METROLOGY AND SURFACE ENGINEERING

QUESTION BANK
UNIT I Systems of limits and fits: Introduction, normal size, tolerance limits, deviations, allowance, fits and their types unilateral and bilateral tolerance system, hole and shaft basis systems interchangeability and selective assembly. Indian standard Institution system British standard system, International Standard system for plain ad screwed work. _________________________________________________________________________________________ 1. i. Identify the type of the following fits and specify shaft based fit equivalent to each of them. i. H9 - h11 ii. H6 - p7 iii. H5 - g8 ii. 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. (Aug/Sep 07) 2. Identify the type of the following fits and specify shaft based fit equivalent to each of them. i. H11 - e11 ii. H6 - u5 iii. H8 - k8 ii. Determine and sketch the limits of tolerance and allowance for a 60mm shaft and hole pair designated H7-k8. The basic size lies in the range of 50-80mm. The multipliers for grades 7 and 8 are 16 and 25 respectively. The fundamental variation for 'k' shaft is (+0.6 D0.33) microns. (Aug/Sep 07) Define terms: Clearance; interference; allowance fit. Draw a conventional diagram for explicit representation of these terms on a shaft and hole pair. ii. he hole and shaft assembly of 90 mm nominal size have tolerances specified as mm for shaft. Determine i. Maximum and minimum clearance (interference) attainable. ii. Allowance (iii) Hole and shaft tolerances (iv) Fundamental deviation (v) MML for shaft and hole (vi) Type of fit. Sketch these values on a conventional diagram. (Aug/Sep 07) i. Explain terms : Interchageablity and selective assembly. Enumerate the differences between them. ii. Determine and skectch the limits of tolerance and allowance for a 25 mm shaft and hole pair designated H8 - d9. The basic size lies in the range of 18-30mm. The multipliers for grades 8 and 9 are 25 and 40 repsectively. The fundamental deviation for 'd' shaft is (-16D0.44) microns. (Apr/May 07) Explicate the classification of various fit. Also provide on a single diagram, the explicit representation of all fits with common zero line. ii. A hole and a mating shaft are to have a nominal assembly size a minimum assembly size of 50 mm. The assembly is to have a maximum clearance if 0.15 mm and a minimum clearance of 0.05 mm. The hole tolerance is 1.5 times the shaft tolerance. Determine the limits for both hole and shaft: by using i. Hole basis system ii. Shaft basis system. (Apr/May 07) i. Define terms: Clearance; interference; allowance fit. ii. The hole and shaft assembly of 90 mm nominal size have tolerances specified as 90 mm for hole and 90 mm for shaft. Determine i. Maximum and minimum clearance (interference) attainable. ii. Allowance (iii) Hole and shaft toerlance (iv) Fundamental deviation (v) MML for shaft and hole (vi) Type of fit. Sketch these values on a conventional diagram. (Apr/May 07) Identify whether the following fits are hole-based or shaft-based. Convert them in to equivalent other systems. (Apr/May 06) i. H11 - d11 ii. H11 - d11 iii. T7 - h6 i. i. i.

3.

4.

5.

6.

7.

8.

Determine and sketch the limits of tolerance and allowance for a 90mm shaft and hole pair designated H8-e9. The basic size lies in the range of 80-100mm. The multipliers for grades 8 and 9 are 25 and 40 respectively. The fundamental deviation for 'e' shaft is (-11 D0.41) microns. (Apr/May 06) i. Explain the terms: Unilateral tolerance system, bilateral tolerance system. Clearly explain the differences between them (Apr/May 06)

9.

10. i. Explain the terms: Hole based system, shaft based system. Enumerate the dierences between them. ii. Determine and sketch the limits of tolerance and allowance for a 50mm 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 fundamental deviation for 'd' shaft is (-16 D0.44) microns. (Apr/May 06) 11. i.

respectively. The

Identify the type of the following fits and specify shaft based fit equivalent to each of them. i. H6 - m7 ii. H8 - p5 iii. H6 - g5 ii. Determine and sketch the limits of tolerance and allowance for a 40mm shaft and hole pair designated H8-g9. The basic size lies in the range of 30-50mm. The multipliers for grades 8 and 9 are 25 and 40 respectively. The fundamental deviation for 'g' shaft is (-2.5 D0.34) microns. (Aug/Sep 06)

12. i.

Draw a conventional diagram for explicit representation of all types of fits of hole based system, with lower deviation of hole coinciding with zero line. Indicate all the basic terms of fits on the same diagram ii. A 20mm diameter shaft and bearing are to be assembled with a clearance fit. The tolerance and allowances are as under: Allowance = 0.002mm Tolerance on hole = 0.005mm Tolerance on shaft = 0.003mm Find the limits of size for the hole and shaft if: i. the hole basis system is used ii. shaft basis system is used.The tolerances are disposed of unilaterally. (Aug/Sep 06) Identify whether the following fits are hole-based or shaft-based. Convert them in to equivalent other systems. i. H9 - f10 ii. N7 - h6 iii. U6 - h5 ii. 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 multipliers for grade 8 is 25. The fundamental deviation for 'c' shaft is (-95-0.8 D) microns. (Aug/Sep 06) Draw a conventional diagram for explicit representation of all types of fits of hole based system, with lower deviation of hole coinciding with zero line. Indicate all the basic terms of fits on the same diagram. (May 05) A 20mm diameter shaft and bearing are to be assembled with a clearance fit. The tolerance and allowances are as under: Allowance = 0.002mm Tolerance on hole = 0.005mm Tolerance on shaft = 0.003mm Find the limits of size for the hole and shaft if: i. the hole basis system is used ii. shaft basis system is used. The tolerances are disposed of unilaterally. (May 05)

13. i.

14.

15.

UNIT II LINEAR MEASUREMENT : Length standard, line and end standard, slip gauges calibration of the slip gauges, Dial indicator, micrometers. MEASUREMENT OF ANGLES AND TAPERS : Different methods Bevel protractor angle slip gauges spirit levels sine bar Sine plate, rollers and spheres used to determine the tapers. LIMIT GAUGES : Taylors principle Design of go and No go gauges, plug ring, snap, gap, taper, profile and position gauges. ________________________________________________________________________________________ 1. i. Describe taking linear measurements with "inside micrometer" ii. Describe the calibration of slip gauges by Eden-Rolt millionth comparator. Discuss various methods of taper measurement of plug and ring gauges. i. Enumerate and explicate various types of limit gauges for tapers .

(Aug/Sep 07) (Aug/Sep 07)

2. 3.

ii. Design and sketch a working gauge with a GO and NO-GO ends for spindle 48.960 mm and a hole of 49.050 mm. (Aug/Sep 07) 4. Describe the general case of slip gauges before and after use. Build up slip gauges from M87 set for measurement of 29.758mm. ii. Explain by means of a simple line diagram the operating mechanism of a plunger type dial test indicator. Explain the magnification obtained by dial indicator. (Aug/Sep 07) i.

5.

i. Explicate the classification of plain limit gauges. ii. Design general type GO and NO-GO gauges for components having 25 H8/f9 fit. The basic size falls in the diameter range of 18-30mm. The fundamental deviation for 'f' shaft=(-5.5 D0.4) microns. The multipliers for 8 and 9 grades are 25 and 40. Take wear allowance as 10% of gauge tolerance. Sketch the gauges with values. (Aug/Sep 07) Explain how the principle of visual gauging heads is incorporated in multigauging machines. (Aug/Sep 07) i. Enumerate various types of outside micrometers and their uses. ii. What are line standards? Explain with examples, the characteristics of line standards. (Aug/Sep 07) Discuss various methods of taper measurement of plug and ring gauges. (Aug/Sep 07) i. Elucidate terms : gauges tolerance and wear allowance as assignable to limit gauges. ii. Design general type GO and NO-GO gauges for components having 65 H7/m6 fit. The basic size falls in the diameter range of 50-80mm. The fundamental deviation for 'm' shaft=(IT7 -IT6) microns. The multipliers for 7 and 6 grades are 16 and 10. Take wear allowance as 10% of gauge tolerance. Sketch the gauges with values. (Aug/Sep 07) i.

6. 7. 8. 9.

10. i. Describe with a neat sketch the working of an outside micrometer to an accuracy of 0.001mm. ii. Explain terms line standards and end standards with examples. (Aug/Sep 07) 11. i. Sketch two forms of sine bars with nomenclature as recommended by IS:5349-1969. ii. Show the arrangement of angle gauges with neat sketches to measure i. 300 -9' -15" and ii. 1020 -8' -42' with minimum number of gauges from a set of [10, 30, 90, 270, 410] [1', 3', 9',27'] and [3", 6", 18", 38"] 12. i.

(Aug/Sep 07)

Explicate i. position gauge ii. snap gauge with sketches. ii. Design and sketch a working gauge with a GO and NO-GO ends for spindle mm and a hole of mm. (Aug/Sep 07) 13. i. Enumerate the sources of errors in sine bars for angular measurement. ii. The angle of wedge shaped block is being checked with 200mm Sine bar. With slip gauges of 26.867mm height at one end of Sine bar, the dial gauge readings at each end of the work piece vary by 0.06mm, the gauge block end being low. If the work piece is 30mm long what should be the next height of the gauge block tried ? Also calculate the angle of the work piece? (Apr/May 07) 14. i. What material properties are " must" for gauges ? ii. Design general type GO and NO-GO gauges for components having 85 H8/n8 fit. The basic size falls in the diameter range of 80-100mm. The fundamental deviation for 'n' shaft=(+D0.34) microns. The multipliers for 8 grade is 25. Take wear allowance as 10% of gauge tolerance. Sketch the gauges with values. (Apr/May 07) 15. i. Describe the selection of minimum number of slip gauges for a dimension of 29.759mm from M112 set. What care of slip gauges is essential ? ii. Describe the working principle and uses of Lever type dial test indicator. (Apr/May 07)

UNIT III

OPTICAL MEASURING INSTRUMENTS : Tool makers microscope and its uses collimators, optical projector optical flats and their uses, interferometer. FLAT SURFACE MEASUREMENT : Measurement of flat surfaces instruments used straight edges surface plates optical flat and auto collimator.
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1.

Explicate the principle of operation of optical flats. How flatness is tested with optical flats? (Aug/Sep 07)

2. 3.

Describe with a sketch the working principle of an autocollimator. What is meant by flatness? How is it measured with autocollimator? What are the uses of the instrument? (Aug/Sep 07) Explicate measurement of flatness by i. Straight edge ii. Spirit level iii. Optical Flat (Aug/Sep 07) Elucidate the working principles of i. Autocollimator ii. Optical projector iii. Straight edge i. Explain terms Ra and Rz values ii. Describe evaluation of surface finish by i. Peak to valley height method ii. The average roughness method. Differentiate between measuring instrument and comparator.

4.

(Aug/Sep 07)

5.

(Aug/Sep 07) (Aug/Sep 07)

6. 7.

What are the possible fringe patterns for taper on gauges while testing with optical flats? How taper of plates is determined with optical flats? (Apr/Sep 2007) i. Describe the working principle of tool markers microscope. What are its uses ii. Explicate the utility of straight edge and surface plate in laboratories. Enunciate Flatness Straightness Optical flat Interferometers.

8.

(Apr/Sep 2007)

9. i. ii. iii. iv. 10. 11. 12. 13.

(Apr/Sep 2007)

Enumerate various optical methods of flatness testing. Describe the flatness testing with optical flats. (Apr/Sep 2007) What is Flatness? What are various methods of checking flatness of surfaces? Describe procedure for determining flatness of surfaces in laboratory. (Aug/Sep 06)

What are the numerous fringe contours in checking slip gauges by means of optical flats? Describe the method of experimental testing of such surfaces. (Aug/Sep 06) Enumerate various optical methods of flatness testing. Describe the flatness testing with optical flats. (Aug/Sep 06) What are the uses of optical flats? Describe testing of optical flats for flatness. (Aug/Sep 06)

14. 15. 16.

What are the numerous fringe contours in checking slip gauges by means of optical flats? Describe the method of experimental testing of such surfaces. (Aug/Sep 06) 17. i. Explicate the working principle of an Autocollimator. ii. Explicate the use of interferometer in measuring flatness of surfaces. (Aug/Sep 06) 18. Enumerate various interferometers. Describe the working principle of Michelson Interferometer with a neat sketch. (Aug/Sep 06) Enumerate various optical projectors. Explain the working principle of the optical system of a projector, with the help of neat sketch. (May 05) Describe the working principle of tool markers microscope. What are its uses Explicate the utility of straight edge and surface plate in laboratories.

19.

20. i. ii.

(May 05)

UNIT IV

SURFACE ROUGHNESS MEASUREMENT : Differences between surface roughness and surface waviness-Numerical assessment of surface finish CLA,R, R.M.S Values Rz values, Rz value, Methods of measurement of surface finish-profilograph. Talysurf, ISI symbols for indication of surface finish. MEASUREMENT THROUGH COMPARATORS : Comparators Mechanical, Electrical and Electronic Comparators, pneumatic comparators and their uses in mass production. ________________________________________________________________________________________ 1. i. What are the factors a_ecting surface roughness? What is the necessity for controlling the surface texture?

ii. Explicate the details of construction, principle and operation of stylus. 2. 3.

(Aug/Sep 07)

Elucidate the working principle of Eden-Rolt millionth comparator. (Aug/Sep 07) i. What are the factors a_ecting surface roughness? What is the necessity for controlling the surface texture? ii. Explicate the details of construction, principle and operation of stylus. (Aug/Sep 07) i. Enumerate various characteristics of a good comparator. ii. Explain the working of sigma comparator with special reference to cross strip lever in detail. (Aug/Sep 07) i. What are the factors a_ecting surface roughness? What is the necessity for controlling the surface texture? ii. Explicate the details of construction, principle and operation of stylus. (Aug/Sep 07) i. What are the factors a_ecting surface roughness? What is the necessity for controlling the surface texture? ii. Explicate the details of construction, principle and operation of stylus. (Apr/May 07) i. Describe the working principle of electronic comparators. (Apr/May 07)

4.

5.

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7. 8.

i. Differentiate between i. Roughness and waviness ii. Direct and indirect methods of roughness measurement ii. Calculate CLA and RMS roughness values for the following date: Sampling length:20 mm, peaks : 40, 42, 40, 41, 42, valleys : 25, 22, 22, 24, 23. (Apr/May 07) i. Differentiate between measuring instrument and comparator. (Apr/May 07)

9.

10. i. What are the advantages and limitations of stylus probe? ii. Describe with a neat sketch the working of profilometer. 11. i. Enlist various types of mechanical comparators and optical comparators.

(Apr/May 07) (Apr/May 07)

12. i. Explicate the measurement of surface roughness by electronic means. ii. The heights of peaks and valleys of 20 successive points on a surface are 80,60, 88, 66, 78, 62, 80, 62, 81, 63, 83, 62, 80, 60, 80, 60, 81, 59, 82, 62 microns respectively, measured over a length 20 mm, Determine CLA and RMS values of roughness surface. (Apr/May 07) 13. i. Enlist the classification and types of comparators. ii. Explicate with special reference to obtainable magnification, the working of electrical comparator. (Apr/May 07) 14. i. What are the advantages and limitations of stylus probe? ii. Describe with a neat sketch the working of profilometer. (Apr/May 06) 15. i. Enlist various types of mechanical comparators and optical comparators. ii. Describe the following alignment tests on a lathe for i. Level of installation ii. Parallelism of tailstock sleeve to saddle movement. (Apr/May 06)

16. i. What are the factors affecting surface roughness? What is the necessity for controlling the surface ii. Explain the details of construction, principle and operation of stylus. (Apr/May 06)

texture?

17. i.

Describe the working principle of a solex pneumatic comparator.

(Apr/May 06)

18. i. What are various orders of geometrical irregularities on surfaces? How these are classified? ii. Describe with a neat sketch the construction, principle and operation of Tomlinson surface meter. (Apr/May 06) 19. i. What are the advantages, uses and disadvantages of electrical comparators? (Apr/May 06) 20. i. Enumerate various direct instrument methods for measurement of surface finish. ii. Describe surface measurement with inspection by comparison methods.

(Apr/May 06)

UNIT-V SCREW THREAD MEASUREMENT : Element of measurement errors in screw threads measurement of effective diameter, angle of thread and thread pitch, profile thread gauges. ________________________________________________________________________________________ 1. Elucidate the Effective diameter measurement by two wire method. (Aug/Sep 07)

2. 8. i.

Describe the pitch measurement of internal and external screw threads by various methods. (Aug/Sep 07) Enumerate various screw thread parameters for metrological measurement. Also enlist instruments corresponding to their measurements. (Aug/Sep 07) Describe pitch measurement of internal and external screw threads by pitch measuring machine . (Aug/Sep 07) Elucidate the Effective diameter measurement by two wire method (Apr/May 07) Elucidate measurement method of thread angle by two ball method. (Apr/May 07) "Measurement of Effective diameter by two wires and micrometer is not accurate" -Explain.(Apr/May 07) Enumerate various screw thread parameters for metrological measurement. Also enlist instruments corresponding to their measurements. (Apr/May 07) Discuss the causes of following errors in screw thread pitches progressive error periodic error Drunken error irregular errors.

4. 5. 6.

i. i. i. i. i.

7.

8. i. ii. iii. iv 9. 10.

(Aug/Sep 06)

Describe pitch measurement of internal and external screw threads by pitch measuring machine .

Enumerate various screw thread parameters for metrological measurement. Also enlist instruments corresponding to their measurements. (Aug/Sep 06) 11. Discuss the effect of pitch errors on i. Effective diameter ii. Flank angle error of screw threads. (Aug/Sep 06) 12. 13. Elucidate the Effective diameter measurement by two wire method Explain the measurement of effective diameter using i. thread micrometer ii. one wire method. (Apr/May 06)

14. 15. 16. 17.

Elucidate the measurement of effective diameter by three wire method (Apr/May 06) Describe an exclusive method for effective diameter measurement which shows variation in drunken thread. Describe an exclusive method for effective diameter measurement which shows variation in drunken thread. 05) Describe the pitch measurement of internal and external screw threads by various methods. (May 05) (May

18.

Enumerate various screw thread parameters for metrological measurement. Also enlist instruments corresponding to their measurements. (May 05) What is " Best size wire" for effective diameter measurement ? Derive a relationship for the best size wire in terms of its effective diameter. (May 05) What is the difference between a comparator and measuring instrument? (May 05)

19.

20.

UNIT VI MACHINE TOOL ALIGNMENT TESTS : Requirements of Machine Tool Alignment Tests, Alignment tests on lathe, milling, drilling machine tools.. Preparation of acceptance charts. ____________________________________________________________________________________________ 1. ii. Enumerate various alignment tests on milling machine. (Aug/Sep 07) ii. Enumerate the various equipments and their essential precision and accuracylevels for performing alignment tests. (Aug/Sep 07) Enumerate various equipment desirable for alignment tests on lathe. Enlist various such tests for lathe. (Aug/Sep 07) Explain the following alignment tests on lathe: i. Parallelism of tailstock sleeve taper socket to saddle movement. ii. True running of head stock center. (Apr/May 07)

2. 3.

4 5

Enumerate various equipment desirable for alignment tests on lathe. Enlist various such tests for lathe. (Apr/May 07) Describe the following alignment tests on a lathe for i. Level of installation ii. Parallelism of tailstock sleeve to saddle movement. (Apr/May 07) Explain the various tests on shaper for alignment. Explain the following alignment tests on lathe: i. True running of locating cylinder of main spindle. ii. True running of taper socket in main spindle. (Apr/May 06)

6. 7.

(May 05)

8.

Explain the following alignment tests on lathe: True running of locating cylinder of main spindle. (Apr/May 06) 9. Describe the following alignment tests on a lathe for i. Level of installation ii. Parallelism of tailstock sleeve to saddle movement. (Apr/May 06) 10. Explain the following alignment tests on lathe: i. Parallelism of tailstock sleeve taper socket to saddle movement. ii. True running of head stock center. i. 11.

(Aug/Sep 06)

Enumerate the various equipments and their essential precision and accuracy levels for performing alignment tests. (Aug/Sep 06) What is the importance of geometrical and allignment tests of machine tools ? List a set of such tests suitable for horizontal milling machine. (May 04) With schematic sketches show the tests for the alignment of spindle axis of a lathe relative to the tail stock axis and lathe bed. (Dec 03) What are the various geometric tests be performed on Milling machine to knew its performance (Dec 02) What are the main instruments required for geometric test for testing machine tools? (Dec 02)

12.

13. 14. 15.

UNIT- VII GEAR MEASUREMENT: Gear measuring instruments, Gear tooth profile measurement. Measurement of diameter, pitch pressure angle and tooth thickness. Coordinate Measuring Machines: Types of CMM, Role of CMM, and Applications of CMM. ___________________________________________________________________________________________ 1. Explicate gear metrology of spur gears with reference to i. Lead ii. pitch (Aug/Sep 07) 2. 3. 2. 3. 4. Describe with the help of a neat sketch the working of "Gear tooth vernier caliper". Enumerate various types of errors in gear. (Aug/Sep 07)

Explicate gear metrology of spur gears with reference to Tooth thickness by constant chord method. (Apr/May 07) Explicate gear metrology of spur gears with reference to Checking pitch by Parkinson gear tester. (Apr/May 07) Describe with the help of a neat sketch the working of "Gear tooth vernier caliper". (Apr/May 07)

5.

Enumerate various gear parameters measured in metrology lab and corresponding instruments required for measurement. (Aug/Sep 06) Enumerate various types of errors in gear. Describe with the help of a neat sketch the working of "Gear tooth vernier caliper". Describe gear metrology of i. pitch ii. profile (Aug/Sep 06) (Aug/Sep 06)

6. 7. 8.

(Aug/Sep 06)

9.

Explicate gear metrology of spur gears with reference to i. Lead ii.pitch Analyze gear metrology of i Run out ii back lash. Explain gear metrology of spur gears with reference to i. Back lash ii. Tooth thickness Explicate gear metrology of spur gears with reference to i. Lead ii. profile Describe with the help of a neat sketch the working of "Gear tooth vernier caliper". Explicate gear metrology of spur gears with reference to i. Concentricity ii. Alignment

(Aug/Sep 06)

10.

(Apr/May 06)

11.

(Apr/May 06)

12.

(May 05) (May 05)

13. 14.

(May 05)

15. i. With the aid of sketch describe the principle of operation of a rolling gear testing machine. ii. Describe a method for inspecting the involute profile of a spur gear tooth. 16. 17. 18. What is a Coordinate Measuring Machine? Illustrate with the help of a neat diagram.

(Dec 03) (R1, Ch 35)

What are the different types of Coordinate Measuring Machines? Explain the role of each machine. (R1, Ch 35) What are the different applications of Coordinate Measuring Machines? (R1, Ch 35)

UNIT VIII SURFACE ENGINEERING : Surface treatment processes and their character tics and applications. (a) Overlay coatings (b) Diffusion coatings (c) Thermal or mechanical modification of Surfaces ___________________________________________________________________________________________ 1. Why surface treatment processes are required? (R1, Ch 33) 2. 3. 4. 5. Name some of the surface treatment processes for various metals. Name and explain some of the mechanical surface treatment processes. What is thermal spraying and what are the different types? What is diffusion coating? Explain the following diffusion coating process: i. Carburizing ii. Nitriding iii. Boronizing What are overlay coatings? What are the different types? Give some applications of mechanical surface treatment. Explicate the following overlay coatings: i. Dip coating ii. Flow coating iii. Electrostatic spraying (R1, Ch 33) (R1, Ch 33) (R1, Ch 33)

(R1, Ch 33) (R1, Ch 33) (R1, Ch 33)

6. 7. 8.

(R1, Ch 33)