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1. A
Micro-Project Report
on
“Dial Gauge Indicator”
Partial Fulfillment of the Requirement for the Diploma in Mechanical
Engineering,
By
1) Nagare Harshal Vilas [2114660156]
2)Kale Sampat Pandurang [2114660157]
3)Pathare Aadesh Ankush [2014660158]
Guided By
Prof. Waghmare A. B
Shree Samarth Academy’s
Shree Samarth Polytechnic
Mhasane Phata, Ahmednagar
Maharashtra State Board of Technical Education
(2020-2021)

2. Shree Samarth Academy’s
Shree Samarth Polytechnic
Department of Mechanical Engineering.
CERTIFICATE
This is to certify that the project work entitled
“Dial Gauge Indicator”
Is
Submitted by
1) Nagare Harshal Vilas [2114660156]
2)Kale Sampat Pandurang [2114660157]
3)Pathare Aadesh Ankush [2014660158]
in the partial fulfillment ofDiploma in Mechanical Engineering has beenSatisfactory
carried out under my guidance as per the requirement ofMaharashtra State Board of
Technical Education, Mumbai during the academic year 2020-2021
Date:
Place:
GUIDE HOD PRINCIPAL
(Prof. Waghmare A. B ) (Prof. Jadhav M. B) (Prof. ANARASE B.V.)

3. ACKNOWLEDGEMENT
An endeavor over long period can be successfulonly with advice and
guidance of many well-wishers.
My sincere thanks to the management and Prof. Anarase B.V sir
Principal of Shree Samarth Polytechnic, Mhasanephata , Ahmednagar for
providing me the opportunity to conduct my project work.
I am highly indebted to Prof. Jadhav M. B sir Head of Department of
Mechanical for his assistanceand constantsourceof encouragement. I wish
to express my profound and deep sense of gratitude of
Prof. Waghmare A. B Sir projectcoordinator for sparing her valuable time to
extent helps in every step of my project work.
I would also like to thank the staff of Mechanical Department for the
generous guidance.
Last but not the least we would like to thank our friends and for their
help in every way for the success of this project report.
Name of student Signature
1) Nagare Harshal Vilas [2114660156]
2)Kale Sampat Pandurang [2114660157]
3)Pathare Aadesh Ankush [2014660158]

4. Micro-Project Proposal
“Dial Gauge Indicator”
1.0 Brief Introduction:
It operates on the principle, that a very slight upward pressure on the spindle at the
contactpoint is multiplied through a system of gears and levers. It is indicated on the
face of the dial by a dial finger. Dial indicators consists of a body with a round
graduated dial and a contact point connected with a spiral or gear train so that hand
on the dial face indicates the amount of movement of the contact point. They are
designed for use on a wide range of standard measuring devices such as dial box
gauges, portaldial, hand gauges, dial depthgauges, diameter gauges and dial indicator
snap gauge.
Corresponds to a spindle movement of 1 mm. The movement mechanism of the
instrument is housed in a metal caseforits protection. Thelarge dial scale is graduated
into 100 divisions. The indicator is set to zero by the use of slip gauges representing
the basic size ofthe part. In orderthat the investigators in different parts ofthe country
and different parts of world may compare the results of their experiments on a
consistent basis, it is necessary to establish certain standard units of length, weight,
time, temperature and electrical, quantities. The National Bureau of Standards has the
primary responsibility for maintaining these standard in the United States. In India,
Indian Standard Institute (ISI), New Delhi has taken the responsibility formaintaining
all the standard measurements. To monitor the standard of measurements, the same
Institute issues instructions to put ISI mark on measuring instruments and items so
that these may be compared with non-standard ones. In the measurement system, the
quantity to be measured, in the direct method, is compared directly against a standard
of same kind of quantity. The magnitude of quantity being measured is expressed in
terms of a chosen unit for the standard and a numerical multiplier.

5. A length can be measured in terms of meter and a numerical constant. Thus, a 10
meter length means a length ten times greater than a meter. Thus, by the means of
standard, it is possible to provide means of establishing and maintaining the
magnitudes of the various units. The simplest kind of standard is a physical object
having desired property. This standard can be used as a basis of comparison.

6. Increase the degree of precision
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Altek Milliamp Calibrators & Altek Voltage Calibrators
Altek’s first products were loop powered 4 to 20 milliamp calibrators – Altek Model
45 and Altek Model 46 – the ages of the owners! A favorite calibrator was the Altek
Model 134 which was a palm sized milliamp calibrator with three 9V batteries that
generated 4 to 20 milliamps and had a toggle switch to quickly go from 4 to 20
milliamps without looking at the calibrator. The pocket sized replacement for the 134
was the Altek Model 134-2 which came out in 1999. The first big seller was the Altek
Model 234 in 1984 which added a 3 1/2 digit LCD display to measure up to 19.99
milliamps.
Instrument technicians suggested improvements led to the Altek Model 334. It was
designed in 1989 with a a full 4 digit display to 24.00 milliamps and a measure DC
Volts range to check batteries and loop power supplies. The Altek Model 334A
replaced the Model 334 in 2000 with a surface mount design. The high accuracyAltek
Model 434 was released in 1999 and was the first handheld calibrator to include a 250
Ohm resistor for HART compatibility.

7. The Altek 235 was a voltage calibrator released in 1985 with ranges for millivolts, 1 to
5 volts and up to 20 volts dc. The Model 934 had a dual display that would
simultaneously source and read milliamps and voltage.
The costofcalibration of a hand-held measuring device such as a micrometer, calliper
or dial indicator is roughly equivalent to the price of a new instrument. Manual
calibration therefore usually involves checking a mere 10 to 20 points. This only gives
a rough figure of the precision of the instrument and is not a complete check of the
scale. To reveal the sources of error for a typical dial indicator, many more points
should be checked. If a dial indicator is used for quality checking on a factory
production line measuring the same dimension thousands of times each year wear
might occur and there would be errors at this single point on the scale of the dial
indicator. If manual calibration was performed this wear would probably not be
revealed and the result would be quality problems when the dial indicator gave
incorrect dimensions to the part onthe productionline. With automatic machine vision-
based systems the calibration can be extended to several hundred points, giving a more
complete picture of the errors. Developing a system of this kind is now bothcheap and
easy, and machine vision-based measurement systems of similar complexity have been
developed in many laboratories and throughout industry. However, during
development work the calculation of the uncertainty of measurement is often poorly
reported. A calculation of uncertainty of measurement can be regarded as good if it
complies with the guidelines given in the Guide to the Expression of Uncertainty in
Measurement [1].
A commercially available instrument is offered by the Steinmeyer Feinmess
corporation. This systemis based ona video camera and a motorized length transducer.
The Institute of Nuclear Energy in Bucharest has developed a laser interferometer-
based instrument [2]. In this instrument the linear displacement of the dial indicator
rod is measured by a Michelson interferometer.

8. A specially designed angular transducer with phototransistors is placed over the face
of the dial indicator. A vision system for calibration of a dial gauge torque wrench is
also described in [3]. The problem of measuring the angle position of the pointer of a
dial gauge torque wrench is similar to the measurement of the angle position of the
pointer ofa dial indicator. In this particular field the authors have not found calculations
of uncertainty of measurement. This paper describes a machine vision-based system,
with emphasis on the calculation of measurement uncertainty. It is assumed that the
reader knows the basics ofthe calculation ofuncertainty according to [1] and is familiar
with dial indicators.
The developedinstrument
The operating principle is shown in figure 1. With future expansion of the instrument
in mind, it was originally designed to be bigger than required for the calibration of dial
indicators (figure 2). The instrument consists ofa motorized stage (Physik Instrumente
M 405.DG), a holder for the dial indicator and two length transducers (Heidenhein
MT25), and a heightadjustable red LED ring light (CSI FPR-100) together with a CCD
camera (figure 3). A fibre ring light was also tested butreflections occurred onthe glass
of the dial indicator under test. The ring light has 65 LEDs, and by adjusting it to the
appropriate height there are almost no shadows or glints on the dial indicator. A CCIR
standard camera (Cohu 4910) with resolution 752 × 582 was installed with a 50 mm
Rainbow G50 lens. The position of the stage was measured by the two length
transducers and their average used as a position reference to eliminate the Abbe error.
The software was written with the Visual Basic 6 development toolin Windows NT 4
using the Matrox ActiveMIL library.
Image aqcuisition and segmentation
The image is digitized at the frame grabber (Matrox Meteor II) to a resolution of 768
× 576. In orderto exclude unwanted features from the image a simple method also used
in [3] was implemented. Removal of the static background comprising the dial is done
by the subtraction of two images of the dial.

9. Since the pointers are the only moving part of the dial, subtraction results in the
removal of everything in the images except the pointers [3]. The resulting image is of
good quality and it was felt that thresholding would not increase the edge-finding
precision. It is assumed that the large pointer is on its right lap, making it unnecessary
to measure the position of the small pointer. The position of the outer part of the large
pointer is found using the edge-finding functions of the MIL library. The centre of the
pointer is given by the user mouseclicking on a pair of points on the image of the dial
indicator assumed to be symmetrical to the centre. The angle of the large pointer is
calculated from the line crossing the assumed static centre and the established position
of the outer part of the pointer. Calibration of the scale marks on the dial is also
implemented in the software as a separate task.
Construction of a Dial indicator changes regarding their categories. As an example,
engineers often use two types of dial indicators such as Sector shape and Circular
shape. But the Sector type dial indicators are not useful for measuring any tool or
workpiece. It is often used by engineers to make the mostaccurate measurement. Also,
the Sector type dial indicators are quite limited in range.
Types of Dial Indicators:
 Balance reading Dial Indicators
 Reversed Balance Dial Indicators
 Continuous Dial Indicators
 Reverse continuous Dial Indicators
 Prelinger Dial Indicators
 Test Dial Indicators
 Lever Dial Indicators

10. Application of Dial Indicators:
 Dial indicators are used to align a workpiece in a machine. Such as, in the
case of EDM, grinding machine, lathe machine, and milling machine.
 The tools are also used to check out the runout of the spindle in a machine
tool.
 Workpieces can be aligned in the spin fixture by the help of Dial Indicators.
 It is also used to measure surface roughness.
 Dial indicators are used to measure parting lines in injection molding.
 It is useful to measure pit depth in EDM (Moldmakingresource, 2020).
 Dial indicators are efficient to measure height difference on a surface plate.
 Along with that, the tools are also very efficient to align a fixture in 5 axes
milling machines.
 Dial indicators are used by engineers to inspect the precision of a workpiece
in a grinding machine.
Advantages of Dial Indicators:
 Dial indicator is the most flawless tool in taking linear measurements.
 The toolis very efficient to assurethe quality ofa workpiece (Luo et al. 2018).
 Due to small tolerances, the size of the tool is very compact and thus, it can
be used seamlessly in mass production.
 Dial indicator is also useful in dimension control.
 Moreover, Dial Indicators are also be used to measure several deviations by
aligning with some other attachments.

11. Disadvantages of Dial Indicators:
 The precision of Dial Indicators often lost due to the vibration of machinery.
 Space constraints can lead to installing the tool at an angle due to which
precision of the measuring device lost.
 Another crucial disadvantage of the tool is the parallax effect.
 End float can act as a devil for Dial Indicators. In the caseof journal bearings
and sleeve bearing, some amount of axial play seems to be incorporated.
Therefore, its impact on the accuracy level of Dial Indicators.
How to Read a Dial Indicator

12. Mount your dial indicator on a stand. Your dial indicator should have an attachment
that you can use to secure it to a stand. The stand will stabilize your dial indicator while
you take your measurements.
If you do not have a stand, it is still possible to calibrate your dial indicator, but it will
not be as easy.
Overview of Dial Indicators
Dial indicators or dial gauges are nifty instruments that measure points on a 3-
dimensional surface by making quick work of accurately measuring angles or distance
between two flat surfaces which would seldom be possible with the naked eye. These
devices are deployed in a plethora of industries to gauge outer surfaces or the inner
expanses of apertures, such as holes, etc. So much so, there are many variants of dial
indicators for students specifically used in labs.
Step by Step Guide to Read a Dial Indicator Like a Professional
Preparing the Dial Indicator
Start off by simply loosening the beam lock of the dial indicator and then carefully
slide the indicator back and forth for a hassle-free operation. Next, close the huge flat
dial indicator jaws by bringing them together completely. Before proceeding to the
next step, ensure the dial gives a 0 reading.
Taking the Measurement
Here is the moment of reckoning and you would want to exercise a little bit of caution.
Measure outer surfaces by gently closing the large flat jaws of the dial gauge on the
part to be measured. Cylindrical surfaces such as pipes can be measured by keeping
the body of the dial gauge perpendicular to the axis of the cylinder. Failure to do the
required action will give imprecise measurements.

13. Now comes the part of measuring inner apertures, where smaller pointed jaws on the
back of the dial indicator’s head are measured by placing these jaws into the aperture
and stretching them out until they touch the inner surfaces. Likewise, if you want to
measure the inside diameter of a round hole, do ensure the bodyof the dial indicator is
held on the same plane as the hole. Failure to comply could result in grossly inaccurate
measurements! Lastly, measure the inside diameter ofa round hole byensuring the dial
gauge jaws measure the complete diameter of the hole. And, bysweeping one jaw back
and forth while keeping one jaw of the dial gauge in, you could easily find the sweet
spotwhere the dial gauge jaw (which is being swept) will no longer have the room to
sweep. This technique lends you credible results for measuring the full diameter of the
hole.
Obtaining the Measurement Reading
To derive a fine reading from a dial indicator, the modus operandi entails determining
the position of the leading surface of the dial gauge head along the marked scale on its
body. Normally, the lines on the body are marked, wherein each number represents a
step of 1 cm. Plus, there are also 10 unnumbered lines in the middle of the numbered
lines where each unnumbered line represents 0.1 cm.
All you have to do is to make use of the highest visible line on the left of the leading
surface of the dial gauge head. Forinstance, if the highest visible line is 2 unnumbered
lines above the numbered line 4, you will have to jot it down as 4.2 cm.
Up next, convert the reading to mm and then multiply by 10. In the aforementioned
example, 4.2 cm will be converted to 42 mm. Next, gather the reading from the dial
indicator’s dial. Remember, one full revolution of the dial equals to 1 mm.
Subsequently, you can see100 divided lines on the face of the dial indicator to provide
you with a resolution of0.01 mm perline. Now add this figure to the reading and you’re
sorted!

14. Teacher Evaluation Sheet
Enrollment No………………………………………………...….………...….………...….………...
Name of Program…………………………………………………….….....….………...….………...
Semester……………………………………………………………….…....….………...….………..
Course Title…………………………………………………………….…...….………...….………..
Code………………………………………………………………………...….………...….………...
Title of the Micro-Project……………………………………………………………………………...

15. Course Outcomes Achieved
………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
Evaluation as per suggestedRubric for Assessment of Micro-Project
Sr.
No.
Characteristic to be
assessed
Poor
(Marks 1-3)
Average
(Marks 4-
5)
Good
(Marks 6-
8)
Excellent
(Marks 9-10)
1 Relevance to the course
2 Literature survey/
Information Collection
3 Project Proposal
4 Completion of the
Target as per project
proposal
5 Analysis of Data &
Representation
6 Quality of
Prototype/Model
7 Report Preparation
8 Presentation
Micro-Project Evaluation Sheet
Process Assessment Product Assessment Total
Marks
10
Part A-
Project
Proposal
(2 marks)
Project
Methodology
(2 mark)
Part B-Project
Report/Working Model
(2 marks)
Individual
Presentation/Viva
(4 mark)
Note:
Every course teacher is expected to assign marks for group evolution in first 3 columns & individual
evaluation in 4th
columns for each group of students as per rubrics

16. Comments/Suggestions about team work/leadership/inter-personal communication (if any).
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Any other comment:
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Name and designation of the faculty member........................................................
Signature...................................................................
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