Assignment1 Straightness Composite Lab 2 Ahmedawad
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Transcript of Assignment1 Straightness Composite Lab 2 Ahmedawad
SHEET 1
STRAIGHTNESS
1. With the aid of neat sketches Describe how the straightness of a machine guide
way may be experimentally determined:
a) Using spirit sensitive level.
b) Rocdale arm (arm comparator).
2. With the aid of neat sketches Describe how the straightness of a shaft may be
experimentally determined using a dial indicator
3. A Shaft of length 500 mm was tested for straightness error by using a dial
indicator. The shaft was divided into 10 equal spaces of 50 mm apart, and the
dial readings were observed at each position (11 readings). The readings were as
shown in the following table. Using the least square method determine the
maximum out of straightness in microns, and Plot the contour of the shaft.
x y x2 xy
y' =0.004099x +1.387838
πΏ = π¦ β π¦β²
0 0.01 0 0 -0.04682 0.05682
50 0.1 2500 5 0.03638 0.06362
100 0.15 10000 15 0.11958 0.03042
150 0.15 22500 22.5 0.20278 -0.05278
200 0.25 40000 50 0.28598 -0.03598
250 0.25 62500 62.5 0.36918 -0.11918
300 0.45 90000 135 0.45238 -0.00238
350 0.6 122500 210 0.53558 0.06442
400 0.4 160000 160 0.61878 -0.21878
450 0.75 202500 337.5 0.70198 0.04802
500 0.95 250000 475 0.78518 0.16482
β 2750 4.06 962500 1472.5
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 100 200 300 400 500 600
y (m
m)
X (mm)
profile
profile
true straight line
π = 11
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
4.06 Γ 962500 β 1472.5 Γ 2750
11 Γ 962500 β 27502 = β0.048681
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
11 Γ 1472.5 β 4.06 Γ 2750
11 Γ 962500 β 27502 = 0.0016636
π = ππ + π = π. ππππππππ β π. ππππππ ππ
Maximum out of straightness = |0.16482| + |β0.21878| = 0.3836ππ = 383.6microns
-0.25
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15
0.2
0 100 200 300 400 500 600
del
ta (
mm
)
x (mm)
Series1
4. A Shaft of length 300 mm was tested for straightness error by using a dial
indicator. The shaft was divided into 6 equal spaces of 50 mm apart, and the dial
readings were observed at each position (7 readings). The readings were as
follows:
2.7
2.9
3.1
3.3
3.5
3.7
3.9
4.1
4.3
0 50 100 150 200 250 300 350
y (m
m)
X (mm)
profile
profile
true straight line
x y x2 xy
y' =0.004216x+2.8965
πΏ = π¦ β π¦β²
0 2.9 0 0 2.8965 0.0035
50 3.15 2500 157.5 3.1073 0.0427
100 3.3 10000 330 3.3181 -0.0181
150 3.45 22500 517.5 3.5289 -0.0789
200 3.752 40000 750.4 3.7397 0.0123
250 4 62500 1000 3.9505 0.0495
300 4.15 90000 1245 4.1613 -0.0789
β 1050 24.702 227500 4000.4
π = 7
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
24.702 Γ 227500 β 1472.5 Γ 1050
7 Γ 227500 β 10502= 2.8965
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
7 Γ 1472.5 β 24.702 Γ 1050
7 Γ 227500 β 10502 = 0.004216
π = ππ + π = π. πππππππ + π. ππππ ππ
Maximum out of straightness = |0.0495| + |β0.0789| = 0.1284ππ = 128.4microns
-0.1
-0.08
-0.06
-0.04
-0.02
0
0.02
0.04
0.06
0 50 100 150 200 250 300 350
del
ta (
mm
)
x (mm)
5. The straightness of a slide was tested using a spirit level of 1.5 scale division and
a radius of curvature of 3 m. The readings taken in the forward direction (in
divisions) were
-3 +4 -1 +2 -3 +4 -3 -2 -7
The readings taken in the backward direction (in divisions) were
+3 -4 +1 -2 +3 -4 +3 +2 +7
Find out the out of straightness semi analytically. The distance between any two
points is 100 mm.
π =π·
π =
1.5
3= 0.5ππ/π
π = 0.05ππ/100ππ
x
y y
average y
accumulative y
mm x2 xy
y' =-0.00022x+ 0.054545
πΏ= π¦ β π¦β²
forward backward
0 0 0 0 0 0 0 0 0.054545 -0.05455
100 -3 3 -3 -3 -0.15 10000 -15 0.032545 -0.18255
200 4 -4 4 1 0.05 40000 10 0.010545 0.039455
300 -1 1 -1 0 0 90000 0 -0.01146 0.011455
400 2 -2 2 2 0.1 160000 40 -0.03346 0.133455
500 -3 3 -3 -1 -0.05 250000 -25 -0.05546 0.005455
600 4 -4 4 3 0.15 360000 90 -0.07746 0.227455
700 -3 3 -3 0 0 490000 0 -0.09946 0.099455
800 -2 2 -2 -2 -0.1 640000 -80 -0.12146 0.021455
900 -7 7 -7 -9 -0.45 810000 -405 -0.14346 -0.30655
sum 4500
-0.45 2850000 -385
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0 200 400 600 800 1000
y (m
m)
X (mm)
profile
true straight line
π = 10
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
β0.45 Γ 2850000 β (β385 Γ 4500)
10 Γ 2850000 β 45002 = 0.0545454
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
10 Γ β385 β (β0.45 Γ 4500)
10 Γ 2850000 β 45002
= β0.00022
π = ππ + π = βπ. ππππππ + π. ππππππ ππ
Maximum out of straightness = |0.227455| + |β0.30655| = 0.534005ππ = 534microns
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0 200 400 600 800 1000
de
lta
(mm
)
x (mm)
semi analytically
x
y y
average
y accumulati
ve
y mm
Y' delta yi-y'
forward backward
0 0 0 0 0 0 0 0
100 -3 3 -3 -3 -0.15 -0.05 -0.1
200 4 -4 4 1 0.05 -0.1 0.15
300 -1 1 -1 0 0 -0.15 0.15
400 2 -2 2 2 0.1 -0.2 0.3
500 -3 3 -3 -1 -0.05 -0.25 0.2
600 4 -4 4 3 0.15 -0.3 0.45
700 -3 3 -3 0 0 -0.35 0.35
800 -2 2 -2 -2 -0.1 -0.4 0.3
900 -7 7 -7 -9 -0.45 -0.45 0
Maximum out of straightness = |0.45| + |β0.1| = 0.55ππ = 550microns
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0 200 400 600 800 1000
y (m
m)
X (mm)
profile
Series2
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
0 200 400 600 800 1000
del
ta (
mm
)
x (mm)
6. The squareness of the guide way of a milling machine was checked using sensitive
level. Its scale value is 0.02 mm/100mm. The readings taken on the guide way of the
bed are given in row "A" while the readings for the guide way of the column are
given in row "B". Find the out the out of squareness
A +1 +2 0 -3 +2 -1 +3
B -2 +1 -1 +2 0 -1 1
x
y
y accumulative
y mm
x2 xy y'
=(0.0000190476)x +(-0.000065895)
πΏ = π¦ β π¦β²
0 0 0 0 0 0 -0.000065895 0.000065895
100 1 1 0.02 10000 2 0.001838865 0.018161135
200 2 3 0.04 40000 8 0.003743625 0.036256375
300 0 3 0 90000 0 0.005648385 -0.00564839
400 -3 0 -0.06 160000 -24 0.007553145 -0.06755315
500 2 2 0.04 250000 20 0.009457905 0.030542095
600 -1 1 -0.02 360000 -12 0.011362665 -0.03136267
700 3 4 0.06 490000 42 0.013267425 0.046732575
sum 2800
0.08 1400000 36
π = 8
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
0.08 Γ 1400000 β (36 Γ 2800)
8 Γ 1400000 β 28002 = β0.000065895
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
8 Γ 36 β (0.08 Γ 2800)
8 Γ 1400000 β 28002 = 0.0000190476
π = ππ + π = π. πππππππππππ β π. πππππππππ ππ
-0.08
-0.06
-0.04
-0.02
0
0.02
0.04
0.06
0.08
0 200 400 600 800y (m
m)
X (mm)
A
Series1
Series2
x
y
y accumulative
y mm
x2 xy y'
=(0.0000285714)x πΏ = π¦ β π¦β²
0 0 0 0 0 0 0 0
100 -2 -2 -0.04 10000 -4 0.00285714 -0.04285714
200 1 -1 0.02 40000 4 0.00571428 0.01428572
300 -1 -2 -0.02 90000 -6 0.00857142 -0.02857142
400 2 0 0.04 160000 16 0.01142856 0.02857144
500 0 0 0 250000 0 0.0142857 -0.0142857
600 -1 -1 -0.02 360000 -12 0.01714284 -0.03714284
700 1 0 0.02 490000 14 0.01999998 2E-08
sum 2800
0 1400000 12
π = 8
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
0 Γ 1400000 β (12 Γ 2800)
8 Γ 1400000 β 28002= 0
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
8 Γ 12 β (0 Γ 2800)
8 Γ 1400000 β 28002 = 0.0000285714
π = ππ + π = π. πππππππππππ ππ
π1
π2β β1
-0.05
-0.04
-0.03
-0.02
-0.01
0
0.01
0.02
0.03
0.04
0.05
0 200 400 600 800y (m
m)
X (mm)
B
profile
true straight line
7. A straight edge is checked using a precision spirit level having scale value
0.5 mm/100 mm. The readings of the bubble in the forward and
backward directions for the five positions taken along the edges are as
shown in the following table, readings are taken as divisions. The interval
distance is 100 mm. Find out the out of straightness.
First Second Third Fourth Fifth
Forward 0 13 17 7 15
Backward 0 -11 -15 -5 -13
x
y y average
y accumulative
y mm
x2 xy y' =0.059x
+0.4 πΏ
= π¦ β π¦β²
forward backward
0 0 0 0 0 0 0 0 0.4 -0.4
100 13 -11 12 12 6 10000 600 6.3 -0.3
200 17 -15 16 28 14 40000 2800 12.2 1.8
300 7 -5 6 34 17 90000 5100 18.1 -1.1
400 15 -13 14 48 24 160000 9600 24 0
sum 1000
61 300000 18100
0
5
10
15
20
25
30
0 100 200 300 400 500
y (m
m)
X (mm)
profile
true straight line
π = 5
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
61 Γ 300000 β (18100 Γ 1000)
5 Γ 300000 β 10002 = 0.4
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
5 Γ 18100 β (61 Γ 1000)
5 Γ 300000 β 10002= 0.059
π = ππ + π = π. ππππ + π. π ππ
Maximum out of straightness = |1.8| + |β1.1| = 2.9ππ = 2900microns
-1.5
-1
-0.5
0
0.5
1
1.5
2
0 100 200 300 400 500del
ta (
mm
)
x (mm)
8. The straightness of a slide was tested using a spirit level of 1.5 mm scale value
and a radius of curvature of 3 m. The readings in the forward direction (in
divisions) are
-3 +4 -1 +2 -3 +4 -3 -2 -7
The readings in the backward direction (in divisions) are
+3 -4 +1 -2 +3 -4 +3 +2 +7
Find out the out of straightness semi analytically. The distance between any two
points is 100 mm.
π =π·
π =
1.5
3= 0.5ππ/π
π = 0.05ππ/100ππ
semi analytically
x
y y
average
y accumulati
ve
y mm
Y' delta yi-y'
forward backward
0 0 0 0 0 0 0 0
100 -3 3 -3 -3 -0.15 -0.05 -0.1
200 4 -4 4 1 0.05 -0.1 0.15
300 -1 1 -1 0 0 -0.15 0.15
400 2 -2 2 2 0.1 -0.2 0.3
500 -3 3 -3 -1 -0.05 -0.25 0.2
600 4 -4 4 3 0.15 -0.3 0.45
700 -3 3 -3 0 0 -0.35 0.35
800 -2 2 -2 -2 -0.1 -0.4 0.3
900 -7 7 -7 -9 -0.45 -0.45 0
Maximum out of straightness = |0.45| + |β0.1| = 0.55ππ = 550microns
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0 200 400 600 800 1000
y (m
m)
X (mm)
profile
Series2
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
0 200 400 600 800 1000
del
ta (
mm
)
x (mm)
9. A flat guide way of length 2000 mm was checked using beam comparator having
a dial indicator of scale value 0.01 mm. The distance between the beam legs is
200 mm. The guide way was divided into 10 divisions as shown and the recorded
readings are listed below. The beam was calibrated by placing it on a reference
straight edge and the indicator reading was observed as 3.15 mm. Find out the
maximum out of straightness.
a------b------c------d------e------f------g------h------i-------g------k
Beam Readings
position abc bed cde def efg fgh ghi hig igh
Reading mm 2.98 2.95 3.02 3.06 2.9 3.11 3.18 3.22 3.25
R corrected
= R-Rref -0.17 -0.2 -0.13 -0.09 -0.25 -0.04 0.03 0.07 0.1
π = 2π β π + π¦
position a b c d e f g h i j k
x 0 200 400 600 800 1000 1200 1400 1600 1800 2000
y 0 0 -0.17 -0.54 -1.04 -1.63 -2.47 -3.35 -4.2 -4.98 -5.66
x y x2 xy
y' =0.066473x
-22.3036 πΏ = π¦ β π¦β²
0 0 0 0 0.876364 -0.87636
200 0 40000 0 0.264364 -0.26436
400 -0.17 160000 -68 -0.34764 0.177636
600 -0.54 360000 -324 -0.95964 0.419636
800 -1.04 640000 -832 -1.57164 0.531636
1000 -1.63 1000000 -1630 -2.18364 0.553636
1200 -2.47 1440000 -2964 -2.79564 0.325636
1400 -3.35 1960000 -4690 -3.40764 0.057636
1600 -4.2 2560000 -6720 -4.01964 -0.18036
1800 -4.98 3240000 -8964 -4.63164 -0.34836
2000 -5.66 4000000 -11320 -5.24364 -0.41636
β 11000 -24.04 15400000 -37512
π = 11
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
β24.04 Γ 15400000 β β37512 Γ 11000
11 Γ 15400000 β 110002= β22.3036
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
11 Γ β37512 β β24.04 Γ 11000
11 Γ 15400000 β 110002 = 0.066473
π = ππ + π = βπ. ππππππ + π. ππππππππ
Maximum out of straightness = |0.553636| + |β0.87636| = 1.42999 ππ
-6
-5
-4
-3
-2
-1
0
1
2
0 500 1000 1500 2000 2500
y (m
m)
X (mm)
profile
true straight line
-1
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
0 500 1000 1500 2000 2500
del
ta (
mm
)
x (mm)
10. A flat guide way of length 2000 mm was checked using beam
comparator having a dial indicator of scale value 0.01 mm. The distance
between the beam legs is 200 mm. The guide way was divided into 10
divisions as shown and the recorded readings are listed below. Readings
were taken by a spirit level of constant 0.15 mm/m along the line abc
and the reading were listed below. Find out the maximum out of
straightness.
a---b---c---d---e---f---g---h---i---j---k
Bam Readings
position abc bcd cde def efg fgh ghi hij ijk
Reading mm
2.98 2.95 3.02 3.06 2.90 3.11 3.18 3.22 3.25
R corrected
2.92 2.89 2.96 3 2.84 3.05 3.12 3.16 3.19
Level readings
bc ab Position
5 R 3 R Forward Reading (Divs) 1 R 1 L Backward
+3 +1 Average
0.09 0.03 (n*c) mm
C=0.15mm/m=0.03mm/200mm
Correction = 0.06 mm
π = 2π β π + π¦
position a b c d e f g h i j k
x 0 200 400 600 800 1000 1200 1400 1600 1800 2000
y 0 0 2.92 8.73 17.5 29.27 43.88 61.54 82.32 106.3 133.4
x y x2 xy
y' =0.066473x-
22.3036 πΏ = π¦ β π¦β²
0 0 0 0 -22.3036 22.3036
200 0 40000 0 -9.009 9.009
400 2.92 160000 1168 4.2856 -1.3656
600 8.73 360000 5238 17.5802 -8.8502
800 17.5 640000 14000 30.8748 -13.3748
1000 29.27 1000000 29270 44.1694 -14.8994
1200 43.88 1440000 52656 57.464 -13.584
1400 61.54 1960000 86156 70.7586 -9.2186
1600 82.32 2560000 131712 84.0532 -1.7332
1800 106.3 3240000 191340 97.3478 8.9522
2000 133.4 4000000 266800 110.6424 22.7576
β 11000 485.86 15400000 778340
-40
-20
0
20
40
60
80
100
120
140
160
0 500 1000 1500 2000 2500
y (m
m)
X (mm)
profile
true straight line
π = 11
c = β y β x2 β β π₯π¦ β x
n β x2 β (β x)2 =
485.86 Γ 15400000 β 778340 Γ 11000
11 Γ 15400000 β 110002= β22.3036
π =π β π₯π¦ β β π¦ β π₯
n β x2 β (β x)2 =
11 Γ 778340 β 485.86 Γ 11000
11 Γ 15400000 β 110002 = 0.066473
π = ππ + π = π. πππππππ β ππ. ππππ ππ
Maximum out of straightness = |22.7576| + |β14.8994| = 37.657ππ
-20
-15
-10
-5
0
5
10
15
20
25
0 500 1000 1500 2000 2500del
ta (
mm
)
x (mm)