1.

RESULT AND DATA ANALYSIS

1. Experimental Value of a Screw Thread Plug Gauge
Major Diameter
(mm)

Minor Diameter
(mm)

Effective
Diameter (mm)

29.974

24.972

27.652

29.992

24.959

27.633

29.970

24.954

27.633

Average

29.979

24.962

27.656

Table 1: Experimental value of a Screw Thread Plug Gauge

2. Theoretical Value of a Screw Thread Plug Gauge
Major Diameter
(mm)

Minor Diameter
(mm)

Effective
Diameter (mm)

Factory
Dimension (mm)

30.000

26.211

27.727

Observed
Dimension (mm)

29.979

24.962

27.656

Percentage error
(%)

0.07

4.765

0.256

Table 2: Theoretical value of a Screw Thread Plug Gauge

3. Percentage Error

Diameter

Experimental Value
(mm)

Theoretical Value
(mm)

Percentage Error (%)

Major Diameter

29.979

30.000

0.07

Minor Diameter

24.962

26.211

4.765

Effective
Diameter

27.656

27.727

0.256

Table 3: Percentage Error by Comparison of Experimental Value with Theoretical

Value

2. SAMPLE CALCULATION
Experiment I: Profile measurement
Theoretical Value from Metric Standard table for Screw Thread ISO 6H:
Nominal Size

Pitch

Major Diameter
(mm)

Effective
Diameter (mm)

Minor Diameter
(mm)

M30

3.5

30

27.727

26.211

Average Major Diameter = (Major Diameter 1 + Major Diameter 2 + Major Diameter 3)

Number of Readings

= 29.974+29.994+29.972
3

29.979 mm

Average Minor Diameter = (Minor Diameter 1 + Minor Diameter 2 + Minor Diameter 3)

Number of Readings

= 24.972+24.959+24.954
3

= 24.962 mm

Percentage Error
Diameter

Experimental Value
(mm)

Theoretical Value (mm)

Percentage Error (%)

Major Diameter

29.979

30.000

0.07

Minor Diameter

24.962

26.211

4.765

Effective
Diameter

27.656

27.727

0.256

Percentage error=

Theoretical ValueExperimental Value

X 100
Theoretical Value

Major Diameter Percentage Error,

Percentage Error

= 30.000 29.979 x 100 %

30.000
= 0.07 %

Minor Diameter Percentage Error,

Percentage Error

= 26.211 24.962 x 100 %

26.211
= 4.765 %

Effective Diameter Percentage Error,

Percentage Error

= 27.727 27.656 x 100%

27.727
= 0.256 %

Experiment II: Profile Measurement and Exposure

1. Specimen

= 10 cents old coin

a) How many marbles are there in Malay Congkak?

45 marbles

b) What is the diameter of the marble?

0.173 mm
0.172 mm
0.180 mm
0.175 mm

Average
Diameter =

2. Specimen

0.175 mm

= 20 cents new coin

a) What can you see in between the flower pattern?

Letters B, N and M

3. Specimen

= 50 cents new coin

a) What can you see in between the flower pattern?

Letters B, N and M

4. Specimen

= Hair

a) What is the thickness value of a strand of hair?

Hair

y (mm)

0.097

0.093

0.079

Average Thickness =

0.0897 mm

3. DISCUSSION
Screw Thread Measurement using Floating Carriage Diameter Measuring Machine
This experiment was conducted to measure the Screw Plug Gauge parameters using
Floating Carriage Diameter Measuring Machine where it is all about screw thread
profiling. It involves the measurement of a plug gauge including major, minor and
effective diameter measurement using the machine mentioned above. With the same
specimen used, the experiment gives different result due to various factors and errors. The
micrometer of the mentioned machine is able to measure up to 4 decimal places. It
consists of sleeve, sub sleeve, thimble and sub thimble. The readings of this 4 scale are
sum up to get the final reading. In this experiment, the first measurement taken and
recorded was the major diameter. In major diameter, reading taken are the micrometer
reading over Standard Cylinder (R1) and the micrometer reading over Screw Plug Gauge
(R2). The second measurement taken and recorded is for Minor diameter where it consists
of the micrometer reading over Standard Cylinder and Core Prisms (R3) and micrometer
reading over thread and Core Prisms (R4). For effective diameter, the measurements taken
and recorded are the micrometer reading over Standard Cylinder and wire cylinders (R5)
and micrometer reading over screw thread and wire cylinder (R6). The readings obtained
are 2.3458mm for R1, 1.6014 for R2, 12.0056 for R3, 6.6612 for R4, 6.4300 for R5 and
3.9468 for R6. To determine the value of major diameter, the formula, Dmajor = D1 + (R2 R1) was used in calculation and resulting the value of 29.2556mm. For minor diameter,
with the usage of formula, Dminor = D1 + (R4 - R3), the obtained value is 24.6556 mm.
Formula used to calculate the effective diameter is D3 = D1 + (R6 - R5) and the obtained
figure is 27.5168 mm. The major diameter resulting in percentage error of 2.481%, minor
diameter resulting in 6.424% percentage error and the percentage error of effective
diameter is 2.9318%.

Profile measurement using Profile Projector (Horizontal/Vertical)

An experiment of measuring the parameters of Screw Thread Plug Gauge was conducted with
the usage of Horizontal and Vertical Profile Projector machine. Another additional
experiment conducted is a set of experiment to examine 10, 20 and 50 cent coins. Thread
designation is stamped on the specimen, which is M30-3.5-ISO6H. Each abbreviated number
and letter stand a different meaning. M refer the unit used in metric form. 30 is the size of
outer diameter, 3.5 is the pitch value, ISO 6H shows the tolerance position and h (no
allowance) indicates normal length of thread engagement of medium quality requirement
used for general purpose applications. Thread plug gauge is an inspection tool used to inspect
parameters and accuracy of threaded product that only give 2 possible outcomes, GO for
accept and NO GO for reject. Profile projectors are available in two types, the horizontal
profile projector and the vertical profile projector. This machine used to measure the hard to
hold small specimen by using its shadow to represents the specimen and gives ultimately
accurate result up to 3 decimal places. The profile projector are also able to point out the
imperfection on the specimen surfaces such as burrs, scratches indentations or undesirable
chamfers that a simple micrometer or calipers cannot show. The readings taken for this
experiment are major, minor and effective diameter. 3 reading was taken from each of the
diameter then average reading was taken into account. Major diameter is simply the largest
diameter of the thread or the larger of two extreme diameters. The first, second and third
readings for the major diameter are 29.974 mm, 29.992 mm and 29.972 mm respectively.
These values thus give an average value of 29.979 mm for major diameter. Minor diameter is
simply the smallest diameter of thread or the lower extreme diameter of a thread. The first,
second and third reading for minor diameter are 24.972 mm, 24.959 mm and 24.954 mm
respectively. The average value obtained is 24.962 mm. The effective diameter is located
equidistantly between the sharp thread crest and root. The first, second and third reading
taken are 27.652 mm, 27.682 mm and 27.633 mm respectively. These 3 values yield an
average of 27.656 mm. A set of calculation had been done to calculate the percentage errors
between the experimental and theoretical values. The percentage errors for major diameter
are 0.07%, 4.765% for minor diameter and 0.256% for effective diameter.

For the additional experiment, the specimen is observed under magnification glass of Vertical
Profile Projector machine. The specimens used in this additional experiment are 10, 20 and
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50 cent coins. For the 10 cent coins, the number of marble available and its diameter in the
congkak was count and measured. There are 45 marbles available and its average diameter is
0.175mm. For the 20 and 50 cent coin specimen, there are letter B, N and M available after
being thoroughly observed. These letters refers to Bank Negara Malaysia where these letters
can be found in between the flower pattern. This is the method used by government to
prevent any illegal money printing counterfeiting activities. Another experiment conducted is
measuring the diameter a strand of hair. The average thickness or diameter of a strand of hair
is 0.0897 mm.

Errors

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Notice that there are errors occur in the experiment. Nevertheless, these values are quite
small, thus they can be accepted. These occurred errors are due to various factors and
reasons. One of the errors that can be logically guessed is human error as micrometer can be
hard to read sometimes due to very sensitive scale range as well as limitation to human eyes.
One alternative to reduce this error is by taking the reading multiple times and takings it
average value. The machine used also can caused errors since it is an old machine used since
1974. Continuous used of machine can cause wear and tear, thus affecting the machine
performance. Thus, to avoid wear and tear, maintenance of machine should be dome
accordingly to its scheduled time. Improper handling of the machine by user is also another
reason. Students should be briefly explained and understand the machine before conducting
the experiment. External factors that cannot be controlled could cause the errors. Such factors
are invisible rustic surface on the specimen, dirt accumulations on the specimen and also too
much pressure exerted on the specimen when placing it on the machine. This factor is hard to
control but precautious steps can be considered and implemented during the experiment.
Misalignment of zero coordinate during setting could also contribute to error. To overcome
this problem, the axis line should be aligned properly with the shadow of the specimen by
touching the outermost line and subsequently set to zero. Make sure the observer eyes are
parallel with the specimen shadow.

Comparisons
Hence, based on the two experiment conducted which are Screw Thread Measurement using
Floating Carriage Diameter Measuring Machine and Profile measurement using Profile
Projector (Horizontal/Vertical), it can be concluded that profile measurement experiment is
much simpler compared to the screw thread measurement experiment. This is because the
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Profile projector is much easier to handle and the reading are measured 100% by the
machine. But in term of accuracy, the Floating Carriage Diameter Measuring Machine is
more accurate and precise. By comparing the percentage of errors between these two
experiments, the Floating Carriage Diameter Measuring Machine yield lesser errors. It give
an accuracy up to 4 decimal places compared to Profile projector that only gives accuracy up
to 3 decimal places. Both machines are costly, but they do help engineers to save a lot of time
and give accuracy in measuring specimen. The Profile projector is a recommend machine for
Research and Development since it is much simpler to handle, easy to use, save times, does
not require expensive maintenance and gives accuracy with small percentage of error. The
machine is also quite the latest technology available in industry. Compared to the Floating
Carriage Diameter Measuring Machine which are more sensitive, Profile projector are ideal.
It can be seen that the profile projector is preferred since it has fulfilled two requirements
which are the accuracy and the consistency of its ranges readings.

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4. CONCLUSION
We need to determine the dimension of the given specimen which is Screw Thread Plug
Gauge by using two different types of machine. In the end of the experiment, we know
how to handle the Profile Projector and Floating Carriage Diameter Measuring Machine.
These machines can be used to measure the dimensional of the specimen. By using these
two machines, the major diameter, minor diameter and effective diameter of a Screw
Thread Plug Gauge has been measured. Using the data that we get from these two
experiments, we can apply some formula in order to get the precision value of the
measurement. Not only that, we also get exciting information about coins and the
thickness of human hair while doing the experiment. The objective of the laboratory
session has been achieved.

5. RECOMMENDATION
Based on the observation did after the experiments, there are some recommendation that
need to be proposed to increase the efficiency of the experiment. Those recommendations
are:
1. The position of monitor should be adjustable. It is because the placement of the
monitor is a bit higher. For example, not all our group member is tall enough to level
the height of the monitor. This situation can lead to parallax error in taking the
displacement of the profile. Another solution for this problem is by installing another
projector on the other position.
2. The other recommendation is on the lightning of the projector. In our observation, the
lightning should be brighter. A brighter lightning give more clear view on the
specimen. By this way, a more accurate can be produced as it can reduce parallax
error during the measuring.
3. Lastly, we also are suggesting some procedure adjustment. The number of reading
taken should be increased from 3 to 5 times. By this way, percentage error can be
reduced and give more accurate reading in the experiment.

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6. Reference

Books:
1. Mikell P Groover, (2011). Principles of Modern Manufacturing, SI Version, 4th
Edition: John Wiley & Son, Inc.
2. Roe, Joseph Wickham (1916), English and American Tool Builders, New Haven,
Connecticut: Yale University Press
3. "Whitworth's workshop micrometer", The Practical Mechanic and Engineer's
magazine.
4. Hartness, James; Porter, Russell (1929). "United States Patent 1703933: Optical
comparator".
5. G.M.S. de Silva (2002). Basic Metrology for ISO 9000 Certification. ButterworthHeinemann

Internet
1. www.nikonmetrology.com
2. www.globalspec.com/industrial-directory/optical_profile_projector

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