Experiment # 1

To measure the diameters of pins using vernier calipers

Apparatus:Vernier calipers, set of pins

Vernier caliper
The vernier is a convenient tool to use when measuring the length of
an object, the outer diameter (OD) of a round or cylindrical object, the
inner diameter (ID) of a pipe, and the depth of a hole.

Parts of a vernier caliper:

1.
2.
3.
4.
5.
6.
7.
8.

Outside jaws: used to measure external lengths

Inside jaws: used to measure internal lengths
Depth probe: used to measure depths
Main scale (cm)
Main scale (inch)
Vernier (cm)
Vernier (inch)
Retainer: used to block movable part to allow the easy
transferring a measurement

Least count:It can be defined as min. reading on

main scale divided by total no. of divisions on vernier scale.
It is actually the min. measurement that an instrument can
take place.
L.C

= Minimum division which can be measured from main scale

No. of division on the vernier scale
=1/10=0.1mm

How the vernier works:

The vernier consists of a main scale engraved on a fixed ruler and an
auxiliary vernier scale engraved on a movable. The movable auxiliary
scale is free to slide along the length of the fixed ruler. This vernier's
main scale is calibrated in centimeters with the smallest division in
millimeters. The auxiliary scale has 10 divisions that cover the same
distance as 9 divisions on the main scale. Therefore, the length of the
auxiliary scale is 9.0 mm.
Principle of working:

PROCEDURE
1 The whole movable jaw assembly is adjusted so that the two
measuring tip just touch
2 the parts to be measured.
3 Final adjustment depending upon the sense of correct feel is
made by the adjusting
4 noted down the reading.
5 The measuring tip is so designed as to measure inside as well as
outside dimension.

Observations and calculations:

Sr. No.

Main scale
reading

Vernier
scale
division

No. of
div.*L.C

Diameters
of pins

1
2
3
4
5

Comments:
a.
b.
c.
d.

Vernier caliper is a precision measuring tool

Capable to read within .001 inch.
Used for inside, outside and depth measurements.
At a time we can take both inches and metrics
measurements

References:

http--itdc_lbcc_edu-cps-machineTool-precisionToolsprecisionToolsALT-images-universal2_jpg.htm
http://www.amazon.co.uk/Silverline-677256-Digital-VernierCalliper/dp/B000OIG00C
http://www.tradekey.com/ks-vernier-calliper/

Experiment # 2
Objective:
To develop dimensions with the help of slip gauges
on gauge blocks.
Apparatus:
Box of slip gauges, Spirit, Soft cloth, Petroleum jell.

Gauge blocks
A gauge block (also known as a gage block, Johansson gauge, slip
gauge, or Jo block) is a precision ground and lapped measuring
standard. It is used as a reference for the setting of measuring
equipment such as micrometers, sine bars, dial indicators (when used
in an inspection role).

Gage blocks are used for:

calibration and inspection of precision instruments

to set comparators/indicators
setting of sine bars
precision layout
machine setups

General Care

Protect gauge blocks from dirt, dust, and moisture by keeping

them enclosed in their case.
While in their case, steel gauge blocks should not become
magnetized. Otherwise, they will attract dust.

Preparation before use

If a protective coating was applied to the blocks after

previous usage, a solvent (isopropyl or methyl alcohol)
should
be used in removing the product.
Measuring faces should be cleaned every time a block is used
with chamois leather or a soft linen cloth.
Keep in mind a thin film of grease should remain on the blocks.

Care in Use

Gloved hands should handle the blocks so as to prevent

finger prints
It is important that the blocks do not take up the heat of the
hand. Before using them for testing purposes, allow the
blocks to adjust themselves to room temperature.
When the highest accuracy is required, the test room should
be 20 C. For ordinary purposes, the block and workpiece (if
they are the same material), may assume the temperature
of the room.

Damaged gauges

The edges undergo the most damage. They can easily be

fixed by drawing an Arkansas type stone across the damaged
edge away from the measuring face of the standard.
Thoroughly clean the edge afterward.
A standard with a damaged measuring face should be
returned to the manufacturer for restoration.

Care after use

Each block should be wiped clean after use and placed back
into its appropriate case.
Remove any fingerprints from the measuring surfaces.
A corrosion preventive substance should be applied to the
blocks before putting them away, if they are used
infrequently.
A preparation should be applied to the measuring surfaces
with a clean linen cloth as opposed to a brush. The brush
may aerate the preparation, creating bubbles which in turn
will result in rusting.

Wringing
It is the process of sliding the two blocks together so that their faces
lightly bond. When combined with a very light film of oil, this action
excludes any air from the gap between the two blocks. The alignment
of the ultra-smooth surfaces in this manner permits molecular
attraction to occur between the blocks, and forms a very strong bond
between the blocks along with no discernible alteration to the stack's
overall dimensions.

Grades Gauge blocks:

They are available in various grades depending on their
intended use.

reference (AAA) small tolerance ( 0.00005 mm or 0.000002

in) used to establish standards
calibration (AA) (tolerance +0.00010 mm to -0.00005 mm)
used to calibrate inspection blocks and very high precision
gauging
inspection (A) (tolerance +0.00015 mm to -0.00005 mm)
used as toolroom standards for setting other gauging tools
workshop (B) large tolerance (tolerance +0.00025 mm to 0.00015 mm) used as shop standards for precision
measurement

More recent grade designations include (U.S. Federal

Specification GGG-G-15C):

0.5 generally equivalent to grade AAA

1 generally equivalent to grade AA
2 generally equivalent to grade A+
3 compromise grade between A and B

Grades are equivalent to former U.S. Federal grades as follows:

00 generally equivalent to grade 1 (most exacting flatness

and accuracy requirements)
0 generally equivalent to grade 2
AS-1 generally equivalent to grade 3 (reportedly stands for
American Standard - 1)
AS-2 generally less accurate than grade 3

K generally equivalent to grade 00 flatness (parallelism) with

grade AS-1 accuracy

Procedure:
To develop any dimension, (mm or inch) the principle is to
start from first digit on the extreme right hand side of the dimension
and then successively moves towards the left.
For example:
To make 3.189 file we shall take the following slip gauges
1.009
1.08
1.1
sum=3.189 mm

Gauge block 1

Gauge block 2

Gauge block 3

Gauge block 4

Required
dimension

Comments:

Blocks are wrung together to form a stack of the required

dimension, with the minimum number of blocks.
They are made of material resistant to wear steel, tungsten
carbide or ceramics.

References:
http--itdc_lbcc_edu-cps-machineTool-precisionToolsprecisionToolsALT-images-universal2_jpg.htm

Experiment no: 3
Objective:
To measure the angle of wedge-shaped block with the
of a sine-bar.

Apparatus:
Wedge shaped blocks, Sine-bar (10%), Set of slip gauges, Surface plates, Dial
indications.

Sine bar
Sine bar is used for checking angles, typically used with gage blocks.
Precise angles are measured using the sine bar.
The sine bar is a precision bar that has been hardened and then
ground and lapped to very precise dimensions. It is also used for
machine setups.

SINE PRINCIPLE:The sine principle uses the ratio of two sides at right angle triangle is
Deriving a given angle .It may be noted that devices operating on sine
principle are capable of self generation. The measurements are usually
limited to 45 from loss of accuracy point of view. Sine bars used in
conjunction with gauges constitute a very good device for the precise
measurement of angles .Sine bars are used to measure angles very
accurately or for locating any work to a given angle within much closed
limit.

Material for sine bar

Sine

bars made from

High carbon steel
High chromium steel
Corrosion resistant steel

CHECKING OF UNKNOWN ANGLES:Many a times, angle of component to be checked is unknown .In such
a case it is necessary to first find the angle approximately with the help
of a bevel protractor. Then the sine bar is set at an angle and clamped
to an angle plate .Next the work is placed on sine bar and clamped to
Angle ,Slip-gauges are so arranged (according to deviation) that the
sprit level is at centre ( the air bubble).

Procedure:The figure below shows a sine bar from the side,

A simple example is - set up a sine bar with an angle of 24-57', if the

sine bar has 5" centres.

The sine bar shown above will only allow a single angle to be set, but
in some cases we want to set two angles, for this a compound sine
plate is used.

Sine Bar Limitations

When using a sine bar, the height setting is limited by the gauge
block divisions available (often 0.0001"). This results in an error
that may be negligible, or in some cases quite significant.

A simple example to illustrate this effect is given below for two

extreme cases. In the first case the sine bar is near horizontal, in
the second case it is near vertical.

Observations and calculations:

No. of
observations
1
2
3
4
5

L(in)

H(in)

Sin

= h/l

(Degrees)

Comments:

A compound angle should not be formed by miss-dignity of w/p

with the sine bar.
This can be avoided by attaching the sine brand work against an
angle plate.
Accuracy of sine bar should be ensured.
As far as possible longer sine bar should be used since4 many
errors are reduced by using longer sine bars

Preferences:

http--claymore_engineer_gvsu_edu-eod-manufact-manufact-212_gif.htm
http://www.eod.gvsu.edu/eod/manufact/manufact-130.html

Experiment#4
Objective:
To measure a taper bore with balls and depth gauge.

Apparatus:
Given piece with taper bore, Spherical ball, Taper bore apparatus, Depth
gauge.

DEPTH GAUGE
The depth gauge micrometer is a precision measuring instrument, used by engineers to
measure depths.

Types:

Dial depth gauge

Digital depth gauge
Dial calipers
Dept micrometer
Digital depth micrometer

Application of depth gauge:

Depth gauge can be used to
Determine the capacity at the fill point.
Determine the distance between the surfaces.
For the inspection of the depth of hole.
Inspect the depth of slots.
In tool and dial industrial applications.

Precautions:
Ball should not drop into the taper but they should give gently roll.
The wedging effects of the balls and the consequent elastic deformation
both of the balls and the gauges can cause appreciable .

Observations and calculations:

h = height of gauge blocks=50mm
h2 = height of smaller ball
h2 = height of bigger ball
r1 = radius of smaller ball
r2 = radius of bigger ball
LM = center to center distance between balls
= taper angle
LM = h2-h1-r1+r2
Sin /2 = (r2-r1)/LM
Sr. no.

R1

R2

H1

H2

LM

Sin /2

1
2
3

Comments:
Small ball does not touch the bottom surfaces
Centre of the large ball is inside the component
lines joining the centers to the tangents are parallel

/2

Experiment : 5
Objective:
To find out the angle of the given flat plates with the help of
bevel protector.

Apparatus:
Given flat plates, Bevel protector.

BEVEL PROTRACTOR
It is used to lay out, measure, or check angles.
The universal bevel protractor is capable of measuring obtuse angles as well as acute
angles when accompanied with the correct attachments. Look at below to give you an idea
as to the uses of the universal bevel protractor.

Main Components:The main component of the bevel protractor is the main scale The main scale is
graduated into four 90-degree components. The main scale is numbered to read from 0 to
0 degrees and then back from 90 degrees to 0.As with other vernier measuring devices, the
vernier scale of the bevel protractor allows the tool to divide each degree into smaller
increments. The vernier scale is divided into 24 spaces, 12 spaces on either side of the
zero.
Least count:Each space on the vernier scale is, therefore, one-twelfth of a degree.
One-twelfth of a degree is equal to 5 minutes.

Main Components:The main component of the bevel protractor is the main scale The
main scale is graduated into four 90-degree components. The main
scale is numbered to read from 0 to 0 degrees and then back from 90
degrees to 0.As with other vernier measuring devices, the vernier scale
of the bevel protractor allows the tool to divide each degree into
smaller increments. The vernier scale is divided into 24 spaces, 12
spaces on either side of the zero.
Least count:Each space on the vernier scale is, therefore, one-twelfth of a degree.
One-twelfth of a degree is equal to 5 minutes.
Procedure:To read the protractor, note where the zero on the vernier cale lines up
with the degrees on the dial in Figure 10. The degrees are read directly
from the main scale. The zero on the vernier scale is just pass the 85
degree mark. Now, adding in the same direction (counter- clockwise),
count, by five, from zero on the ernier scale to the lines that match up
on the dial. Add this number of minutes to the number of whole

degrees. The total number of degrees and minutes in figure would

equal 85 degrees and 30 minutes.

Types of bevel protractor: A

B
C
D
In types A, B the vernier is graduated to read 5min arcs whereas in
case C the scale is graduated to read in degrees and the bevel
protractor is without vernier or fine adjustment. the difference between
type A and B is that a is provided with fine adjustment devices or acute
angle attachment whereas type is not the scale of all types are
graduated either as a full circle marked 0-90-0-90 with one vernier
as semi circle marked 0-90-0 with two vernier 180 apart .Type D is
graduated in degrees and is not provided with either vernier or fine
adjustment devices or acute angle attachment.

Comments: When reading from 90 degrees, make sure to note the positions
where the angle and the supplement are from.

Working surfaces should be plane.

It should not use for precise measurements

Observations and calculations:

angle 0f plates

Angle found out

Refrences:

http://process-equipment.globalspec.com/IndustrialDirectory/bevel_protractor
http://materialhandling.globalspec.com/LearnMore/Manufacturing_Proc
ess_Equipment/Inspection_Tools_Instruments/Protracto
rs_Angle_Gages
http://www.manufacturers.com.tw/office/BevelProtractor.html

Experiment # 6
Objective:
To draw the histogram based on the data obtained in
experiment no. 1.

Histogram
Purpose Of A Histogram
A histogram is used to graphically summarize and display the distribution of a
process data set.

Mathematical definition
In a more general mathematical sense, a histogram is a mapping mi
that counts the number of observations that fall into various disjoint
categories (known as bins), whereas the graph of a histogram is
merely one way to represent a histogram. Thus, if we let n be the total
number of observations and k be the total number of bins, the
histogram mi meets the following conditions:

Cumulative histogram:
A cumulative histogram is a mapping that counts the cumulative
number of observations in all of the bins up to the specified bin. That
is, the cumulative histogram Mi of a histogram mi is defined as:

Class limit:
The class limits are defined as the numbers or the values of the
variables which describe the classes. The smaller no. is the lower class limit
and the larger no. is the upper class limit. There should be no overlapping
between the classes.

Class boundaries:
These are the precise numbers which separate the two classes.
They form the boundary between the two. This particular number is common
for both classes.

Class width or interval:

It is equal to the difference between the two successive lower
class limits.

Observations and calculations:

No of
observations Measurements
1
2
3
4
5
6
7
8
9

5.7
5.6
5.8
5.6
5.7
5.6
5.5
5.4
5.5

10

5.4

5.9
5.8

Series1

5.8
5.7

Series2

5.7

Series3

5.7
5.6

5.6

Series4

5.6

5.6
5.5

Series5

5.5

Series6

5.5
5.4
5.4

5.4

Series7
Series8
Series9

5.3

Series10
5.2
1

Preferences:
http--itdc_lbcc_edu-cps-machineTool-precisionToolsprecisionToolsALT-images-universal2_jpg.htm
http://www.amazon.co.uk/Silverline-677256-Digital-VernierCalliper/dp/B000OIG00C
http://www.tradekey.com/ks-vernier-calliper/