VVGV/8.5.1/FT10.

TEACHING PLAN

Department: MECHANICAL ENGINEERING Name of the faculty: M SIVA NAGA MUNEENDRA

Designation: ASSISTANT PROFESSOR Name of the subject: METROLOGY

Semester / Year: II-SEM/ III-B.TECH AY: 2019-2020 Date: 01/06/2019

Course objectives: The students will learn

 Inspection of engineering parts with various precision instruments
 Design of part, tolerances and fits
 Principles of measuring instruments and gauges and their uses
 Evaluation and inspection of surface roughness
 Inspection of spur gear and thread elements
 Machine tool testing to evaluate machine tool quality

Cumulati
Sl. No. of Tentative
No Unit/topic covered classes
ve no. of
date
classes
UNIT –I (SYSTEMS OF LIMITS AND FITS)
1 Introduction 01 1 18-11-2019
2 nominal size, tolerance, limits 01 2 19-11-2019
3 deviations, fits 01 3 21-11-2019
4 Unilateral and bilateral tolerance system 01 4 22-11-2019
5 hole and shaft basis systems 01 5 22-11-2019
6 Interchangeability, selective assembly 01 6 25-11-2019
7 determistic & statistical tolerances 01 7 26-11-2019
8 International standard system of tolerances 01 8 28-11-2019
9 Selection of limits and tolerances for correct functioning. 01 9 29-11-2019
10 Tutorial class 01 10 29-11-2019
11 Tutorial class 01 11 2-12-2019
12 Total 11 11
UNIT – II
LINEAR MEASUREMENT, MEASUREMENT OF ANGLES AND TAPERS and LIMIT
GAUGES

13 Length standards, end standards 01 12 3-12-2019

14 slip gauges- calibration of the slip gauges 01 13 5-12-2019
15 Dial indicators, micrometers 01 14 6-12-2019
16 Different methods – bevel protractor 01 15 6-12-2019
17 angle slip gauges 01 16 9-12-2019
 18 angle dekkor 01 17 10-12-2019
19 spirit levels- sine bar- sine table 01 18 12-12-2019
20 rollers and spheres used to measure angles and tapers 01 19 13-12-2019
21 Taylor’s principle 01 20 13-12-2019
22 design of goes and no go gauges 01 21 16-12-2019
23 plug, ring, snap, 01 22 17-12-2019
24 gap, taper, profile and position gauges 01 23 19-12-2019
25 Tutorial class 01 24 20-12-2019
26 Tutorial class 01 25 20-12-2019
27 Total 14 25
UNIT-III
OPTICAL MEASURING INSTRUMENTS and INTERFEROMETRY
28 Tools maker’s microscope and uses 01 26 23-12-2019
29 Autocollimators 01 27 24-12-2019
30 Optical projector 01 28 26-12-2019
31 Optical flats and their uses 01 29 27-12-2019
32 Interference of light 01 30 27-12-2019
33 Michelson’s interferometer 01 31 30-12-2019
34 NPL flatness interferometer 01 32 31-12-2019
35 NPL gauge interferometer 01 33 02-01-2020
36 Tutorial class 01 34 03-01-2020
37 Tutorial class 01 35 06-01-2020
38 Total 10 35
UNIT –IV
SURFACE ROUGHNESS MEASUREMENT and COMPARATORS
39 Differences between surface roughness and surface waviness 01 36 24-01-2020
40 Numerical assessment of surface finish 01 37 27-01-2020
41 CLA, Rt 01 38 28-01-2020
42 R.M.S. Rz, R10 values 01 39 30-01-2020
43 Method of measurement of surface finish 01 40 31-01-2020
44 Profilograph, Talysurf 01 41 31-01-2020
45 ISI symbols for indication of surface finish 01 42 03-02-2020
46 COMPARATORS: Types - mechanical 01 43 04-02-2020
47 optical, electrical 01 44 06-02-2020
48 Pneumatic comparators and their uses. 01 45 07-02-2020
49 Tutorial class 01 46 07-02-2020
50 Tutorial class 01 47 10-02-2020
51 Total 12 47
UNIT-V
GEAR MEASUREMENT and SCREW THREAD MEASUREMENT
52 Nomenclature of gear tooth 01 48 11-02-2020
53 tooth thickness measurement with gear tooth vernier 01 49 13-02-2020
54 flange micro meter, pitch measurement 01 50 14-02-2020
55 total composite error 01 51 14-02-2020
56 tooth to tooth composite errors 01 52 17-02-2020
57 rolling gear tester, involute profile checking 01 53 18-02-2020
SCREW THREAD MEASUREMENT: Elements of 01 54 20-02-2020
58
measurement
59 errors in screw threads 01 55 21-02-2020
60 concept of virtual effective diameter 01 56 21-02-2020
61 measurement of effective diameter 01 57 24-02-2020
62 angle of thread and thread pitch 01 58 25-02-2020
63 profile thread gauges 01 59 27-02-2020
64 Tutorial class 01 60 28-02-2020
65 Tutorial class 01 61 28-02-2020
66 Total 14 61
UNIT –VI
FLATNESS MEASUREMENT and MACHINE TOOL ALIGNMENT TESTS
67 Measurement of flatness of surfaces 01 62 02-03-2020
68 instruments used 01 63 03-03-2020
69 straight edges 01 64 05-03-2020
70 surface plates 01 65 06-03-2020
71 auto collimator 01 66 06-03-2020
72 Principles of machine tool alignment testing on lathe 01 67 09-03-2020
73 Principles of machine tool alignment testing on drilling 01 68 10-03-2020
74 Principles of machine tool alignment testing on milling machines 01 69 12-03-2020
75 Tutorial class 01 70 13-03-2020
76 Tutorial class 01 71 13-03-2020
77 Tutorial class 01 72 16-03-2020
78 Total 10 72
79 TOTAL CLASS 72

Course outcomes:

Students will be able to design tolerances and fits for selected product quality. They can choose
appropriate method and instruments for inspection of various gear elements and thread elements. They can
understand the standards of length, angles, they can understand the evaluation of surface finish and
measure the parts with various comparators. The quality of the machine tool with alignment test can also be
evaluated by them.

Text Books:
1. Dimensional Metrology/Connie Dotson/Cengage Learning
2. Engineering Metrology / R.K.Jain / Khanna Publishers

References:
1. Engineering Metrology / Mahajan / Dhanpat Rai Publishers
2. Engineering Metrology / I.C.Gupta / Dhanpat Rai Publishers
3. Precision Engineering in Manufacturing / R.L.Murthy / New Age
4. Engineering Metrology and Measurements / NV


UNIT-1 SYSTEMS OF LIMITS AND FITS
III B. Tech II Semester Regular Examinations, April/May - 2019

1. a) What is bilateral tolerance system? [2M]

b) A 50 mm diameter shaft and bearing are to be assembled with a clearance fit. The tolerance and
allowance are as under. Allowance = 0.035 mm Tolerance on hole = 0.025 mm
Tolerance of shaft = 0.017 mm
Find the limits of size for the hole and shaft if (i) Hole basis system is used (ii) Shaft basis system[5M]
c) Describe interchangeable assembly with suitable example. State its advantages. [3M]

2.a) What is meant by unilateral tolerance system? [2M]

b) Determine limit dimensions for a clearance fit between mating parts of diameter 40 mm,
providing a minimum clearance of 0.10 mm with a tolerance on the hole equal
to 0.025mm and on shaft 0.05mm using both systems. [3M]
b) Explain briefly about interchangeable manufacturing and selective assembly? [5M]

3.a) Define limit and tolerance. [2M]

b) Explain briefly different types of fits with necessary sketches? [4M]
c) Differentiate between unilateral and bilateral tolerance with examples? Explain the
need for providing tolerance on a dimension. [4M]

4.a) What is hole and shaft basis system [2M]

b) Determine the dimensions and tolerances of the shaft and hole having the size of 25H7/f8. 25mm falls in
diameter steps of 18-30. Also indicate the type of fit and show the tolerances with sketch. Assume the
following data, The fundamental deviation for shaft ‘f’ is -5.5D 0.41 , The standard tolerance unit i=0.45
D1/3+0.001D , where D is the geometric mean of the lower and upper limits of diameter step in which the
diameter consideration lies, D is in mm, The standard tolerance for IT7=16i and IT8=25i. [4M]
c) Define fit and describe various types of fits in brief? [4M]

III B. Tech I Semester Regular/Supplementary Examinations, October/November – 2017

5.a) Differentiate between shaft based and hole based systems. [2M]
b) Define and explain about interchangeability and selective assembly. [4M]
c) Determine and sketch the limits of tolerance and allowance for a 45mm shaft and hole pair designated H7−d8. The
basic size lies in the range of 30-50mm. The multipliers for grades 7 and 8 are 16 and 25 respectively. The
fundamental deviation for‘d’ shaft is (-16 D0.44) microns. [4M]

6.a) Differentiate between tolerance and allowance. [2M]

b) Explain the terms: Hole based system, shaft based system. Enumerate the differences between them. [4M]
c) Briefly explain the features of Indian Standard limit system and compare it with the I.S.O system. [4M]

7.a) Differentiate between Unilateral and bilateral tolerance system. [2M]

b) What is a deviation? Explain its importance in the system of limits. [4M]
c) Determine and sketch the limits of tolerance and allowance for a 70mm shaft and hole pair designated H8−n9.
The basic size lies in the range of 50-80mm. The multipliers for grades 8 and 9 are 25 and 40 respectively.
The fundamental deviation for ‘n’ shaft is (+5 D0.34) microns. [4M]

8.a) what is selective assembly? [2M]

b) Explain the disadvantages associated with trial and error method of assembly. [4M]
c) Determine and sketch the limits of tolerance and allowance for a 50mm shaft and hole pair designated H8 −c8.
The basic size lies in the range of 30-50mm. The multiplier for grade 8 is 25. The fundamental deviation for ‘c’ shaft
is (-95 D -0.8) microns. [4M]

UNIT-2
 LINEAR MEASUREMENT, MEASUREMENT OF ANGLES AND TAPERS AND LIMIT
GAUGES

III B. Tech II Semester Regular Examinations, April/May - 2019

1.a) State the principle of micrometer and its least count? [2M]
b) Write detailed notes on progressive and positional limit gauges? [3M]
c) Explain the construction and uses of i) Vernier bevel protractor ii) Sine bar [5M]

2.a) Name some linear measurement instruments. [2M]

b) With the help of sketches explain the working of an external micrometer? [4M]
c) Explain the following in connection with gauge design:
(i) Gauge tolerance (ii) Wear allowance. [4M]

3.a) State the taylor’s principle of gauge design. [2M]

b) Explain the need for gauge maker’s tolerance? Discuss how the wear allowance is
provided on gauges? [4M]
c) Explain with a neat sketch, the construction and uses of Vernier bevel protractor? [4M]

4.a) Mention few applications of sine bar? [2M]

b) What are limit gauges? Sketch and explain any two types of the limit gauges. [4M]
c) What is the difference between line standard and end standard? Explain them with examples. [4M]

III B. Tech I Semester Regular/Supplementary Examinations, October/November – 2017

1 a) What is meant by Angle Dekkor? [2M]

b) Mention the materials used for the manufacture of GO and NOGO gauges. Explain the disposition of
tolerance on GO and NO GO gauges by taking reference to work tolerances. [4M]
c) Why is a Sine bar not used for generating angles greater than 450, if high accuracy is needed?
Explain it with a suitable graph. Explain the different sources of errors in Sine Bars. [4M]

2 a) What are the advantages & limitations of Johanson’s mickrokator? [2M]

b) Explain how you determine the taper angle of a taper ring gauge using spheres and Depth micrometer.
Derive the expression used. [4M]
c) Explain the principle of GO and NOGO gauges. Describe the necessity of Gauge maker’s tolerance in gauge
design. [4M]

3 a) What is ring gauge? Give its applications. [2M]

b) What are angle gauges? Explain the use of Angle gauges by means of a neat sketch. How do you set 320 51_
24__. [4M]
c) A conical taper gauge is to be measured by the technique using Sine centre in which the Sine Bar is set to one
half of the included angle of the conical piece. If the included angle of taper is intended to be 100 and the length
of conical taper gauge is 100 mm, calculate the height of block gauges required to set up the 250 mm sine
centres. Draw a neat sketch of required set up. [4M]

4 a) What is plug gauge? Give its applications. [2M]

b) State the meaning wringing? What are the essential conditions for wringing of slip gauges? What precautions
should be taken while using slip gauges? [5M]
c) An angle of 1020-8’-42’’ is to be measured with the help of standard 13 pieces set of angle gauges and a
square block. Sketch the combinations. [3M]

UNIT-3
OPTICAL MEASURING INSTRUMENTS AND INTERFEROMETRY

III B. Tech II Semester Regular Examinations, April/May – 2019

1.a) What do you mean by interferometers? [2M]
b) Explain NPL flatness interferometer with neat sketch and write its applications? [4M]
c) Describe the working of an optical projector? What are its applications? [4M]

2.a) State the principle of interference? [2M]

b) Explain briefly about optical flat with a neat sketch? [4M]
c) Explain the working of michelson’s interferometer with neat sketch. [4M]

3.a) What are uses of optical flat? [2M]

b) Explain the need for gauge maker’s tolerance? Discuss how the wear allowance is
provided on gauges? [4M]
c) Explain with a neat sketch, the construction and uses of Vernier bevel protractor? [4M]

4.a) List the uses of auto collimator. [2M]

b) Compare Michelson’s and NPL flatness interferometers? [4M]
c) Explain how flatness errors of lapped surfaces are measured with an optical flat. [4M]

III B. Tech I Semester Regular/Supplementary Examinations, October/November – 2017

5.a) List out the applications of NPL gauge interferometer. [2M]

b) With a sketch, explain the construction of autocollimator. What are its applications? [4M] c)
Explain the working of Michelson’s interferometer with neat sketch.
List out the advantages and limitations. [4M]

6.a) What is the importance of optical projector? [2M]

b) With a sketch, explain the construction of a tool maker’s microscope. What are its applications? [4M]
c) Illustrate the principle of Interferometry with neat sketch. [4M]

7.a) Name the common sources of light used for interferrometry [2M]
b) What are interferometers? What are their advantages over optical flats? [5M]
c) Write a short note on optical flats and their uses. [3M]

4)a) What is the importance of optical flat? [2M]

b) What is the principle of interferometry? How is it adopted in optical interferometer? [5M]
c) Write short notes on optical projector and their uses. [3M]

UNIT-4
SURFACE ROUGHNESS MEASUREMENT AND COMPARATORS

III B. Tech II Semester Regular Examinations, April/May – 2019

1.a) Differentiate between primary and secondary texture? [2M]
b) With help of neat sketch describe the construction and working of Taylor –HobsonbTaly surf. [4M]
c) Describe the working and uses of visual gauging heads. [4M]

2.a) List the advantages of electronic comparators? [2M]

b) Describe the working principle of profilograph? [4M]
c) Explain the basic principle of a pneumatic comparator with neat sketch. [4M]

3.a) How is surface roughness calculated by CLA and R.M.S methods? [2M]
b) The heights of peaks and valleys of 20 successive points on a surface are 35, 25, 40, 22, 37,
19, 41, 21, 42, 18, 42, 24, 44, 25, 40, 18, 40, 18, 39, and 21 microns respectively, measured over
a length 20mm. Determine CLA and RMS values of roughness surface? [4M]
c) Differentiate between a comparator and measuring machine? Discuss the Fundamental
requirements of a comparator. [4M]

4.a) Define Lay and explain different types of lay with a neat sketch? [2M]
b) Describe the various numerical methods for assessment of surface Finish? [4M]
c) Describe the working principle of a solex pneumatic comparator. [4M]

III B. Tech I Semester Regular/Supplementary Examinations, October/November – 2017

5.a) Differentiate between primary and secondary texture. [2M]

b) State the possible causes of each of the various types of irregularities found in surface texture. Show how
surfaces having the same numerical assessment may have the different properties and textures. [4M]
c) What are the requirements of a good comparator? Explain with the help of a neat sketch
how these features are achievable in the “Sigma comparator”. [4M]

6.a) Brief about Tomlinson surface recorder. [2M]

b) Describe Centre Line Average method of finding surface roughness value.
How do you determine Mean line? Describe with a graph. Explain the terms Traversing Length and True Profile
length of a surface texture. [4M]
c) Differentiate between a comparator and measuring machine. Discuss the fundamental requirements of a
comparator. [4M]

7.a) What is comparator? How does it differ from measuring instruments? [2M]
b) How surface texture is related to tolerances on a surface dimensions?
Discuss which measure of surface roughness is now recommended by ISO? [4M]
c) Explain the specific advantages and limitations of pneumatic comparator over other
comparators used in practice. [4M]

8.a) Ennumerate the different modes of defining surface texture. [2M]

b) Describe the principle and working of Tracer type profilogram with the help of a neat sketch. [4M]
c) Describe and sketch two types of comparators with special reference to the means of magnifying and
movements of the stylus. [4M]

UNIT-5
GEAR MEASUREMENT AND SCREW THREAD MEASUREMENT

III B. Tech II Semester Regular Examinations, April/May – 2019

1.a) Explain how various elements of screw thread are measured? [2M]
b) With a neat sketch explain how the simple effective diameter of a screw thread may be checked
using the two wire method. [4M]
c) Describe the following terms in screw threads:
(i) Major diameter, (ii) Minor diameter, (iii) Tooth thickness and (iv) Pitch [4M]

2.a) What do you mean by error in screw threads? [2M]

b) Describe the parkinson’s gear tester and state its limitations. [4M]
c) List out the advantages and disadvantages of three wire method when compared
with two wire method? [4M]

3.a) What are the applications of flange micro meter? [2M]

b) What are the various errors in screw threads? Discuss sources of these errors and
precautions need to minimize or completely eliminate these errors [4M]
c) Explain the gear terminology with a neat sketch? [4M]

4.a) Describe in detail various types of errors occurring in gears? [2M]

b) Describe a gear tooth vernier caliper and show how it is used for gears? [4M]
c) With a neat sketch explain how the effective diameter of a screw thread may be checked using
the three wire method? [4M]

III B. Tech I Semester Regular/Supplementary Examinations, October/November – 2017

5.a) Calculate chord length and its distance below the tooth tip for a gear of module 4mm and
pressure angle 20°. [2M]
b) Define "Effective diameter". Explain the 3-wire method of finding the effective diameter of
screw threads. [4M]
c) Explain with a sketch, how the chordal thickness is measured by using gear tooth vernier calliper. [4M]

6.a) Name some alignment tests performed on Lathe machine. [2M]

b) Describe with a neat sketch the measurement of pitch of internal and external screw threads using a pitch
measuring machine. [4M]
c) Explain the constant cord method of measuring the tooth thickness in gears. [4M]

7.a) What do you know about Constant chord method for gear tooth thickness? [2M]
b) Calculate effective diameter and best wire diameter for M22x2.5 screw plug by using floating carriage
micrometer for which reading were taken as: Diameter of standard cylinder = 20mm
Micrometer reading over standard cylinder with two wire = 15.9334 mm
Micrometer reading over plug screw guage with two wire = 15.2245 mm [8M]

8.a) Brief about Parkinson’s gear tester. [2M]

b) Define error in measurement. Explain the types of errors in screw thread and gear measurement. [4M]
c) Derive an expression for best size wire diameter. [4M]

UNIT-6
FLATNESS MEASUREMENT AND MACHINE TOOL ALIGNMENT TESTS

III B. Tech II Semester Regular Examinations, April/May – 2019

1.a) Name some instruments required for alignment tests. [2M]
b) Define flatness. Describe any one method of testing flatness of a surface. [4M]
c) Explain the parallelism of tailstock sleeve of a lathe machine to saddle movement? [4M]

2.a) What is the purpose of performing alignment test on machine tool? [2M]
b) Explain with suitable sketches the various alignment tests performed on Milling machine? [4M]
c) Explicate the utility of straight edge and surface plate in laboratories? [4M]

3.a) Distinguish between alignment tests and performance tests on machine tools? [2M]
b) List out and briefly explain any two flatness measurement instruments? [4M]
c) Explain with suitable sketches the various alignment tests performed on drilling machine? [4M]

4.a) Name the various instruments required for performing the alignment tests on machine tool? [2M]
b) What are the various alignment tests performed on lathe machine and discuss any
two of them in detail? [4M]
c) Describe the various methods for checking flatness of machined surfaces. [4M]

III B. Tech I Semester Regular/Supplementary Examinations, October/November – 2017

5.a) State Abbe principle of alignment. Explain it with suitable example. [2M]
b) Describe procedures for straightness, flatness & circularity measurement. [4M]
c) Explain alignment tests for lathe machine. [4M]

6.a) Describe Parkinson gear Tester. [2M]

b) Explain the principle of autocollimator for flatness measurement with neat sketch. [4M]
c) Explain alignment tests for drilling machine. [4M]

7.a) What are the uses of surface plates? [2M]

b) List out and briefly explain any two flatness measurement instruments. [4M]
c) Explain alignment tests for milling machine. [4M]

8.a) List out different methods of measuring flatness. [2M]

b) List out and briefly explain any two instruments used for straightness measurement. [4M]
c) Explain the principles of alignment with suitable examples. [4M]