Code No: R5320302 1

III B.Tech II Semester(R05) Regular/Supplementary Examinations, April/May 2009

METROLOGY AND SURFACE ENGINEERING
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. Three 200 mm end bars are measured on a level comparator by first wringing them together and
comparing with a 350 mm bar and then inter comparing them. The 350 mm bar has a known error
of +40 µm and the three bars together measures 60 µm less than the 350 mm bar. Bar A is 15 µm
longer than bar B and 20 µm longer than bar c. Find the actual length of each bar. [16]
2. (a) With the help of neat sketches, explain how a sine bar is used to determine the taper angle of an
inclined surface?
(b) Name the Various factors affecting the accuracy of the sine bar and state the specification of sine
bar. [8+8]
3. What are the most common aberrations found in optical projector? Explain how they are caused.
How can you overcome these? [16]
4. The heights of peaks and valleys of 20 successive points on a surface are 21, 18, 22,57, 86, 56, 78,
23, 17, 24, 23, 35, 13, 87, 73,67, 55, 44, 64, 39 microns respectively, measured over a length 20 mm.
Determine CLA and RMS values of roughness surface. [16]
5. What are the different elements of a screw thread? What instruments can be used to measure these
elements. Describe any two of them. [16]
6. Describe the following alignment tests on a milling machine with neat sketches.
(a) Parallelism of tailstock sleeve to saddle movement.
(b) True running of internal taper of the main spindle of milling machine. [8+8]
7. (a) Describe the features of the coordinate measuring machine (CMM)?
(b) Explicate gear metrology of spur gears with reference to Backlash. [8+8]
8. Describe and give their applications.
(a) Electroplating
(b) Parkerizing. [8+8]

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Code No: R5320302 2
III B.Tech II Semester(R05) Regular/Supplementary Examinations, April/May 2009
METROLOGY AND SURFACE ENGINEERING
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A hole and mating shaft are to have a nominal assembly size of 55 mm. The assembly is to have a
maximum clearance of 0.34 mm and a minimum clearance of 0.25 mm. The hole tolerance is 1.5 times
the shaft tolerance. Determine the limits for both hole and shaft: By using
(a) Hole basis system
(b) Shaft basis system. [8+8]
2. A 120 mm sine bar is used to set an angle of 32.50 . Determine the list of slip gauges needed? Estimate
the error in the angle if
(a) Distance between rollers is not correct by ±0.01 mm
(b) If diameter of rollers is out by ±0.005 mm. [16]
3. (a) What are the necessary conditions for interference of light waves?
(b) At what angle the bands should be viewed in interferometric measurement and what is the effect
if it is too large? [8+8]
4. (a) Discuss the fundamental requirements a comparator should meet.
(b) Write short notes on:
i. Visual gauging heads
ii. Multi gauging machines. [4+12]
5. (a) What is Drunken Thread? Explain with neat sketch.
(b) What difficulties does it pose in finagling the pitch of the thread? [8+8]
6. (a) Distinguish between geometrical and practical tests on machine tools.
(b) Explain various instruments required for performing the alignment tests on machine tools. [8+8]
7. Describe the Davis-Brown involute machine working principle and conotruction.
[16]
8. Write notes on:
(a) Phosphate coating
(b) Chromate coating
(c) Galvanizing
(d) Electroplating. [4+4+4+4]

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Code No: R5320302 3
III B.Tech II Semester(R05) Regular/Supplementary Examinations, April/May 2009
METROLOGY AND SURFACE ENGINEERING
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A slip gauge set M38 consists of the following.

Range (mm) Steps (mm) No of blocks
1.005 --- 1
1.01 to 1.09 0.01 9
1.1 to 1.9 0.1 9
1 to 9 1 9
10 to 100 10 10
Choose the suitable minimum number of slips to build up the following dimensions and explain with
neat sketch.
(a) 15.08
(b) 38.925 [8+8]
2. What are the essential considerations in selection of materials for gauges and what are the common
materials used for gauges? Explain the various processes of manufacturing gauges? [16]
3. Defferatiate between straitness and flatness. Describe a surface plate with reference to its construction
use and material. [16]
4. (a) Write advantages and disadvantages of mechanical comparator?
(b) Explain the working of mechanical optical comparator? [8+8]
5. (a) What is meant by drunken thread? What troubles does it present in finding the pitch of the
thread?
(b) Describe an exclusive method for effective diameter measurement which shows variation in drunken
thread. [8+8]
6. How are the following alignment tests carried out on a lathe machine? with figure.
(a) Parallelism of the main spindle to saddle movement
(b) Parallelism of quill movement of lathe tailstock with machine bed guides.
[8+8]
7. Describe briefly the following method of tooth thickness measurement
(a) Constant chord method
(b) Base Tangent method. [8+8]
8. Write notes on on the following, and state the reasons for material selection.
(a) Organic coating
(b) Degreasing. [8+8]

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Code No: R5320302 4
III B.Tech II Semester(R05) Regular/Supplementary Examinations, April/May 2009
METROLOGY AND SURFACE ENGINEERING
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. Identify whether the following fits are hole based or shaft based. Convert them in to equivalent other
system.
(a) H7 - f8
(b) F6 - h4
(c) H5 - n4
(d) H7 - c6 . [16]
2. Explain the classification of plain limit gauges? Sketch and explain any four types of plug gauges?
[16]
3. Defferatiate between straitness and flatness. Describe a surface plate with reference to its construction
use and material. [16]
4. (a) What is a comparator describe the essential characteristics of comparator.
(b) How comparators are classified? Briefly discuss each. [8+8]
5. (a) Distinguish between left hand thread and right hand thread. Sketch these threads. Give few
applications of each type.
(b) What are the different elements of a screw thread? What are the instruments used for the
measurement of the above elements. [8+8]
6. (a) What is meant by an alignment test on machine tools and why they are necessary?
(b) How are alignment tests carried out on a radial drilling machine? Sketch and explain. [8+8]
7. (a) Differentiate between Point inspection and Continuous inspection.
(b) What are the possible sources of errors in CMM? [8+8]
8. Describe the following coating processes
(a) Galvanizing
(b) Electro static plating. [8+8]

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