Mapa University

Muralla St. Intramuros, Manila

Department of Mechanical and Manufacturing Engineering

SHOP PRACTICE NO.2

INSIDE AND OUTSIDE CALIPER

ANGELES, Marison C.

ME-2

ME137L/ A3
GRADE
2015100221

Group 04

Engr. Jose V. Hernandez

Instructor
OBJECTIVES:
1. To be able to make an inside and outside caliper.
2. To practice different bench work practice.
3. To be able to select the proper hacksaw, files in cutting and filing
operations.
4. To be able to apply cold forming method in this project.

METHODS AND ANALYSIS:

The most common incorrectly used and abused tools in the machine shop are
the hacksaw and files. It will take time and practice for the students to be more
proficient in their use. Bench work practice will accelerate the students to think ways
to make their work easier and safe working attitude.

MATERIALS:
2 pieces of 7 x 1 x 1/16 flat bar
2 pieces of tail, cut in four pieces using rivets

TOOLS AND EQUIPMENT:

Angle hacksaw
Anvil
Ball peen hammer
Bench metal vise
Chalk
Electric drill press (Drill bit: 1/8)
Flat File
Hacksaw
Marker
Rasp File
Ruler
Steel brush
Try Square
Vice grip tongs
PROCEDURES:
1. Measure and cut the 1/16 inch thick flat bar into 1 inch width and 7 inches
length.
2. Draw a 1 inch line to the edges on each flat bar. Then, draw a diagonal line
to connect the lines.
3. Cut the diagonal line using hack saw.
4. File the edges using a flat file.
5. For the inside caliper, carefully bend the piece to 90 degrees using anvil,
ball-peen hammer, and vice grip tongs.
6. Join the two tips for the outside caliper. Carefully pound until the desired
shape is achieved.
7. Adjust some measurements if needed.
8. Precisely align the workpiece together for each caliper.
9. By using ball-peen hammer and marker, make a mark (point) on the center
of the rounded part of the caliper.
10. Use the electric drill press with a drill bit size of 1/8 to drill a hole at the
marked point.
11. File the filler metal for smaller diameter and cut it with the use of hacksaw.
12. Use ball peen hammer to insert the rivets for each caliper. Pound it to
attach the pairs of work piece together.
13. For finishing, file the caliper.

QUESTIONS:
1. What is the meaning of 24 teeth hack saw blade?
- A 24 teeth per inch is for angle, iron, heavy pipe, brass and copper. Hack
saw blades with 24 teeth per inch are used for medium steel and regular
walled tubing.
2. What procedure is recommended if a saw blade breaks or becomes dull in a
partially finished cut?
- First, replace the saw blade. Second, turn the work piece one half turn so
the unfinished cut is at the bottom then the new cut will bind to the
unfinished cut.

3. Describe and state the purpose of:

a. Single-cut files
- They have rows of teeth cut parallel to each other at an angle of about 65
degrees from the centerline. Single-cut files are used for sharpening tools,
finish filing and draw-filing. They are also the best tools for smoothing the
edges of sheet metal.
b. Double-cut files
- They have rows of teeth crisscrossed so teeth become diamond-shaped for
fast cutting. Use double-cut files for quick removal of material and for
rough work.

4. Name the most commonly used degrees of coarseness which files are
manufactured.
o Bastard - medium coarse with 26 teeth per inch, fewest number
of teeth per inch (TPI).
o Second Cut - medium smooth with 36 teeth per inch, medium
number of teeth per inch (TPI).
o Smooth - with 60 teeth per inch, greatest number of teeth per
inch (TPI).

5. List four important aspects of file care.

a. Do not store the files where they will knock each other.
b. Keep the files in a dry place, rust will corrode the teeth of the file.
c. Apply pressure only on the forward stroke when filling. Pressure on the
return stroke will dull the file.
d. Keep the files, use a steel brush or file card to loosen the accumulated filling
between the teeth of the file. Always remember that a dirty file is a dull file.
6. How can pinning of a file be kept to a minimum?
- Keep file clean and push brass, copper or wood through the teeth to remove
pins. Applying chalk to the face of the file will lessen the pinning. Pinning
results in too much pressure that causes scratches.

7. What is cold forming?

- Cold forming is the process of forging metals at near room temperatures.

8. Why is there a need of adjusting the blade tension of a hacksaw?

- It is necessary to adjust the blade tension of a hacksaw to tighten it and for
easier cutting of a material. Also to prevent it from buckling or drifting.

9. Why is there a need to place a handle in file?

- Placing a handle in file provides better grip so that the file can be used
easily and comfortably. Also, without a handle it will be hard to file due to
the stress the hand is putting to file a work piece meaning more work is
done. With a file the filling will be much more fast and easier.

10.Give at least seven types of files used by a machinist. Make a simple

drawing of each type and their uses

Flat File - used to file flat surfaces. It is also the most common type of file
for all types of work except inside curves, the flat file tapers in both width
and thickness toward the head.
Round File - used to file round holes or in curved surfaces. The round file
tapers toward the point and is used to enlarge or smooth round openings and
to finish concave surfaces.

Half Round File - one side is rounded and one flat, so the tool can be used
on flat, concave and convex surfaces. It also files both wood and metal. Use
it for work on larger circular areas.

Hand File - it is flat in cross section but has parallel sides right up to the tip,
tapering only in thickness.
Pillar File - a slimmer version of the hand file, with one safe edge. It is
mostly used for slots and keyways.

Square File- is used to file square holes or angles. The square file is used on
rectangular slots, keyways and spines.

Triangular File - has three flat sides. It is used to file acute internal angles,
clean cut square corners, enlarge and clean up angular holes and sharpen
serrated jaws and saw teeth.
MECHANICAL DRAWINGS:

OUTSIDE CALIPER
FRONT VIEW (Scale: 1: 1)

TOP VIEW (Scale: 1: 1)

RIGHT SIDE VIEW (Scale: 1: 1)

ISOMETRIC VIEW (Scale: 1: 1)

INSIDE CALIPER

FRONT VIEW (Scale: 1: 1)

TOP VIEW (Scale: 1: 1)

RIGHT SIDE VIEW (Scale: 1: 1)

ISOMETRIC VIEW (Scale: 1: 1)

DISCUSSION:
The earliest caliper has been found in the Greek Giglio wreck near the
Italian coast. The ship find dates to the 6th century BC. The wooden piece already
featured a fixed and a movable jaw. Although rare finds, caliper remained in use
by the Greeks and Romans. The modern vernier caliper, reading to thousandths of
an inch, was invented by American Joseph R. Brown in 1851. It was the first
practical tool for exact measurements that could be sold at a price within the reach
of ordinary machinists.
A caliper is a device used to measure the distance between two opposite
sides of an object. A caliper can be as simple as a compass with inward or
outward-facing points. The tips of the caliper are adjusted to fit across the points to
be measured, the caliper is then removed and the distance read by measuring
between the tips with a measuring tool, such as a ruler. It is used in many fields
such as mechanical engineering, metalworking, forestry, woodworking, science
and medicine.

CONCLUSION & RECOMMENDATION:

This experiment enables the students to make an inside and outside
caliper. Students were able to practice different bench work practice. Also, students
were able to choose proper hacksaw, files in cutting, and filing operations. Lastly,
this experiment enables students to apply cold forming method.
I would recommend to be more careful on using some tools and making the
calipers, since it may cause accidents. Also, proper consuming of time doing the
experiment is required. Having communication and teamwork to groupmates by
dividing each part simultaneously will help to have accurate and faster work.

REFERENCES:
http://www.simondsint.com/handfiles/HAND%20FILES%20PUBLICATIO
NS/File%20Facts.pdf
http://www.deringerney.com/products-and-capabilities/cold-forming/cold-
forming-process/
https://en.wikipedia.org/wiki/Calipers
https://books.google.com.ph/books?id=dgsLAQAAMAAJ