Muhammad Waleed Tariq

2012-ME-166

Metrology and Quality

Assurance Lab
Lab Reports 01 to 05

Submitted To

Engr. Muhammad Waqas

Rafique
Submitted By

Lab Session 01
To measure the lengths and diameters of given sample pins by Vernier Caliper

Apparatus

Sample pins

Vernier Caliper

Theory
Vernier Caliper
A measuring device that consists of a main scale with a fixed jaw and a sliding jaw
with an attached Vernier. It can measure the object with an accuracy of hundreds of
millimeters.
Types of Vernier Caliper
i) Inner / Internal Vernier Caliper
The inner calipers are used to measure the internal size of an object.

ii) External Vernier Caliper

External calipers are used to measure the external size of an object.

iii) Divider / Pointer Vernier Caliper

A divider caliper, popularly called a compass, is used in the process of marking
out locations. A divider caliper is also used to measure a distance between two points on
a map. The two caliper's ends are brought to the two points whose distance is being
measured.

iv) Dial / Analogue Vernier Caliper

Instead of using a Vernier mechanism, which requires some practice to use, the dial
caliper reads the final fraction of a millimeter or inch on a simple dial.

v) Digital Vernier Caliper

An electronic digital display on which the reading is displayed as a single value.

Parts of Vernier Caliper

1.

Outside large jaws: used to measure external diameter or width of an

object

2.

Inside small jaws: used to measure internal diameter of an object

3.

Depth probe: used to measure depths of an object or a hole

4.

Main scale: scale marked every mm

5.

Main scale: scale marked in inches and fractions

6.

Vernier scale: gives interpolated measurements to 0.1 mm or better

7.

Vernier scale: gives interpolated measurements in fractions of an inch

8.

Retainer: used to block movable part to allow the easy transferring of a

measurement

Observations
Least count of Vernier caliper L.C = 0.05 mm
Vernier scale divisions = 20
Least Count = 0 mm
Table
Sample Pin 1

Sr. No.

Sample Pin

Main Scale

Vernier

Total

Total

Measurement
s

Reading

Scale
Reading

mm

Reading

Reading

mm

in

D1

25

25.3

0.996

D2

15

16

15.8

0.622

D3

9.4

0.370

H1

12

12.1

0.476

H2

43

19

43.95

1.730

H3

72

17

72.85

2.868

Sample Pin
Measurement
s

Main Scale
Reading

Vernier
Scale
Reading

Total
Reading

Total
Reading

mm

in

Sample Pin 2

Sr. No.

mm
1

D1

25

25.2

0.992

D2

15

16

15.8

0.622

D3

9.4

0.370

H1

12

12.25

0.4822

H2

43

17

43.85

1.726

H3

72

19

72.95

2.870

Specimen Calculation
For Sample Pin 1

Total Reading=Main Scale Reading +Vernier Scale Reading Least Count Zero Error
Total Reading=25+6 0.05 0=25.3 mm=0.996
For Sample Pin 2

Total Reading=25+ 4 0.05 0=25.2 mm=0.992

Safety Precautions
i) When the jaw of the calipers is opened, a thin metal guide extends from the bottom
of the calipers that could cause injury.
ii) The depth probe has the pointy end so must be handle with care.
Comments
i) Close the jaws firmly while the object in between them.
ii) Look for the smooth surface to close between the jaws.
iii) Better look the most closely coincident division of the Vernier scale with the main
scale.
iv) The sample pin may have rough surface that gives different readings.
Conclusions
i) Instead of giving the dimensions of the sample, Vernier caliper tells us about the
smoothness of the surface
ii) Taking more readings of a dimension leads to more accurate one.
References
1. Joseph Wickham Roe, English and American tool builders (1916) p. 203
2. http://www.mackinmfg.com/ shows a picture of the calipers but does not support the RAM claim.
3. http://www.starrett.com/download/246_p108_114.pdf
4. http://www.msi-viking.com/digital_caliper/

Lab Session 02
Develop the lengths with the help of block gauges.
Apparatus
i) Block gauges
ii) Petrol for cleaning
iii) Petroleum Jelly
Theory
Block gauges
Gauge blocks (also known as gage blocks, Johansson gauges, slip gauges, or Jo
blocks) are a system for producing precision lengths. The individual gauge block is a metal
or ceramic block that has been precision ground and lapped to a specific thickness. Gauge
blocks come in sets of blocks with a range of standard lengths. In use, the blocks are
stacked to make up a desired length.

Uses of Block gauges

They are used as a reference for the calibration of measuring equipment used
in machine shops, such as micrometers, sine bars, calipers, and dial indicators (when used in
an inspection role). Gauge blocks are the main means of length standardization used by
industry.
Wringing Process

Wringing is the process of sliding two blocks together so that their faces lightly
bond. Because of their ultra-flat surfaces, when wrung, gauge blocks adhere to each other
tightly.

The process of wringing involves four steps:

1. Wiping a clean gauge block across an oiled pad.
2. Wiping any extra oil off the gauge block using a dry pad.
3. The block is then slid perpendicularly across the other block while applying
moderate pressure until they form a cruciform.
4. Finally, the block is rotated until it is in line with the other block.

Why Block gauges stick together

Air pressure applies pressure between the blocks because the air is squeezed

out of the joint.

Surface tension from oil and water vapor that is present between the blocks.

Molecular attraction occurs when two very flat surfaces are brought into
contact. This force causes gauge blocks to adhere even without surface
lubricants, and in a vacuum.

Observation Table

Sr. No

Required Length

Gauges
1

10.5

0.5

16.05

10

1.05

25.003

15

1.003

24.5

12

10

1.5

46.10

20

18

0.5

3.505

1.003

1.002

1.001

0.5

75.008

50

20

1.008

Specimen Calculation

Required Reading=Total of individuals block gauges

10.5=5+ 4+1+ 0.5
Safety Precautions
i) Before using a gauge, thoroughly wash the gauge and product with gas oil or
kerosene, or wipe them with a clean cloth to remove dust and dirt.
ii) Before using a gauge, check the gauge for any rust, flaw, burr, etc. If rust,
flaw or burr is found, remove it carefully.
Comments
i) Frequent use of block gauges make their surface rough and inaccuracy
prevails.
ii) Wash the block gauges before using it.
iii) Low pressure applied on the gauge may result in the not sticking of the
gauges.
References
i) Doiron, Ted; John Beers (2009), The Gauge Block Handbook, USA: Dimensional Metrology
Group, US National Institute of Standards and Technology, pp. 14
ii) Friedel, Dave, Wring ability, archived from original on 2010-12-22, retrieved 2010-12-22.
iii) The Gauge Block Handbook, NIST, p. 138-139
iv) Krar 2005, p. 98.

Lab Session 03
To develop the angle with the help of angle gauges

Apparatus
i) Angle gauges
ii) Petrol for cleaning
iii) Petroleum Jelly
Theory
Angle gauges
A series of fixed angles are used for comparative assessment of the angle between
the two surfaces. Important specifications to consider when searching for angle gauges
include angular range and angular resolution. Angle gauges come in sets of blocks with a
range of standard angles.

Observation Table
Sr.
No

Required Angle

Gauges
A

1o30

10

30

69o

60o

9o

3o5

3o

99o

90o

90

14o15

14o

15

Specimen Calculation

Required angle= of total anlges of angle gauges

'

1 30 =1 + 30'
Safety Precautions
i) Before using a gauge, thoroughly wash the gauge and product with gas oil or
kerosene, or wipe them with a clean cloth to remove dust and dirt.
ii) Before using a gauge, check the gauge for any rust, flaw, burr, etc. If rust,
flaw or burr is found, remove it carefully.
Comments
i) Frequent use of angle gauges make their surface rough and inaccuracy
prevails.
ii) Wash the angle gauges before using it.
iii) Low pressure applied on the gauge may result in the not sticking of the
gauges.
References
i)

Metrology & Measurement By Bewoor

Lab Session 04
To measure the internal angle with the help of Bevel Protractor

Apparatus
i) Sample models
ii) Bevel protractor
Theory
Bevel Protractor
A bevel protractor is a graduated circular protractor with one pivoted arm; used for measuring or
marking off angles. The bevel protractor is used to establish and test angles to very close tolerances.

Parts of Bevel Protractor

i) Base: When measuring an angle, the base is placed on the bottom side of
the angle.
ii) Blade:The blade is placed on the opposite side of the angle and can be
released from the bevel protractor using a nut/screw, which allows the
protractor to be moved up and down the length of the blade to fit an angle.

iii) Main Scale: This is the "primary scale" of the bevel protractor, measuring
angles in (as usual) degrees.
iv) Vernier Scale: The Vernier scale is a "secondary scale" and allows the angle
to be measured with a greater degree of accuracy. It is measured in
"minutes" and is read second.
v) Fine adjustment knob: It is designed to allow the user to move the blade
around with a greater degree of accuracy, especially when trying to make the
final alignment with the object to be measured.
vi) Magnifying glass: Some bevel protractors come with a magnifying glass
attached, which helps when reading the angles more clearly.
Observations
Least count of Vernier scale = 5
Zero error = 0o
Table
Sr. No
1

Sample Models
A

Angles
97o25
86o45
88o30
112o40
79o35
90o15
920
52045

Specimen Calculation

Angle=Main Scaleangle+ vernier scale division L. C Zero error

'

Angle=97 + ( 5 5 ) =97 25 '

Safety Precautions
i) While using protractor make sure that nothing struck the magnifying glass,
otherwise it will get destroyed.
ii) The jaws should be firmly tightened with the help of knobs with work piece in
between them otherwise the work piece may lose grip and can create
damage.
Comments
i) The structure of the work piece does not fit in between the jaws.
ii) The jaws are not firmly fixed that gives inaccurate reading.
References
i)
ii)

FCS Engineering technology 2 By Carolyn Ingram, Abduraghman Abrahams

Hearst Magazines (December 1993). Popular Mechanics

Lab Session 05
To measure the angle of wedge-shaped model with the help of sine bar.

Apparatus
i)
ii)
iii)
iv)

Sine bar
Wedge-shaped model
Block gauge
Dial gauge

Theory
Sine bar
A sine bar consists of a hardened, precision ground body with two precision ground
cylinders fixed at the ends. The distance between the centers of the cylinders is precisely
controlled, and the top of the bar is parallel to a line through the centers of the two
rollers.

When a sine bar is placed on a level surface the top edge will be parallel to that
surface. If one roller is raised by a known distance, usually using gauge blocks, then the
top edge of the bar will be tilted by the same amount forming an angle that may be
calculated by the application of the sine rule.

The hypotenuse is a constant dimension

The height is obtained from the dimension between the bottom of one roller
and the table's surface.

The angle is calculated by using the sine rule.

Uses of Sine bar

i) Measuring known angles or locating any work to a given angle.
ii) Checking of unknown angles. Many a times, angle of a component to be
checked is unknown.

iii) Checking of unknown angles of heavy component. In such cases where

components are heavy and cant be mounted on the sine bar, then sine bar is
mounted on the component.
Observation Table
Deflection
h

Length of
model
l

Length of
sine bar
L

mm
4.41

mm
101.6

mm
254

Thickness of
block gauge
used
P
mm
11.025

Angle

degrees
2.49o

Specimen Calculation

Thickness of block gauge ( P )=Deflection (h)

P=4.41

sin =

Length of sine ( L )
Length of model(l)

254
=11.025
101.6

Perpendicular P 11.025
= =
=0.0434
Hypotenuse
L
254

=sin1 ( 0.0434 )=2.49

Safety Precautions
i) A compound angle should not be formed by mis-aligning of work piece with
the sine bar. This can be avoided by attaching the sine bar and work against
an angle plate.
ii) Accuracy of sine bar should be ensured.
iii) As far as possible longer sine bar should be used since many errors are
reduced by using longer sine bars.
Comments
i) While moving the sine bar, the work piece slides thus disturbs the reading.
ii) The base of the rollers wear that causes the disturbance in experimentation.
iii) The surface of sine bar may wear due to which the angle measures is not
accurate.
iv) The surface on which sine bar is placed might not be parallel to the surface of
sine bar.

References
i)
ii)

http://what-when-how.com/metrology/sine-principle-and-sine-bars-metrology/
gold books (India)

2012-ME-166