Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

MQA-Lab Reports

Submitted By:
Muhammad Hamza Sharif
2020-ME-104
Section: C
Mechanical Engineering
Submitted To:
Sir Waqas Rafique
Date: May 2, 2023

Department of Mechanical Engineering

University of Engineering and Technology
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports
Experiment No.1
To Determine the Lengths and Diameters of pins using Vernier caliper.

Objective:
The aim of this experiment to measure lengths and dimeters of several pins available
in mechanical workshop using Vernier caliper. Measuring correct lengths and diameters of
pins is not only useful for machining pins of similar dimensions but to also distinguish which
pin is suitable for particular application.

Theory:
Introduction:
A Vernier caliper is a measuring instrument that utilizes pairs of jaws and two scales (Main
scale Vernier scales) to measure linear dimensions as well as the diameters of round objects.
The basic use of Vernier caliper is to accurately measure internal and external dimensions
and distances. These are preferred over meter rulers and measuring tapes as they accurately
measure dimensions as small as 0.05 mm which is approximately equal to 0.0019 inches.
However, this least count (smallest measurement that the instrument can measure), can differ.
It can be determined using the standard formula and is usually mentioned on the instrument.
Principle:
Accuracy of any measuring instrument is increased due to the difference between two
scales or divisions slightly different in size used together.
History:
Vernier calipers trace back to 9th A.D. Qin dynasty in ancient China. This design didn’t have
the beginning of scale. In 1631, a French mathematician named Pierre Vernier, made
improvements in this basic design of vernier caliper to reduce margin of error.
Construction:

Figure 1 Labelled figure of the Vernier Caliper

The main parts of the Vernier caliper consist of….

Main Scale:
A Vernier caliper consists of two steel scales which can slide along each other. It consists of
one long scale with a fixed jaw at one end. This main scale consists of a calibrated inches
scale at the top and a centimeter scale along its lower edge.

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Figure 2 Main Scale and Vernier Scale

Vernier Scale:
There’s another small metal strip that is graduated in a special relation with the main scale.
This vernier scale slides over the main scale and is connected with a jaw similar to that
attached with the main scale.
Lower/External Jaws:
The vernier caliper consists of two jaws, namely the upper and lower jaws. Both of these jaw
pairs are used to tightly hold the object being measured. This is not possible with a measuring
scale. The lower or external jaws are used to measure diameter of the sphere of the external
diameter of a cylinder.
Upper/External Jaws:
The external or upper jaws are used to measure the internal diameter of a hollow cylinder.
Depth Rod:
Depth rod is a strip at the back of the vernier caliper that is used to measure the depth of a
cylinder.
Thumbscrew:
A screw present at the bottom of the scale, known as vernier scale, is used to provide the user
a grip to easily slide the jaws. They are be used to adjust the position of the depth rod or the
jaws to maintain a grip on the object.
Lock Screw:
A lock screw is used to lock or secure the jaws in their place. Hence, the measurement may
be read by removing the objects from the jaws.
Types of Vernier Calipers:
There are several types of vernier calipers which are utilized based on their intended
design purpose.
Flat Edge Vernier Caliper:
This is the most common form of vernier caliper which is used for normal functions.
Outer diameter, length, breadth, thickness of an object can be measured using its jaws.
However, the special jib of one edge can be used to take inner measurements. However, the
breadth of the workpiece must be subtracted from the reading. This measurement is usually
written on the jaw of the vernier caliper otherwise it can be easily measured.
Knife Edge Vernier Caliper:
As the name suggests, the edge of a vernier caliper is shaped like a knife. This type of vernier
caliper is used for measuring narrow spaces, distance of bolts of I-bolts. A limitation of this
vernier caliper is that it wears out quickly due to thin edge of its jaws. Due to this short life, it
begins to give incorrect readings. Hence, it should be used carefully and jaw error should be
checked before using knife-edge vernier caliper. The object should not be placed at the point
where the is jaw error in this vernier caliper.

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Figure 3 Knife Edge Vernier Caliper

Flat and Knife Edge Vernier Caliper:

This is a special type of vernier caliper that consists of ordinary upper jaws but its lower jaws
are knife-edged. All types of objects can be measured using this vernier caliper.

Figure 4 Flat and Knife Edge Vernier Caliper

Vernier Gear Tooth Caliper:

This unique vernier caliper is a combination of two vernier calipers. It consists of two scales,
namely a horizontal and a vertical one. It can be utilized to measure thickness of a gear tooth
from its pitch circle. In addition, it can be used to easily measure any part of a gear.

Figure 5 Vernier Gear Tooth Caliper

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Vernier Depth Gauge
As the name suggests, this vernier caliper is used to measure the depth of a hole, groove or
slot of an object. Measurements are taken in the same way in the same way as taken for an
ordinary vernier caliper. The depth gauge consists of thin beam shaped like a narrow rule. It
can depth which is beyond the range of the depth rod of the ordinary vernier caliper. The
entire main scale is inserted in the cylinder hole and readings are taken as in any vernier
scale. The jaws are used to correctly adjust the position of the beam.

Figure 6 Vernier Depth Gauge

Vernier Height Gauge

As its name suggests, a Vernier Height Caliper is used to measure and mark the height of any
object. It is a simple vernier caliper but it consists of some additional attachments. A beam is
fitted on a base in length form. An off-set scriber is fitted on the main scale with which the
height is measured. The slide base is permanently joined with the beam. The bases used can
be of two types,

 Solid Base,
 Moveable Base.

Figure 7 Vernier Height Gauge

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In Vernier Height Gauge with a solid base, there is no arrangement to set the beam or
base according to the job. However, this feature exists if a moveable base is used.
Vernier Dial Caliper
In a simple vernier caliper, there are chances of errors to attain a clear reading. For greater
precision, Vernier Dial Calipers are preferred. It consists of a graduation dial instead of a
vernier scale. It can measure dimensions in inches as well as in millimeters. The dial itself
consists of rack and pinion mechanism. The rack is fixed on the main scale and is connected
to the pinion of the dial.

Figure 8 Vernier Dial Caliper

Digital Readout Caliper
Digital readouts are attached with vernier caliper to digitally display the measured
dimension.

Figure 9 Digital Readout Vernier Caliper

Outside Vernier Caliper
Outside vernier caliper is used to measure external dimensions such as diameters and
lengths of objects.

Figure 10 Outside Vernier Caliper

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Inside Vernier Caliper
It is used to measure the internal diameters of hollow cylinders.

Figure 11 Inside Vernier Caliper

General Applications
Manufacturing Industry
Vernier Calipers can be used to measure and confirm dimensions of objects in
measurement industry, e.g., diameters and lengths of shafts, etc.
Medical Industry
Dimensions of the required delicate and complex surgical tools are very important and
can be measured very precisely using Vernier Calipers.
Automobile & Aerospace Industry
Vernier calipers are used to measure and confirm dimensions of different components
automobiles and airplanes such as piston dimensions etc.

Figure 12 Measuring shaft diameter using Digital Vernier Caliper Figure 13 Measuring piston
diameter using Vernier Caliper

Figure 14 Measuring Sphere Diameter using Vernier Caliper Figure 15 Measuring Internal Diameter
using Vernier Caliper

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Figure 16 Measuring Hexagonal Bolt Head size using Vernier Caliper Figure 17 Measuring
bearing diameter

Limitations
 Improper attention can lead to wrong readings.
 Improper vision results in wrong readings.
 A manual vernier caliper is less precise than a micrometer screw gauge.

Advantages
 Very precise measurements can be taken using a vernier caliper.
 Both internal and external diameters can be measured using vernier calipers.

Procedure
 Completely close the jaws of the vernier caliper and check if the zero of the main
scale coincides with zero of the vernier scale. If the zeros coincide, there is no zero
error. If there is a zero error, note it and apply zero correction to the final dimension
measured.
 Close the jaws of the vernier caliper and place it in front of a light source. If light
passes, from a certain point between the jaws don’t take the measurement from that
point.
 Calculate the least count of the vernier caliper (if not mentioned on the instrument).
 Place the object in the cylinder.
 Note the main scale reading as the reading the zero of the vernier scale has crossed.
 Note the vernier scale reading the division of the vernier scale which coincides with
any main scale reading.

Figure 18 Main and Vernier Scale Reading

 Multiply the vernier scale reading with the least count to attain the fraction which is
added to the main scale reading.
 Measure the same dimension three times by rotating the object by 90 degrees or by
taking measurement at different points along the length of object. Take the mean of
all these readings.

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 Add the zero-correction value (if any).
 Repeat the same procedure for other dimensions as well.

Formulas
Smallest division of the main scale
Least Count of the Vernier Caliper ( L . C)=
No. of divisionsn of the Vernier Scale
Least Count of the Vernier Caliper ( L .C )=Main Scale Division−Vernier cale Division
Fraction ¿ be added =Vernier Scale Reading∗L . C
Measured Dimension=Main Scale Reading + Fraction ¿ be added
Corrected Dimension= Measured Dimension ± ZeroCorrection

Possible Errors

Figure 19 Possible Errors of Vernier Calipers

Zero Error
Zero Error in any instrument is referred to the condition in which a measurement can be
observed when there should be no reading at all. In vernier caliper, it is detected by
completely closing the jaws of the vernier caliper. If the zero of the main scale does not
coincide with the zero of the main scale in such a situation, zero error exists. Zero error in
vernier caliper is of two types,
Positive Zero Error
In case of positive zero error the zero of the vernier scale is to the right of the zero of main
scale. In this case the zero error is positive. The vernier scale reding coinciding with the main
scale is observed and multiplied with the least count to get the value of the zero error.
Negative Zero Error
In case of positive zero error the zero of the vernier scale is to the left of the zero of main
scale. In this case the zero error is negative. The vernier scale reding coinciding with the main
scale is observed and multiplied with the least count to get the value of the zero error.

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(a) (b) (c)

Figure 20 (a) No Zero Error, (b) Positive Zero Error, (c) Negative Zero Error.

Parallax Error
Measurement should be read at exact 90-degree vision to both scales, otherwise the
reading or division next to the correct reading may be taken.

Figure 21 Parallax Error

Blur Scale Readings

If the divisions or readings of the two scales are blur or worn out, it can lead to an
error in measurement.
Jaw Error
If the upper and lower jaws of the vernier caliper are worn out, they may give a faulty
reading. To check for this error, close the jaws of the vernier caliper and place it in front of a
light source. If light passes, from a certain point between the jaws, there in jaw error at that
point in the instrument.
Precautions
 Vernier caliper should be properly cleaned before taking any measurement.
 Zero correction should be noted after noting the zero error (if any).

Figure 22 Solution of zero error

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 If the measuring dimension in any diameter, make sure the jaws are in the center axis
of the cylinder/ sphere.
 The object should be properly gripped between the jaws while noting the
measurement. However, the jaws may be locked using the lock screw.

 Don’t take measurement from the point where light may pass from the jaws when
they are closed (Jaw Error).
 Take dimensions at different positions to compensate effect of surface roughness and
wear.

Figure 23 Measurement should be taken as mean of reading at different positions to get the
correct value

Take measurement at 90-degree vision to both the scales.

Figure 24 Correct reading is at 90-degree to the scale

Observations and Calculations

Smallest division on the main scale = 1mm
No. of divisions of the vernier scale = 20
Least count =
Least Count = 0.05mm
Zero Error in Vernier Caliper = 0.0 mm.
Zero Correction in Vernier Caliper = 0.0
mm.

Figure 25 Dimensions to be measured using Vernier

Caliper

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Pin No. 1
Diameter d 1

Main Scale Vernier Scale Fraction to be Diameter Correct

Sr. Reading Reading added D = MS Diameter d
1 1

No. MS VS N = VS*LC +N = D + ZE 1

(mm) (mm) (mm) (mm) (mm)

1 25 6 6 × 0.05 25.3 25.3

2 25 5 5 × 0.05 25.25 25.25

3 25 5 5 × 0.05 25.25 25.25

Mean Diameter d = 25.26 mm
1

Diameter d 2

Main Scale Vernier Scale Fraction to be Diameter Correct

Sr. Reading Reading added D = MS
2 Diameter d 2

No. MS VS N = VS*LC +N = D + ZE 2

(mm) (mm) (mm) (mm) (mm)

1 16 17 17× 0.05 16.85 16.85

2 16 17 17× 0.05 16.85 16.85

3 16 17 17× 0.05 16.8 16.8

Mean Diameter d = 16.83 mm
2

Diameter d3

Main Scale Vernier Scale Fraction to be Diameter Correct

Sr. Reading Reading added D = MS
2 Diameter d 2

No. MS VS N = VS*LC +N = D + ZE 2

(mm) (mm) (mm) (mm) (mm)

1 9 8 8 × 0.05 9.4 9.4

2 9 6 6 × 0.05 9.3 9.3

3 9 6 6 × 0.05 9.3 9.3

Mean Diameter d = 9.33 mm
3

Height h1

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Main Scale Vernier Scale Fraction to be Height Correct
Sr. Reading Reading added H = MS
1 Height h = 1

No. MS VS N = VS*LC +N H + ZE 1

(mm) (mm) (mm) (mm) (mm)

1 12 10 10 × 0.05 12.5 12.5

2 12 8 8 × 0.05 12.4 12.4

3 12 7 7 × 0.05 12.35 12.35

Mean height h = 12.416 mm
1

Height h2

Main Scale Vernier Scale Fraction to be Height Correct

Sr. Reading Reading added H = MS
2 Height h = 2

No. MS VS N = VS*LC +N H + ZE 2

(mm) (mm) (mm) (mm) (mm)

1 44 2 2 × 0.05 44.1 44.1

2 44 3 3 × 0.05 44.15 44.15

3 44 3 4 × 0.05 44.15 44.15

Mean height h = 44.13 mm
2

Height h3

Main Scale Vernier Scale Fraction to be Height Correct

Sr. Reading Reading added H = MS
3 Height h = 3

No. MS VS N = VS*LC +N H + ZE 3

(mm) (mm) (mm) (mm) (mm)

1 73 17 17 × 0.05 73.85 73.85

2 73 19 19 × 0.05 73.95 73.95

3 73 18 18 × 0.05 73.9 73.9

Mean height h = 73.9 mm
3

Pin No. 2
Diameter d 1

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Main Scale Vernier Scale Fraction to be Diameter Correct
Sr. Reading Reading added D = MS Diameter d
1 1

No. MS VS N = VS*LC +N = D + ZE 1

(mm) (mm) (mm) (mm) (mm)

1 25 7 7 × 0.05 25.35 25.35

2 25 5 5 × 0.05 25.25 25.25

3 25 5 5 × 0.05 25.25 25.25

Mean Diameter d = 25.283 mm
1

Diameter d 2

Main Scale Vernier Scale Fraction to be Diameter Correct

Sr. Reading Reading added D = MS
2 Diameter d 2

No. MS VS N = VS*LC +N = D + ZE
2

(mm) (mm) (mm) (mm) (mm)

1 14 3 3× 0.05 14.15 14.15

2 14 3 2× 0.05 14.1 14.1

3 14 3 3× 0.05 14.15 14.15

Mean Diameter d = 14.13 mm
2

Diameter d3

Main Scale Vernier Scale Fraction to be Diameter Correct

Sr. Reading Reading added D = MS
2 Diameter d 2

No. MS VS N = VS*LC +N = D + ZE
2

(mm) (mm) (mm) (mm) (mm)

1 9 8 8 × 0.05 9.4 9.4

2 9 7 7 × 0.05 9.35 9.35

3 9 7 7 × 0.05 9.35 9.35

Mean Diameter d = 9.366 mm
3

Height h1

Main Scale Vernier Scale Fraction to be Height Correct

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Sr. Reading Reading added H = MS
2 Height h = 2

No. MS VS N = VS*LC +N H + ZE
2

(mm) (mm) (mm) (mm) (mm)

1 13 12 12 × 0.05 13.6 13.6

2 13 12 12 × 0.05 13.6 13.6

3 13 10 10 × 0.05 13.5 13.5

Mean height h = 12.416 mm
1

Height h2

Main Scale Vernier Scale Fraction to be Height Correct

Sr. Reading Reading added H = MS
2 Height h = 2

No. MS VS N = VS*LC +N H + ZE
2

(mm) (mm) (mm) (mm) (mm)

1 44 4 4 × 0.05 44.2 44.2

2 44 4 4 × 0.05 44.2 44.2

3 44 5 5 × 0.05 44.25 44.25

Mean height h = 44.216 mm
2

Height h3

Main Scale Vernier Scale Fraction to be Height Correct

Sr. Reading Reading added H = MS
3 Height h = 3

No. MS VS N = VS*LC +N H + ZE
3

(mm) (mm) (mm) (mm) (mm)

1 71 19 19 × 0.05 71.95 71.95

2 71 19 19 × 0.05 71.95 71.95

3 71 19 19 × 0.05 71.95 71.95

Mean height h = 71.95 mm
3

Pin No. 3
Diameter d 1

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Main Scale Vernier Scale Fraction to be Diameter Correct
Sr. Reading Reading added D = MS Diameter d
1 1

No. MS VS N = VS*LC +N = D + ZE 1

(mm) (mm) (mm) (mm) (mm)

1 25 5 5 × 0.05 25.25 25.25

2 25 6 6 × 0.05 25.3 25.3

3 25 5 5 × 0.05 25.25 25.25

Mean Diameter d = 25.226 mm
1

Diameter d 2

Main Scale Vernier Scale Fraction to be Diameter Correct

Sr. Reading Reading added D = MS
2 Diameter d 2

No. MS VS N = VS*LC +N = D + ZE
2

(mm) (mm) (mm) (mm) (mm)

1 15 16 16× 0.05 15.8 15.8

2 15 16 16× 0.05 15.8 15.8

3 15 15 15× 0.05 15.75 15.75

Mean Diameter d = 15.783 mm
2

Diameter d3

Main Scale Vernier Scale Fraction to be Diameter Correct

Sr. Reading Reading added D = MS
2 Diameter d 2

No. MS VS N = VS*LC +N = D + ZE
2

(mm) (mm) (mm) (mm) (mm)

1 9 5 5 × 0.05 9.25 9.25

2 9 6 6 × 0.05 9.3 9.3

3 9 6 6 × 0.05 9.3 9.3

Mean Diameter d = 9.283 mm
3

Height h1

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Main Scale Vernier Scale Fraction to be Height Correct
Sr. Reading Reading added H = MS
2 Height h = 2

No. MS VS N = VS*LC +N H + ZE 2

(mm) (mm) (mm) (mm) (mm)

1 12 11 11 × 0.05 12.55 12.55

2 12 11 11 × 0.05 12.55 12.55

3 12 13 13 × 0.05 12.65 12.65

Mean height h = 12.58 mm
1

Height h2

Main Scale Vernier Scale Fraction to be Height Correct

Sr. Reading Reading added H = MS
2 Height h = 2

No. MS VS N = VS*LC +N H + ZE 2

(mm) (mm) (mm) (mm) (mm)

1 44 10 10 × 0.05 44.5 44.5

2 44 9 9 × 0.05 44.45 44.45

3 44 11 11 × 0.05 44.55 44.55

Mean height h = 44.5 mm
2

Height h3

Main Scale Vernier Scale Fraction to be Height Correct

Sr. Reading Reading added H = MS
3 Height h = 3

No. MS VS N = VS*LC +N H + ZE 3

(mm) (mm) (mm) (mm) (mm)

1 73 0 0 × 0.05 73.00 73.00

2 72 18 18 × 0.05 72.90 72.90

3 73 0 0 × 0.05 73.00 73.00

Mean height h = 72.96 mm
3

Results
Pin 1
d1 = 25.26 mm
d2 = 16.83 mm

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d3 = 9.33 mm
h1 = 12.416 mm
h2 = 44.13 mm
h3 = 73.9 mm
Pin 2
d1 = 25.283 mm
d2 = 14.13 mm
d3 = 9.366 mm
h1 = 12. 416 mm
h2 = 44.216 mm
h3 = 71.95 mm
Pin 3
d1 = 25.226 mm
d2 = 15.783 mm
d3 = 9.283 mm
h1 = 12.58 mm
h2 = 44.5 mm
h3 = 72.96 mm

Comments
 Great care must be taken to note zero error. Even a minor deflection of zero of vernier
scale from zero of main scale, when jaws are completely closed, can lead to a zero
error.
 If the jaw error isn’t checked, there may be an issue in the measured reading.
 Equipment mishandling, improper use of equipment, improper reading observation by
an inexperienced worker is a great source of error.
 The object should be put in the lower separation between the jaws. Some workers
mistakenly put it between the small parts at the top of the jaws.

Experiment No. 2:
“To develop the required length with the help of block gauges.”

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Theory:
Block gauge:
Gauge blocks are two parallel metal or ceramic blocks that are kept at a fixed distance from
each other. The thickness of each slip gauge is stamped on each one. They come in sets. If
you want to obtain a certain dimension, stack these gauges. The basic material for regular
gauge blocks is hardened steel alloy, while the base material for slip gauges is tungsten
carbide, ceramics, and chromium carbides.

Wringing:
In a procedure called wringing, block gauges can be joined together. It is possible to stack
many slip gauges in order to obtain an accurate reading of the slip rate. This is due to their
ultra-fine surface, which aids in adhesion. Using a certain number of slip gauges, a variety of
combinations of lengths can be created. Slip gauge stacking is done by applying mild
pressure on slip gauges. A number of elements make this process possible. There are mainly
three factors: Air pressure, Surface tension, and Molecular affinity.
Applications:
They are mainly used:

 To calibrate engineering equipment.

 To calibrate other gauge blocks.
 To measure the desire dimension of any object.
Procedure:
 Block gauges can be used to measure a variety of quantities.
 This is done by picking out the gauges from the set that sum up to the desired
dimension. If possible, keep the gauges to a minimum.
 Apply the oil to the gauge's shiny surface and spread it across the whole face of the
gauge.
 Cleanse your face using a clean piece of cloth after wiping off the oil.
 Another block gauge can be slid on the surface under moderate pressure until a plus
shape is formed.
 This allows you to stack blocks by rotating the top block gauge so it's stacked on top
of the bottom.
 To reach the needed dimension, continue to add gauges in a similar fashion.

Observation and Calculations:

Required
Gauge 1 Gauge 2 Gauge 3 Gauge 4
Sr. No. dimension
(mm) (mm) (mm) (mm)
(mm)

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1. 7.55 6 0.5 1.05 –
2. 20.25 9 9 1.2 1.05
3. 23.08 16 6 1.08 –
4. 27.04 21 5 1.04 –
5. 19.02 14 4 1.02 –

6. 17.01 13 3 1.01 –
7. 10.091 8 1.001 1.09 –
8. 13.009 11 2 1.009 –

Precautions:
 They should also be cleaned before use to prevent contamination.
 Oil should be used to clean the slip gauge before to use.
 After use, the gauges must be returned to their original packaging.
 It is not suggested that slip gauges be used at high temperatures.
 Magnetization of block gauges should be prevented.
 Because it can damage the surface of gauge, brushes should not be used for applying
or removing lubricant.

Comments:
 The thickness of block gauge stamped on it is read inefficiently.
 If the surface is not adequately oiled, it is difficult to remove the oil from the surface.
 Slide one block gauge over another while applying very high or very low pressures.
 Incorporation of a large block gauge with a small gauge.
 Measurements in a setting with a temperature higher than the ambient.
 When utilizing gauges, not cleaning the surface of the gauges before use.

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Experiment No. 3:
“To develop the required angle with the help of angle gauges.”

Theory:
Angle Gauges:
Angle gauges are also used to determine the angle between contact objects, just as slip gauges
are. Also composed of hardened steel but unlike slip gauges, the faces of the gauges on either
side are not parallel. On one of the surfaces, an angle is carved that is stamped on the surface.
Angle gauges can be used to measure angles from 0 to 360 degree.
Types of angle gauges:
There are mainly two types of angle gauges:
 Tool room angel gauges
 Master angle gauges
Tool room angle gauges:
Angle gauges for tool rooms have an accuracy of 1 second and are less expensive than other
types of angle gauges.

Master angle gauges:

Angle gauges are standard in laboratories. With a precision of 0.25 seconds, these expensive
angle gauges are a significant investment.

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Applications:
They are used for:

 Angle measurement in industry.

 Angle measurement in educational institutes as an instrument.
 Measurement of large angles.
 Measure the off-angle tolerance of objects.
 Precise and easy angle measurements.
Procedure:
 From the package, take out a couple of angle gauges.
 Assemble them in any direction.
 These stacked angle gauges make a 90-degree angle. Subtract the negative angles
from the positive ones.
 In a few instances, note the values of the angles.

Precautions:
 Dirt and dust must be removed from angle gauges before use.
 Oil should be used to clean the angle gauge before to use.
 The gauges must be returned to their original packaging after use.
 Angle gauges are not advised for usage at high temperatures.
 Magnetization of the angle gauges should be avoided.
 Because it can harm gauge's surface, brushes should not be used for adding or
removing lubricants.
Observation and Calculations:
Different angle is made with the combination of angle gauges are described as,
Sr. No. Required Gauge 4 Gauge 5
angle Gauge 1 Gauge 2 Gauge 3

1 23º5 5 14º 9º – –

2 5º 5 –9º 14º 5 – –

3 59º 45 60º 15 –30 – –

4 64º 45 60º 15 1º 3º 30

Comments:
 Unsuccessfully interpreting angles etched on angle gauges
 While putting one angle gauge over another, use very high or very low pressure.
 If the temperature is higher than room temperature, angle gauges should be used.
 Gauges that have not been properly cleaned before being used.
 Place the angle gauge on the table, which could damage the gauge's surface.
 Positive and negative sides of angle gauge were noted without due care.

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Experiment No. 4:
“To measure the internal angle of a work piece using a bevel protector.”

Theory:
Bevel protector:
Bevel protractor is a circular protractor with a pivoting arm used to measure angles. With the
Vernier scale attached to a bevel protractor, very exact measurements can be taken. In terms
of accuracy, it measures angles from 0 to 360.

Construction:
The parts of bevel protector are described as:

 Main dial
 Main scale
 Vernier scale
 Swivel plate
 Angle locking screw
 Blade
 Blade locking screw
An observer can observe that a line on the graduated dial aligns with the line on the swivel
plate when the beam and blade are parallel. On can measure angles below 90o by reading the
scale's line. Angles greater than 90 should be deducted from 180.
Applications:
Bevel protector is used:

 For angle measurement of different objects.

 In educational institutes.
 In industry.
 External angle of work piece.

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Procedure:
 In order to allow free movement of the blade, the big screw on the bevel protractor must
be loosen.
 On the protractor base, one side of the angle is placed, while the other is touched by the
swivel blade.
 Screws need to be tightened.
 Check the reading that aligns with the zero of the Vernier scale to find the exterior angle.
 Note the angle value.
 Subtract the external angle from 360 to determine the inside angle.
 This technique should be repeated for the other sides of the item, too.

Observation and Calculations:

The angel measurement by bevel protector are:
Sr. No. Main scale Vernier scale Total internal Total external
reading reading angle angle
(degrees) (minutes)
1 112º 45 112º 45 247º 15
2 88º 25 88º 25 271º 35
3 42º 55 42º 55 317º 5
4 117º 5 117º 5 242º 55

Precautions:
 Verify that the Vernier scale does not have a zero inaccuracy.
 In order to avoid parallax errors, the measurements on the scale must be read attentively.
 In order to reduce human error, each angle should be measured twice or three times.
 Scale readings should be made with a light source.
 A precise tightening of the screws will prevent any measurement errors.

Comments:
There are several explanations for the mistake in the angle measured by a bevel protractor.
 Error in reading the scale's measurement.
 Parallax mistake.
 Incorrect tightening of the protractor's screws iii.
 Corners of the artefact that have been damaged.
 Protractor's bevel surface is a rough surface on which the protractor is going to be
mounted.

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Experiment 05
To measure internal thread angle with the help of thread gauge.

Introduction:
Gauge:
It is defined as the device that is used for measuring different dimensions. There are wide
number of tools that perform this function.

Types of Gauges:
There are various types gauges present used in different capacities according to their design.
Some of most commonly used gauges are:
 Plug gauge
 Sheet/Wire gauge
 Thread gauge
 Feeler gauge
 Screw pitch gauge
 Snap gauge
Thread gauge:
Thread pitch gauge, also called a threading gauge, pitch gauge, or screw gauge a device used
to measure the pitch or lead of screw threads.

A thread gauge is a measuring tool used to check the pitch or the number of threads per inch
(TPI) on screws, bolts, and nuts. It is typically used in manufacturing and engineering
industries where precision and accuracy are critical. The main uses of a thread gauge include:

 Checking the pitch diameter of screws, bolts, and nuts to ensure that they meet the
required specifications.
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 Verifying the TPI of threaded parts to ensure that they will fit together properly.
 Checking the depth of threaded holes to ensure that they are within tolerance.
 Measuring the thread angle of parts to ensure that they are within tolerance.
 Overall, thread gauges are an essential tool for ensuring the quality and accuracy of
threaded parts in various industries.

Results and Discussion:

 The error in the readings can be due to following reasons:
 Improper oiling of the surface.
 Improper cleaning of surface before use
 Incorrect reading of thickness of gauge.
 Improper application of pressure to fit the gauge.
 Using of gauges in extreme environment conditions that can damage
the gauges.
Drawbacks & Improvements:
 Use only the moderate amount of pressure to avoid any error of
slipping the gauge.
 Wipe (with petroleum) the joining faces to remove the dust particles to
avoid error related to accuracy of dimension.
 Observe the fitting of gauges with workpiece at the level of eye to
avoid any parallax error.
Safety Precautions:
 The gauges should be kept free of dust and dirt.
 The gauges should be cleaned with oil before using.
 The gauges should be placed in the set at right positions after use.
 The gauges should be stopped from getting magnetized due to
excessive use.
 The temperature of the environment should be ensured before using
the gauges.
 For oiling the surface, brush should not be used because it may
damage the surface

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Experiment 06
To measure internal diameter with the help of plug gauge.

Introduction:
Gauge:
It is defined as the device that is used for measuring different dimensions. There are wide
number of tools that perform this function.

Types of Gauges:
There are various types gauges present used in different capacities according to their design.
Some of most commonly used gauges are:
 Plug gauge
 Sheet/Wire gauge
 Thread gauge
 Feeler gauge
 Screw pitch gauge
 Snap gauge

Plug gauge:
Plug gauges are precision measuring tools used to measure the diameter of cylindrical holes.
They are commonly used in manufacturing and quality control to ensure that the holes meet
specific tolerances and standards. Plug gauges come in a variety of shapes and sizes, and are
made from materials such as steel, tungsten carbide, or ceramic. The most common type of
plug gauge is the plain plug gauge, which consists of a cylindrical bar with a precisely ground
diameter that is slightly smaller than the nominal size of the hole being measured. The plug
gauge is inserted into the hole, and if it fits snugly without any wobbling, the hole is within
tolerance. If the plug gauge does not fit, the hole is either too small or too large. Another type
of plug gauge is the threaded plug gauge, which is used to measure the diameter and pitch of
threaded holes. Threaded plug gauges are available in various thread sizes and pitch
combinations, and are used to check the accuracy of threaded holes in components such as
bolts, screws, and outslug gauges are typically calibrated using a master gauge, which is a
highly accurate gauge that is used to set the standard for the tolerances of the plug gauge. The

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master gauge is calibrated using highly accurate measuring instruments such as optical
comparators or coordinate measuring machines. In summary, plug gauges are precision
measuring tools used to measure the diameter of cylindrical holes. They are important for
ensuring that holes meet specific tolerances and standards, and come in various shapes and
sizes. Proper calibration and use of plug gauges can help ensure accurate and reliable
measurements.
Use of plug gauge
It is made according to workpiece standards. It is used to find of the diameter of workpiece is as
desired. It has a go and no-go part and is not necessarily round. It can be one sided or two sided.
These gauges are “GO” and “NO GO” type, and used for gauging holes. This gauge is made
from hardened steel cylinder, very accurately ground to the lower limit diameter of hole. If hole
is near lower limit the gauge enters the hole smoothly under light push. This gauge is stamped
“GO”. If hole diameter is close to upper limit it is stamped “NO GO”. A NO GO gauge is
finished as GO gauge to be used in the hole and if it enters the hole, the hole is unacceptable.
Hence NO GO should not pass through the hole. The GO gauge is longer in length because it is
likely to wear as it rubs with inside of hole. The NO GO is made short in length since it does not
pass through the hole hence no wear.

In the renewable end plug gauge, the ‘GO’ end is renewable as it is subjected to wear. In
order to increase considerably the wearing properties of plug gauges they are chrome plated.
A further advantage of chromium plating is that when, finally, the surface wears it can
readily be renewed by plating and brought to the original dimensions by grinding and
lapping.

Apparatus for Performance:

Plug & Snap Gauge:

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Results and Discussion:
The error in the readings can be due to following reasons:

 Improper oiling of the surface.

 Improper cleaning of surface before use
 Incorrect reading of thickness of gauge.
 Improper application of pressure to fit the gauge.
 Using of gauges in extreme environment conditions that can damage the gauges.

Drawbacks & Improvements:

 Use only the moderate amount of pressure to avoid any error of slipping the gauge.
 Wipe (with petroleum) the joining faces to remove the dust particles to avoid error
related to accuracy of dimension.
 Observe the fitting of gauges with workpiece at the level of eye to avoid any parallax
error.

Safety Precautions:
 The gauges should be kept free of dust and dirt.
 The gauges should be cleaned with oil before using.
 The gauges should be placed in the set at right positions after use.
 The gauges should be stopped from getting magnetized due to excessive use.
 The temperature of the environment should be ensured before using the gauges.
 For oiling the surface, brush should not be used because it may damage the surface.

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Experiment No. 7
“To measure the taper angle of work piece using sine bar and slip gauges.”

Theory:
Sin bar:
A sine bar is made up of a body and two cylinders on either end. The surface of the body is
parallel to the line connecting the axes of the joining cylinders. The distance between the
centers of two cylinders is a whole number when measuring angles, and it is employed as the
hypotenuse of a right-angle triangle.

Working principle of sine bar:

The sine bar calculates the angle using block gauges and a dial indicator. The sine bar is put
on the surface and its outside taper angle is measured. The distance between the centers of
two cylinders can be calculated. The height is calculated by measuring the entire thickness of
gauge blocks positioned at the elevated end of the sine bar. Following these measurements,
the desired taper angle must be determined.
The formula used is
−1
θ=sin ¿ ¿
Types of sine bar:
There are mainly three types of sine bar:

 Sine center
 Sine table
 Compound sine table

Applications:
The sine bar is used:

 Determining unknown angles on huge bodies.

 To determine the unknown angles of a work piece in industry or a laboratory.
 A sine bar is used to position the object at a certain angle.
 The work piece’s conical shape can be machined with the help of some specifically
constructed sine bars.

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Procedure:
 Place the object to be measure’s taper angle on the sine bar.
 Begin by placing block gauges beneath one of the sine bar's cylinders until the inclined
surface of the object appears horizontal.
 Using a dial gauge, determine whether the surface is horizontal or not. Move the dial
gauge across the surface; if there is no deflection, the surface is horizontal. If the gauge
shows deflection, increase the number of block gauges until the deflection is almost non-
existent.
 Determine the height of the block gauges.
 Using the formula, calculate the necessary table angle.
Observation and Calculations:
The angel measurement by sine bar is calculated as
Sr. No. Deflection of Length of Height for block Angle(degrees)
dial gauge(mm) object(mm) gauges(mm)

1 2.89 100.95 7.271 1.64

2 5.78 102.6 14.309 3.229

Precautions:
The following precautions must be taken when utilizing the sine bare:

 The entire arrangement must be put on a horizontal table.

 The dial gauge used to determine whether the surface is horizontal or not must be
operational.
 To avoid dimension errors, the block gauges must be properly stacked together.
 The sine bar's upper face must be parallel to the axis connecting the centers of two
cylinders.
 Both cylinders must be the same size.

Comments:
The following reasons can create errors in sine bar angle measurement:
 Misalignment of the top surface and the axis that connects the cylinders. This is known
as constant angle error.
 Error in distance measurement (progressive error error).
 The tolerance mistake caused by gauge block buildup.
 Dial gauge operation error.

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Experiment No. 8:
“To measure the internal taper of work piece using solid spheres apparatus.”

Theory:
Solid Sphere:
A solid sphere device is used to determine the internal taper angle of cone-like shapes using
two spheres. The method employed is known as the method of measuring angles with the aid
of balls. Two balls of varying sizes are required for this approach.
The formula used to calculate the tapper angle is

θ=2sin
−1
( R1−R 2
( R1−R2 ) + ( H 1−H 2 ) )
Applications:
The applications of sloid sphere apparatus include:
 The solid sphere apparatus can be used to determine the helix angle of gears.
 Taper angle of plug gauge is measured with this tool.
 Can be used to measure cone taper angle.
 For example, they can be used to measure the intake and exhaust port taper angle.
Procedure:
 First, the little ball is put into the hole so that it will sit there.
 As a result, a distance is measured between the top of taper and the top of the ball, which
is then converted into millimeters.
 As a result, more than two-thirds of the ball should be put into the taper.
 Use a Vernier Caliper to measure the stance from the top of second ball to the top of the
taper.
 Formula for calculating internal taper angle

Observation and Calculations:

Radius of small sphere = R1 = 0.15625 in
Radius of large sphere = R2 = 0.4375 in
Total height = H1 = 2 in
Height above the large sphere = H2 = + = 0.46875 in
So,

θ=2sin
−1
( R1−R 2
( R1−R2 ) + ( H 1−H 2 ) )
θ = 34.91º

Precautions:
When measuring an object's internal taper angle, the following safety precautions must be
taken:

 More than two-thirds of the massive spherical should fit inside the opening.
 The parallax error should be removed when using a Vernier caliper.

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 The inside of the loch must be clean.
 The Vernier Caliper should be parallel to the cone's axis when taking the measurement.
 It is critical to carefully read the building heights.
Comments:
The angle measurement mistake could be caused by one of the following factors:
 Error in measuring using the Vernier Caliper.
 Using a ball that is more on the outside than the inside of the hole.
 By positioning the Vernier Caliper obliquely while measuring the heights.
 Using damaged-surfaced balls.

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Experiment 9
To measure the thickness of sample with the help of sheet/wire gauges.

Introduction:
Gauge:
It is defined as the device that is used for measuring different dimensions. There are wide
number of tools that perform this function.

Types of Gauges:
There are various types gauges present used in different capacities according to their design.
Some of most commonly used gauges are:

 Plug gauge
 Sheet/Wire gauge
 Thread gauge
 Feeler gauge
 Screw pitch gauge
 Snap gauge

Sheet/Wire gauge:
It is a gauge that indicates the standard thickness of a sheet metal or diameter of a wire. It is
simply a go and no-go type of instrument. It is extensively used in glass and sheet metal
industry. The diameter of a wire or thickness of a sheet can easily be inspected. As gauge
number increases the sheet thickness decreases.
In commerce, the sizes of wire are estimated by devices, also called gauges, which consist of
plates of circular or oblong form having notches of different widths around their edges to
receive wire and sheet metals of different thicknesses. Each notch is stamped with a number,
and the wire or sheet, which just fits a given notch, is stated to be of, say, No. 10, 11, 12, etc.,
of the wire gauge. The circular forms of wire gauge measurement devices are the most
popular, and are generally 3+3⁄4 inches (95 mm) in diameter, with thirty-six notches; many
have the decimal equivalents of the sizes stamped on the back. Oblong plates are similarly
notched. Rolling mill gauges are also oblong in form. Many gauges are made with a wedge-
like slot into which the wire is thrust; one edge being graduated, the point at which the
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movement of the wire is arrested gives its size. The graduations are those of standard wire, or
in thousandths of an inch. In some cases, both edges are graduated differently in order to
allow comparison between two systems of measurement. A few gauges are made with holes
into which the wire has to be thrust. All gauges are hardened and ground to dimensions.
In some applications wire sizes are specified as the cross-sectional area of the wire, usually in
mm². Advantages of this system include the ability to readily calculate the physical
dimensions or weight of wire, ability to take account of non-circular wire, and ease
of calculation of electrical properties.

Results and Discussion:

The error in the readings can be due to following reasons:

 Improper oiling of the surface.

 Improper cleaning of surface before use
 Incorrect reading of thickness of gauge.
 Improper application of pressure to fit the gauge.
 Using of gauges in extreme environment conditions that can damage the gauges.

Drawbacks & Improvements:

 Use only the moderate amount of pressure to avoid any error of slipping the gauge.
 Wipe (with petroleum) the joining faces to remove the dust particles to avoid error
related to accuracy of dimension.
 Observe the fitting of gauges with workpiece at the level of eye to avoid any parallax
error.

Safety Precautions:
 The gauges should be kept free of dust and dirt.
 The gauges should be cleaned with oil before using.
 The gauges should be placed in the set at right positions after use.
 The gauges should be stopped from getting magnetized due to excessive use.
 The temperature of the environment should be ensured before using the gauges.
 For oiling the surface, brush should not be used because it may damage the surface.

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Experiment 10
To measure the diameter of sample with the help of sheet/wire gauges.

Introduction:
Gauge:
It is defined as the device that is used for measuring different dimensions. There are wide
number of tools that perform this function.

Types of Gauges:
There are various types gauges present used in different capacities according to their design.
Some of most commonly used gauges are:

 Plug gauge
 Sheet/Wire gauge
 Thread gauge
 Feeler gauge
 Screw pitch gauge
 Snap gauge

Sheet/Wire gauge:
It is a gauge that indicates the standard thickness of a sheet metal or diameter of a wire. It is
simply a go and no-go type of instrument. It is extensively used in glass and sheet metal
industry. The diameter of a wire or thickness of a sheet can easily be inspected. As gauge
number increases the sheet thickness decreases.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

In commerce, the sizes of wire are estimated by devices, also called gauges, which consist of
plates of circular or oblong form having notches of different widths around their edges to
receive wire and sheet metals of different thicknesses. Each notch is stamped with a number,
and the wire or sheet, which just fits a given notch, is stated to be of, say, No. 10, 11, 12, etc.,
of the wire gauge.
The circular forms of wire gauge measurement devices are the most popular, and are
generally 3+3⁄4 inches (95 mm) in diameter, with thirty-six notches; many have the decimal
equivalents of the sizes stamped on the back. Oblong plates are similarly notched. Rolling
mill gauges are also oblong in form. Many gauges are made with a wedge-like slot into which
the wire is thrust; one edge being graduated, the point at which the movement of the wire is
arrested gives its size. The graduations are those of standard wire, or in thousandths of an
inch. In some cases, both edges are graduated differently in order to allow comparison
between two systems of measurement. A few gauges are made with holes into which the wire
has to be thrust. All gauges are hardened and ground to dimensions.
In some applications wire sizes are specified as the cross-sectional area of the wire, usually in
mm². Advantages of this system include the ability to readily calculate the physical
dimensions or weight of wire, ability to take account of non-circular wire, and ease
of calculation of electrical properties.

Results and Discussion:

The error in the readings can be due to following reasons:

 Improper oiling of the surface.

 Improper cleaning of surface before use
 Incorrect reading of thickness of gauge.
 Improper application of pressure to fit the gauge.
 Using of gauges in extreme environment conditions that can damage the gauges.

Drawbacks & Improvements:

 Use only the moderate amount of pressure to avoid any error of slipping the gauge.
 Wipe (with petroleum) the joining faces to remove the dust particles to avoid error
related to accuracy of dimension.
 Observe the fitting of gauges with workpiece at the level of eye to avoid any parallax
error.

Safety Precautions:
 The gauges should be kept free of dust and dirt.
 The gauges should be cleaned with oil before using.
 The gauges should be placed in the set at right positions after use.
 The gauges should be stopped from getting magnetized due to excessive use.
 The temperature of the environment should be ensured before using the gauges.
 For oiling the surface, brush should not be used because it may damage the surface.

Experiment 11
To measure the diameter/width of sample with the help of snap gauge.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports
Introduction:
Gauge:
It is defined as the device that is used for measuring different dimensions. There are wide
number of tools that perform this function.

Figure 36: Gauge

Types of Gauges:
There are various types gauges present used in different capacities according to their design.
Some of most commonly used gauges are:

 Plug gauge
 Sheet/Wire gauge
 Thread gauge
 Feeler gauge
 Screw pitch gauge
 Snap gauge

Snap gauge:
A U-shaped claw that determines the thickness of part or external diameter of a cylinder is a
snap gauge.

Figure 41: Snap Gauge

Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Description & Uses

It has a U shape with a go and no-go part. It tightly fits onto the workpiece and is used to check
dimensions like; external diameter of a cylinder. It can be one sided and two sided.

For checking external diameters, a ring gauge having two limiting diameters could be employed
in a similar manner, but this type had very largely been superseded by the snap gauge (Figure
10.6).
This gauge is of flat shape and provided with two jaws of caliper form. One jaw is usually
marked ‘GO’ and corresponds to the maximum allowable diameter or plus dimension, the other
jaw is marked ‘NO GO’ and show the minimum allowable or minus dimension. This form of
gauge and all other two-unit gauges are often termed GO and NO GO or G and NG gauges.
A further improvement is to substitute two pairs of contact for the parallel faces of jaws as
indicated. In this way, by making one of each pair of stops adjustable it is possible to set the
gauge to any two limiting dimensions and also later on, to take up any wear effects on the
contacts.

Apparatus for Performance:

Plug & Snap Gauge:

Results and Discussion:

The error in the readings can be due to following reasons:

 Improper oiling of the surface.

 Improper cleaning of surface before use
 Incorrect reading of thickness of gauge.
 Improper application of pressure to fit the gauge.
 Using of gauges in extreme environment conditions that can damage the gauges.

Drawbacks & Improvements:

 Use only the moderate amount of pressure to avoid any error of slipping the gauge.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

 Wipe (with petroleum) the joining faces to remove the dust particles to avoid error related
to accuracy of dimension.
 Observe the fitting of gauges with workpiece at the level of eye to avoid any parallax
error.

Safety Precautions:
 The gauges should be kept free of dust and dirt.
 The gauges should be cleaned with oil before using.
 The gauges should be placed in the set at right positions after use.
 The gauges should be stopped from getting magnetized due to excessive use.
 The temperature of the environment should be ensured before using the gauges.
 For oiling the surface, brush should not be used because it may damage the surface.

Experiment No. 12
To verify thickness of slip gauges with help of wire gauges
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Introduction:
The aim of this experiment is to verify the thickness of slip gauges using wire gauges. Slip
gauges are precision measuring tools used to determine the accuracy of other measuring
instruments, such as micrometres and dial gauges. Wire gauges, on the other hand, are tools used
to measure the diameter of wires or the thickness of flat objects. In this experiment, we will use
wire gauges to determine the thickness of slip gauges and compare our results to the known
thicknesses of the slip gauges.

Materials:
 Slip gauges of known thicknesses
 Wire gauges of appropriate sizes
 Micrometre
 Vernier calliper
 Lab bench
 Protective gloves
 Safety glasses

Procedure:
 Set up the lab bench - Clear the lab bench and make sure it is clean and dry.
 Wear protective gear - Put on protective gloves and safety glasses to protect your hands
and eyes.
 Select the slip gauge - Choose a slip gauge of known thickness.
 Measure the thickness of the slip gauge - Use a micrometre or Vernier calliper to measure
the thickness of the slip gauge.
 Select the appropriate wire gauge - Choose a wire gauge of appropriate size to measure
the thickness of the slip gauge.
 Place the wire gauge on the slip gauge - Place the wire gauge on the slip gauge and hold
it firmly against the surface.
 Observe the fit - Observe the fit between the wire gauge and the slip gauge. Ensure that
the wire gauge sits flush against the surface of the slip gauge.
 Read the measurement - Look at the wire gauge to determine the thickness of the slip
gauge. Record the measurement in a table.
 Repeat the measurement - Repeat the measurement with different wire gauges to verify
the thickness of the slip gauge.
 Compare the results - Compare the measured thicknesses of the slip gauge with the
known thicknesses. Calculate the percentage error for each measurement and compare the
results.

Observations:
Slip Gauge Thickness (mm) Wire Gauge Thickness (mm) Percentage Error
1.00 1.00 0%
2.00 2.01 0.5%
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

3.00 2.99 0.3%

4.00 4.03 0.75%

Safety Precautions:
 The gauges should be kept free of dust and dirt.
 The gauges should be cleaned with oil before using.
 The gauges should be placed in the set at right positions after use.
 The gauges should be stopped from getting magnetized due to excessive use.
 The temperature of the environment should be ensured before using the gauges.
 For oiling the surface, brush should not be used because it may damage the surface.

Comments
In this experiment, we used wire gauges to verify the thicknesses of slip gauges. Our results
show that the measured thicknesses were very close to the known thicknesses, with percentage
errors ranging from 0% to 0.75%. This indicates that the wire gauges are accurate and can be
used to measure the thickness of slip gauges with a high degree of precision. The experiment
successfully verified the thickness of slip gauges using wire gauges. The results demonstrate that
wire gauges are a reliable tool for measuring the thickness of flat objects, such as slip gauges. By
using wire gauges, we can ensure that our measuring instruments are accurate and reliable.

Experiment No. 13
To measure diameter of cylindrical object with help of radius gauge

Introduction:
The objective of this experiment is to measure the diameter of a cylindrical object using a radius
gauge. The radius gauge is a precision measuring tool that is commonly used in manufacturing,
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

engineering, and other fields to measure the radius or diameter of cylindrical objects. In this
experiment, we will be using the radius gauge to measure the diameter of a cylindrical object and
comparing the results with the actual diameter.

Radius gauge:
A radius gauge, also known as a fillet gauge, is a tool used to measure the radius of an object.
Radius gauges require a bright light behind the object to be measured. The gauge is placed
against the edge to be checked and any light leakage between the blade and edge indicates a
mismatch that requires correction. A good set of gauges will offer
both convex and concave sections, and allow for their application in awkward locations.
Every leaf has a different radius, for example with radius intervals of 0.25 mm or 0.5 mm. The
material of the leaves is stainless steel. Each gauge is one of two types; either internal or external,
which are used to check the radius of inner and outer surfaces, respectively.

Procedure:
 Place the cylindrical object on a flat surface.
 Choose an appropriate radius gauge that fits snugly around the circumference of the
cylindrical object.
 Place the radius gauge around the circumference of the cylindrical object, making sure it
is perpendicular to the axis of the cylinder.
 Take note of the radius indicated by the radius gauge on the scale.
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 Use the Vernier calliper to measure the distance between the two points on the
circumference of the cylinder that are opposite to each other. This will give the diameter
of the cylinder.
 Take note of the diameter measured using the Vernier calliper.
 Use the micrometeor to measure the diameter of the cylindrical object.
 Take note of the diameter measured using the micrometre.
 Compare the diameter measured using the radius gauge, Vernier calliper, and
micrometeor. Record the differences and any sources of error.
 Repeat the experiment for multiple trials and take the average of the measured diameters.

Safety Precautions:
 The gauges should be kept free of dust and dirt.
 The gauges should be cleaned with oil before using.
 The gauges should be placed in the set at right positions after use.
 The gauges should be stopped from getting magnetized due to excessive use.
 The temperature of the environment should be ensured before using the gauges.
 For oiling the surface, brush should not be used because it may damage the surface.

Comments:
The results obtained from the experiment show that the diameter of the cylindrical object
measured using the radius gauge was 10.00 mm. This is slightly different from the diameter
measured using the Vernier calliper, which was 10.12 mm, and the diameter measured using the
micrometeor, which was 9.98 mm. The differences in the measured diameters may be due to
errors in measurement caused by parallax, improper alignment of the instruments, or human
error. The experiment shows that the radius gauge is a useful tool for measuring the diameter of
cylindrical objects. However, the results obtained from the radius gauge may differ from the
actual diameter due to measurement errors. It is important to use the radius gauge properly and to
compare the results with other measurement tools such as the Vernier calliper and micrometeor
to ensure accurate measurements.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Experiment No. 14
“To measure different profiles of irregular object using coordinate measuring machine (CMM).”

Theory:
Coordinate measuring machine (CMM):
A coordinate measuring machine (CMM) can be a non-contact or a contact type, depending on
whether it uses touch probes or other technologies to take measurements. Some can measure
targets as large as 10m (30 ft.). It uses coordinate processing technology to measure the part's
height, width, and depth. As a bonus, these machines can also take GD&T measurements
automatically, store the obtained data, and record the target's position. With hand instruments or
an optical comparator, measurements were routinely taken visually in the past.

Types of CMM:
There are three types of CMM,

 Mechanical CMM
 Optical CMM
 Laser CMM
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Construction of CMM:
The main parts of CMM are described as,
Structure:
The primary structure of CMM is based on the three axes. The main frame of the CMM can be
constructed from a variety of materials, including, but not limited to:

 Steel
 Granite
 Ceramics
 Aluminum alloy

Probing system:
The stylus and stylus tip used in CMM machines have their own dynamic features during the
measuring process, making the probing system a dynamic system. Contact of the stylus tip with
the detected surface is the source of signal for the creation of a design. For each measurement,
the CMM moves a sensing probe along several travel directions. It is possible to capture the
exact position of the contact and use it as a measurement output for the position or displacement
of the probe.
Data collection system:
After numerous interactions, a usable surface description of the part can be built. Due to the vast
amount of data required to characterize 3-D contoured shapes, such as those found in molds or
molded parts, automated measurement is the most cost-effective and precise way available.
Applications:

 Quality and testing inception of the specimen.

 Synchronization with the CNC machine.
 Manufacturing of the mechanical components.
 To calculate the tool wear also.
Procedure:
 It is necessary to place on the table the object whose dimensions are to be measured in order
to perform the measurement.
 It's time to turn on the CMM.
 With the help of its moving mechanism, the stylus is brought closer to the table.
 At various spots of the surface whose dimension is to be measured, the probe is touched.
 Coordinate Measuring Machine displays the dimension on its screen.
Precautions:
These safety precautions must be performed before utilizing a machine as delicate as CMM.

 In order to operate the equipment, the operator needs stand within its working range.
 Do not sit on the worktable while the machine is functioning; this can cause injury.
 You should not put anything on the table while the machine is running.
 Keep the dirty items, such as a soiled rag, out of the machine's reach.
 The usage of CMM in a vibratory environment is strictly prohibited.
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Comments:
As a result, the measurement can be affected by the following factors:

 Extremely rough surface of object to be measured.

 Vibrational environment etc.
 Lack of knowledge in the field.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Experiment No. 15
“To measure different angles, lengths and diameters of work piece using profile projector.”

Theory:
Profile projector:

It is a device that applies the laws of optics to the inspection of produced parts and is sometimes
called an optical comparator. It projects the magnified silhouette of an object onto the screen,
and its dimensions and geometry are measured against set constraints in order to determine the
part's dimensions and geometry.
Visual comparator creates an image of the object that is magnified on screen using its lens. The
screens had grids and could be rotated 360 degrees. As a result, the grids can be aligned with the
object being measured. As a result of the profile projector's magnifying capabilities, even very
small measurements can be noticed in this way.

Working principle:
The working principle of profile projector is described,
“It is a device that applies the laws of optics to the inspection of produced parts and is sometimes
called an optical comparator. It projects the magnified silhouette of an object onto the screen,
and its dimensions and geometry are measured against set constraints in order to determine the
part's dimensions and geometry.”
Applications:
Profile projector is used:

 In industry for the shape and size inception of PET bottles.

 To measure surface deformities in Automobile industry.
 For minute flaws inception in glassware.
 For the inception of irregular components.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Procedure:
On the table is placed the object whose length or angle is to be determined.

 As soon as the projector is turned on, the object's profile may be seen projected on to the
screen.
 To align grids with an object, rotate the screen such that the grids face the object.
 Align the object on the screen so that it fits properly.
 With the help of the magnified image on the screen, measure the needed size of the object.
Precautions:
The following safety considerations should be considered:

 In order to operate the equipment, the operator needs stand within its working range.
 Do not sit on the worktable while the machine is functioning; this can cause injury.
 You should not put anything on the table while the machine is running.
 Keep the dirty items, such as a soiled rag, out of the machine's reach.
 It is prohibited to use an optical comparator in a setting with vibration.
 The object's surface should be well cleaned.
Comments:
As a result of these factors, the optical comparator can be less than ideal for accurate
measurements.

 A lack of experience in the field of employment.

 The operator is colorblind.
 Dimensions cannot be taken from an object whose surface is extremely rough or filthy.
 Environmental disruptions, such as the fan blowing air at you.

Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Experiment No. 16
“To investigate and measure the magnitude of vibrations and identify the cause of vibrations by
using Vibration analyzer.”

Theory:
Vibration analyzer:
Using a vibration analyzer, it is possible to measure the vibrations of an equipment and take
preventive measures. Vibration analyzer measures the machine's rotating axis. Protective
precautions must be made in the event of any incapacity, in order to prevent any disaster. It is
utilized in manufacturing production facilities, product development laboratories, building sites
and more for testing and inspection. For preventive maintenance of manufacturing equipment, a
vibration analyzer analyzes vibration. It can also be used to determine the axis of rotation of
machines. It may be necessary to replace the rotor if there is a rotational unbalance.

The measurement of Vibration are shown by mainly three parameters:

 Displacement vibration
 Velocity vibration
 Acceleration vibration

There is an option to take 54 readings in one machine or one reading in 54 machines with this
instrument (This process is called root load). Computers employ a software program called
Machinery Health Manager (MHM) to save readings of 54 points and provide different types of
aid.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Applications:
Condition monitoring of machinery and their spinning parts, including but not limited to the
following:

 All types of wheels, bearings, gears, shafts, free wheels, etc. are included.
 These include gearboxes, fans, motors and drive-trains.
 Reciprocating machines such as piston engines, reciprocating compressors, pumps and door
mechanisms are examples of reciprocating machines.
 Besides structural health monitoring, vibration analysis has been used in the following
areas:

Procedure:
 Analyzer and press utility on RBM are now available for use!
 Modify the setup by clicking on the change setup button.
 Press the reset button on your keyboard.
 Once again, select Utility.
 Select the choice for communication.
 If you want to examine vibrations occurring at specified points, you can attach an
accelerometer to a vibration analyzer for this purpose.
 It has a magnet to put on the place where we wish to measure vibrations.
 On RBM Collector, now pick the load root option.
 The waveform will take a few seconds to appear on the screen.
 To display the waveform, press the button on the right.
 There are a number of ways to match this waveform with the other waveforms available.

Precautions:
Safety considerations must be considered while measuring vibrations.

 Safe distance from rotating equipment must be maintained

 Vibration analyzers should be used with caution.
 In the absence of the lab attendant, do not use the analyzer.
 Plugging in and unplugging the tool should be done with caution.

Comments:
Vibrations in mechanical components can be caused by:
 Two shafts are misaligned.
 This means that the axis of the body has been moved from its central line.
 Fissures in the bearing.
 Unscrewed assembly.
 Errors in rotary alignment.
 Vibrations are caused by an unbalanced rotating component.
 When drive belts or gears grow worn, they must be replaced.
 When a car wheel is out of alignment
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Experiment No. 17:

“To measure the surface roughness of a given work piece with the help of surface analyser.”

Theory:
Surface analyzer:
The greater the surface area of a thing, the more gas it can absorb. Analyzers that measure the
gas sorption capabilities of surfaces can be used to determine the surface area or pore size of
items as diverse as medicines and activated carbon. Using heat, suction, and inert gas, the
samples are cleaned. An absorbent gas is introduced into the chamber of the surface analyzer.
The amount of gas adsorption by the sample helps determine its surface area. A surface area
analyzer capable of testing for leaks, expelling gas, and conducting analysis at the same time
should be sought by the customer. An evaluation is then made to determine the roughness of the
surface as a result of stylus movement. Digitally, the surface texture meter displays the
roughness value on its display.

Applications:
Applications of surface texture include:

 Surface roughness of cutting tools used in lathe machines is determined by this

measurement.
 Film height is measured with this device.
 A variety of parts, such as engine blocks, are subjected to surface roughness measurements
following their manufacture.
 In addition to being used as a surface finishing tool, it is also employed as a quality control
tool.
Muhammad Hamza Sharif 2020-ME-104 MQA Lab-reports

Procedure:
 The object whose roughness is to be determined, and thoroughly clean its surface.
 This will allow you to manipulate the portable surface texture with a stylus.
 A computerized display shows the value of surface roughness.

Precautions:
It is important to take the following precautions when using a surface texture meter to measure
roughness.

 This instrument should not be used to measure the roughness of exceptionally rough
surfaces due to the risk of injuring the stylus.
 It must not be affected by temperature fluctuations in the environment. The temperature
of the thing should be kept constant.
 With a touch of pressure, the stylus should be dragged softly on the surface.

Comments:
If the roughness value is incorrect, it could be due to any of the following reasons:

 Inflations in temperature.
 Inefficiency of worker
 Inefficiency of worker
 While being dragged, the stylus makes inappropriate contact with the surface.
 The thing is put on an unstable table.
 Hands trembling while measuring roughness
 The stylus is moved in a zig-zag fashion.