVEL POTRACTOR
• The universal bevel protractor is used for
measuring and laying out of angles accurately
and precisely within 5 minutes.
• The protractor dial is slotted to hold a blade
which can be rotated with the dial to the
required angle.
• It can also be adjusted independently to any
desired length.
• The blade can be locked in any position.
UNIVERSAL BEVEL POTRACTOR
OPTICAL BEVEL POTRACTOR
• This is a recent development of the Vernier bevel protractor.
• It is possible to take reading upto approximately 2 minutes of an
arc.
• The interval circular scale is graduated in division of 10 minutes
of arc.
• Readings are taken against Vernier by means optical magnifying
system which is integral with the system.
• The zero position corresponds to the condition when the blade is
parallel to the stock.
• Provision is also made for adjusting the focus of the system for
normal variation in the eye sight.
• The scale and the Vernier are so arranged that they are always in
focus in the optical system.
OPTICAL BEVEL POTRACTOR
SPIRIT LEVELS
• Spirit level is one of the most commonly used instruments
for inspecting the horizontal position of surfaces and for
evaluating the direction and magnitude of minor deviation
from that nominal condition.
• It essentially consists of a close glass tube of accurate form.
• It is called as the vial.
• It is filled almost entirely with a liquid, leaving a small space
for the formation of an air or gas bubble. Generally, low
viscosity fluids, such as ether, alcohol or benzol, are
preferred for filling the vial.
• The liquid due to its greater specific weight tends to fill the
lower portion of the closed space.
SPIRIT LEVELS
• Upper side of the vial is graduated in linear units.
• Inclination of a surface can be known from the
deviation of the bubble from its position when the
spirit level is kept in a horizontal plane.
• Temperature variations in the ambient condition cause
both liquid and vial to expand or contract.
• Therefore, selection of proper liquid and material for
the spirit level is very important for accurate result.
• To reduce the effect of heat transfer in handling spirit
levels are made of a relatively stable casting and are
equipped with thermally insulated handles.
SPIRIT LEVELS
SPIRIT LEVELS SENSITIVITY
Sensitivity of the vial used in spirit level is commonly
expressed in the following two ways.
• Each graduation line representing a specific slope is
defined by a tangent relationship,
e.g. 0.01 cm per meter.
• An angular value is assigned to the vial length
covered by the distance of two adjacent graduation
lines, i.e. the distance moved by the bubble from the
zero will correspond the angle directly.
SINE BAR
• Sine bar is a tool used for accurate setting out
of angles by arranging to convert angular
measurement to linear ones.
• Sine bars in conjunction with slip gauges
constitute a very good device for precise
measurement of angles. Sine bars are used
either to measure angles very accurately or
for locating any work to a given angle with
very close limits.
SINE BARS
SINE BAR
• Sine bars are made from high carbon steel, high
chromium, corrosion resistant steel, hardened, ground &
stabilized. The axes of the cylinders used in sine bars are
mutually parallel to each other and also parallel to and at
equal distance from the upper surface of the sine bar
• Distance b/w the axis of two cylinders is exactly 5 or 10
inches in British system, and 100, 200 & 300 mm in
metric system.
• All the working surfaces and surfaces of rollers are
finished to surface finish of 0.2mm or better
SINE BAR
Measures for Accurate Results:
i. Contact rollers must be equal diameter & true
geometric cylinders
ii. Distance b/w the rollers axis must be precise &
known, & these axis must be mutually parallel
iii. The upper surface of the bar must be flat &
parallel with the roller axes, & equidistance
from each other
SINE BAR
Use of Sine Bars
1. Measuring known angles, or locating any work to a given angle
θ = sin¯¹ (H/L)
H – height of slip gauges
L – Length of the sine bar i.e. distance between rollers
2. Checking of unknown angles
3. Checking of Unknown angles of heavy components
SINE BAR
SINE BAR
SINE BAR
SINE BAR
Precautions in the use of Sine Bars
1. As for as possible longer sine bar should be
used since many errors are reduced by using
longer sine bars
2. The sine bar should not used for angle greater
than 60 degree because any possible error in
construction is accentuated at this limit
3. Accuracy of sine bar should be ensured
SINE BAR
Limitations of sine bar are:
• Sine principle is fairly reliable at angles less than 15°but becomes
inaccurate as the angle increases.
• The sine bar is physically clumsy to hold in position.
• The body of the sine bar obstructs the gauge block stack, even if
relieved.
• Slight errors of the sine bar cause large angular errors.
• Long gauge stacks are not nearly as accurate as shorter gauge
blocks.
• A difference in deformation occurs at the point of roller contact
supporting the surface and to the gauge blocks, because at higher
angles, the load is shifted more towards the fulcrum roller.
Limit gauges

115
Gauges
• Basic dimension: exact size of part from
which all limiting variations made
• Limits: maximum and minimum
dimensions
• Tolerance: permissible variation of part
– unilateral: one direction only
– Bilateral: both plus and minus (two directions)
• Allowance: intentional difference in
dimensions of mating parts
116
Fixed Gauges
• Used for inspection purposes
– Provide quick means of checking specific
dimension
• Easy to use and accurately finished to
required tolerance
– Generally finished to ten times the
tolerance designed to control

117
Cylindrical
Plug Gauges
Go

Dimensions usually
stamped on handle
at each end.

"go" end longer than


"no-go" for easy
identification

Many made with carbide


tips to increase gauge life

118
Cylindrical Plug Gauges

119
Cylindrical Plug gauge

120
Plain Ring Gauges

• Used to check outside diameter of pieces


• Ground and lapped internally to desired size
– Size stamped on side of gauge
• Outside diameter knurled and "no-go" end
identified by annular groove on knurled
surface
• Precautions and procedures similar to those
outlined for a plug gauge
121
Plain Ring gauges

122
Taper Plug Gauges

• Used to check size of hole and taper accuracy


• Made with standard or special tapers
• Some have "go" and "no-go" rings scribed
– gauge fits into hole between two rings means
within required tolerance

123
Taper Plug and Ring Gauges

124
Thread Plug Gauges

• Used for checking internal threads of the


"go" and "no-go" variety
• Based on same principle as cylindrical plug
gauges
• "go" end (longer end)
– Should be turned in flush to bottom of hole
• "no-go" end
– Should just start into hole and become snug
before third thread enters
125
Thread Plug Gauges

126
Thread Ring Gauges

127
Snap Gauges
• One of most common types of comparative
measuring instruments
• Faster to use than micrometers
• Limited in their application
• Used to check diameters within certain
limits by comparing part size to preset
dimension of snap gauge

128
Snap Gauges

• Have C-shaped frame with adjustable


gauging anvils or rolls set to "go" and
"no-go" limits
of the part
• Several styles

129

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