BASIC ENGINEERING WORKSHOP

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INSTRUCTION FOR WRITING THE RECORD

Students should follow the instructions given below to write the Lab Record.

Right Hand Page in the Record book:

1. Serial number and Date of Experiment
2. Name of the Experiment
3. Aim of the Experiment
4. Tools required
5. Procedures for preparation of model
6. Result
7. Conclusion

Left Hand Page in the Record book:

1. Neat drawings of materials and prepared models
2. Dimensions of drawings and models prepared
3. Observation table
4. Marks table

Note:
1. Students should maintain their manual and record the reading neatly.
2. Given models to be prepared on the day and to be submitted to the faculty for the
correction and initials on the same day.
3. Students should submit the record of the previous experiments (models prepared) when
they come for the next practical classes.
4. All the suggestions given by the faculty should be attended to when the records are taken
back.
5. All measurements, results etc., must be expressed in S.I. Units only.

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Fitting Shop:
Safety precautions:
1. All the tools and measuring instruments are to be cleaned and kept in the respective places
when not in use.
2. The sliding parts and pins are to be properly lubricated.
3. The vice should not be over tightened; otherwise, it may damage the spindle.
4. The sharp edges of a chisel or scriber are to be covered with a cap to avoid getting
damaged and to prevent accidents.
5. The handles of hammers are to be checked for cracks etc.
6. The surface plate must be covered and kept when not in use and tools and jobs should not
be thrown on the surface plate to avoid damage to the surfaces.
7. Care is to be taken to see that the marking dots are not crossed, which is indicated by the
half of the punch dots left on the pieces.
8. Apply pressure in forward direction during hack sawing.
9. Don’t rub steel rule on the job.
10.Fix blade in hack saw frame with correct tension.
11.During hack sawing the coolant like water or lubricating oil is to be used.
12.Use precision instruments like Vernier calipers and Vernier height gauge carefully.
13.Files are to be cleaned properly after using.

Sheet Metal Shop:

Safety precautions:
1. Sufficient care is to be taken while cutting and folding of G.I. sheet.
2. Always wear uniform in the workshop, never wear loose clothes.
3. Never touch moving parts, belts or rotating tools etc.
4. In case of any fire, the electric supply should be disconnected.
5. Do not cut meal heavier than the capacity of snipes or shears.
6. Appropriate cutting tools and machines should be used for cutting tin sheets.
7. Do not use blunt cutting edges tools.
8. Do not place the hot soldering iron on any wooden surface; keep it on its stand.
9. Avoid breathing of flumes emanating from soldering flux.
10. Save your hands while working on sheet bending or sheet rolling machines.
11. Be careful while working on sharp edges to avoid injury.

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Welding Shop:
Safety precautions:
1. Do not weld around combustible or inflammable materials, where spark may cause fire.
2. Never weld containers, which have been used for storing gasoline, oil or similar materials,
without first having them thoroughly cleaned.
3. Check the welding machine to make sure that it is properly grounded and that all leads
properly insulated.
4. Never look at the arc with the naked eye. The arc can burn your eyes severely. Always use
a face shield while welding.
5. Prevent welding cables from coming in contact with hot metal, water, oil, or grease. Avoid
dragging the cables around sharp coroners.
6. Ensure proper insulation of the cables and check for opening.
7. Always wear the safety hand gloves, apron and leather shoes.
8. Always turn off the machine when leaving the work
9. Apply eye drops after welding is over for the day, to relive the strain on the eyes.
10. While welding, stand on dry footing and keep the body insulated from the electrode,
any other parts of the electrode holder and the work.

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INTRODUCTION TO MEASURING INSTRUMENTS

Engineering metrology: Measurement of dimension: length, thickness, diameter, taper angle,

flatness, straightness, profiles and others.
Ex: Slideway for machine tool (lathe), it must have specific dimension angle and flatness for its
desiredfunction.

Inspection: Checking the dimension of any defects of a part which has been produced.

Need of inspection:
i. To ensure that the part material or a component conforms to the
establishedstandard.
ii. To meet the interchangeability of manufacture.
iii. To control the performance of manufacturing process.
iv. It helps in the process of quality control.
v. It protects the customers in accepting the products.
vi. It helps in mass production of assembled part.
vii. It helps to assemble various parts produce at different station/place.
viii. It provides the means of finding out shortcoming in manufacture.

Sources of errors:
 Calibration error
 Error due to supports
 Error due to alignment
 Parallax error
 Error due to vibration
 Error due to location

Basic types of error:

i) Controllable (or systematic) error
ii) Uncontrollable (or Random) error

Precision and Accuracy: The performance of a measuring instrument is represented

by the terms precision and accuracy. A good instrument must be precise and accurate.

Precision: Precision of an instrument is the extent to which the instrument repeats its
result while making repeat measurement on the same unit of product. It is the
repeatability of the measuring process. It refers to the repeat measurement for the same
unit of product under identical condition. It indicates to what extent the identically
performed measurement agree with each other. If the instrument is not precise it will
give widely varying results for the same dimension when measured again and again.
The set of observations will scatter about the mean. The scatter of these measurement
is designated as (= the standard deviation) it is used as an index of precision. The less
the scattering the more precise is the measurement.

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Accuracy:
Accuracy of an instrument is the extent to which the average of a long series of repeat
measurement made on the same unit of product differs from the true value of the product. The
difference between the true value and the measured value is known as errorof measurement. It is
practically difficult to measure exactly the true value. Therefore aset of observation is made
whose mean value is taken as the true value of the quality measured.

Definition of standard:
A standard is something that is setup and established by authority as a rule for
measurement of quality and value etc.
Throughout the world generally 2 standards are followed for linear measurement
(i) British/English (yard)
(ii) Metric (metres) followed by most of the countries due to convenience.

Some important terminologies used in measurement:

1. Sensitivity it should be noted that sensitivity is a term associated with the measuring
equipment whereas accuracy & precision are associated with measuring process.
Sensitivity means the ability of a measuring device to detect small differences in a
quantity being measured.
2. Readability: Readability refers to the case with which the readings of a measuring
instrument can be read. It is the susceptibility of a measuring device to have its
indication converted into more meaningful number. Fine and widely spaced
graduation lines ordinarily improve the readability. If the graduation lines are very
finely spaced the scale will be more readable by using the microscope however with
naked eye the readability will be poor.
3. Repeatability: It is the ability of the measuring instrument to repeat the same results
when measurement are carried out by same observer, with the same instrument, under
the same conditions, without any change in location, without change in the method of
measurement.
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4. Reproducibility: Reproducibility is the consistency of pattern of variation in

measurement i.e closeness of the agreement between the results of measurement of
the same quantity when individual measurement are carried out by different observer, by
different methods, using different instruments, under different condition, locationand times.
5. Calibration: The calibration of any measuring instrument is necessary for the sake
of accruing of measurement process. It is the process of framing the scale of the
instrument by applying some standard (known) signals. Calibration is a pre-
measurement process generally carried out by manufactures. If accuracy is to be
maintained the instrument must be checked and recalibrated if necessary. As far as
possible the calibration should be performed under similar environmental condition
with the environment of actual measurement.
6. Magnification: Magnification means increasing the magnitude of output signal of
measuring instrument many times to make it more readable. The degree of
magnification should bear some relation to the accuracy of measurement desired and
should not be larger than necessary. Generally the greater the magnification the
smaller is the range of measurement.

Vernier Caliper: It has jaws on both sides for external and internal measurement
and also has blade/stem for depth measurement. The vernier calipers are made of
suitable good quality steel. The beam should be flat through its length.
The measuring faces should have ground finish, the portion of the jaw between the beam
and measuring faces are relieved. The fixed jaw is the integral part of the beam and the
sliding jaw in required to have good sliding fit along with the beam and should have
seizure free movement along the beam. A suitable locking arrangement should provided
on the sliding jaw in order to clamp it on the main beam. All graduations should be clearly
engraved so that they are legible.

Parts of Vernier Caliper:

1. Main Sale: It gives measurement upto one decimal places.
2. Vernier Scale: It gives measurement upto two places.
3. Knob/Thumb Screw: It use for the easy movement of jaws.
4. Depth Probe: It use to measure depth or hole.
5. Outer Jaws: It use to measure external gaps or width of an object.
6. Internal Jaws: It use to measure internal gaps/internal diameter of an object.
7. Locking Screw: It should be locked when object is placed in between the jaws.
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Micrometer: In order to achieve greater precision measuring equipment of a greater

accuracy and sensitivity must be used. Micrometer is one of the most common and most
popular forms of measuring instrument for precise measurement with 0.01 mm accuracy.
However micrometer with 0.001 mm accuracy is also available.

Principle of micrometer:
Micrometers work on the principle of screw and nut. We know that when a screw is turned
through nut by one revolution it advances by one pitch distance if the circumference of
the screw is divided into equal parts, its rotation through one division will cause the screw
to advance through length. Thus the minimum length that can be measured by such
arrangement will be so either by reducing the pitch of the screw thread or by increasing
the number of division on the circumference of screw, the length value corresponding to
one circumferential division can be reduced and consequently the accuracy of
measurement can be increased.

Least count of micrometer

LC = (pitch of the spindle screw / number of division in the spindle)

Figure illustrate an outside micrometer. It is used to measure the outside diameter and
length of small parts to accuracy of 0.01mm. The main parts of an outside caliper are:
1. U shaped steel frame
2. Anvil & spindle
3. Lock nut
4. Sleeve or barrel
5. Thimble
6. Ratchet

1. U shaped steel frame: The outside micrometer has U shaped or C shaped frame. It
holds all the micrometer parts together. The gap of the frame permits the maximum
diameter or length of the job to be measured. The frame is generally made of steel,
cast iron, malleable cast iron or light alloy. It is desirable that the frame of the
micrometer be provided with conveniently placed finger grips of heat insulting
materials.
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2. Anvil & spindle: The micrometer has a fixed anvil protruding 3mm from the left
hand side frame. The diameter of the anvil is the same as the diameter of spindle.
Another movable anvil is provided on the front of the spindle. The anvils are accuracy
ground and lapped with its measuring faces flat and parallel to the spindle. The spindle
is the movable measuring face with the anvil on the front side. The spindle engages
with the nut. It should run freely and smoothly throughout the length of its travel.
There should be no backlash between the spindle screw and nut. There should be full
engagement of nut & screw when the micrometer is at its full reading.
3. Lock nut: A lock nut is provided on the micrometer spindle to lock it when the
micrometer is at its correct reading. The design of the locknut is such that it effectively
locks the spindle without altering the distance between the measuring faces. It thus
retains the spindle in perfect alignment.
4. Sleeve or Barrel: The sleeve is accurately divided and clearly marked in 0.5mm
division along its length which serves as a main scale. It is chrome plated and
adjustable for zero setting.
5. Thimble: The thimble can be moved over the barrel, it has 50 equal divisions around
its circumference.
6. Ratchet: The ratchet is provided at the end of the thimble. It is used to assure accurate
measurement and to prevent too much pressure being applied to the micrometer.
When the spindle ratches near the work surface to be measured the operator uses the
ratchet screw to tighten the thimble. The ratchet automatically slips when the correct
(uniform) pressure is applied and prevents the application of too much pressure.

Basic concept of limit fits and tolerances:

Whatever may be the advancement in the field of machine tool technology, it is not
possible to make any part precisely to a given dimension due to Tool wear, Deflection,
Vibration of m/c tool, Change of temperature, Human error etc. Secondly if by chance
the part is made exactly to a given dimension, it is impossible to measure it accurately
enough to prove it. Thirdly if attempts are made to achieve perfect size, the cost of
production will increase tremendously.

A. Limit: The limits of size of a part are two extreme permissible sizes between
which the actual size may lie. Since it is not possible to make all parts exactly
alike and to exact dimension (due to variability in man machine tool) and material,
some permissible variations in dimensions are allowed. Ex: If a 20mm nominal
diameter is to be produced the limits may be 19.9 to 20.1 mm.
B. Fits: Fit is defined as the degree of tightness or looseness between two making
parts to perform a definite function when they are assembled together. Ex shaft in
a bearing.
C. Tolerance: Tolerance is the permissible variation in the dimension of a part as it
is not possible to produce a part to exact specified dimension. It is the differences
between higher and lower limits of dimension of a part.

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EXPERIMENT

VERNIER CALIPER

AIM: To measure various physical quantities like length, height, diameter and depth using
vernier caliper.

TOOLS / EQUIPMENT REQUIRED: Vernier caliper, different components.

PRINCIPLE:
Vernier Calipers is the most commonly used instrument for measuring outer and inner
diameters. It works on the principle of Vernier Scale which is some fixed units of length
(Ex: 49mm) divided into 1 less or 1 more parts of the unit (Ex: 49mm are divided into 50
parts). The exact measurement with up to 0.02mm accuracy can be determined by the
coinciding line between Main Scale and Vernier Scale.
Total Reading = M.S.R + (L.C * V.S.C)
Where: M.S.R – Main Scale Reading
L.C – Least Count
V.S.C – Vernier Scale Coincidence

PROCEDURE:
1. The Least Count is to be determined as L.C= 1MSD - 1VSD = 1- 49/50 =0.02mm.
2. The workpiece is placed between the jaws of Vernier Caliper correctly.
3. Push the jaws firmly against the work piece.
4. Lock the clamp screw so that the jaws don't move, and take the reading.
5. The reading on Main scale which is just behind the first Vernier Scale Division is noted
as Main Scale Reading.
6. The Division on Vernier Scale which coincides with the line on Main Scale is noted
down as Vernier Coincidence.
7. The length, height and diameter can be calculated using the given Formula.

OBSERVATION TABLE:
Physical Main scale Vernier scale Total Reading
Component quantity Reading Reading (MSR) + (VSC
measured (MSR) (VSC X LC) X LC)

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RESULT: Physical quantities like length, height, diameter and depth of the given specimens
are measured using Vernier caliper.

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MICROMETER

AIM: To measure the length and diameter using micrometer.

TOOLS / EQUIPMENT REQUIRED: Micrometer, different components.

PRINCIPLE:
Micrometer is one of the most common and most popular forms of measuring
instrument for precise measurement with 0.01mm accuracy. It works on the
principle of screw and nut. We know that when a screw is rotated through one
revolution it advances by one pitch distance i.e. one rotation of screw
corresponding to a linear movement of a distance equal to pitch of the screw
thread.
On a Metric Micrometer head scale is graduated into 50 equal divisions. In
the BarrelScale (pitch scale) each division is 0.5mm.
Total Reading = BSR +
(TSC * LC)Where BSR:
Barrel Scale Reading TSC:
Thimble Scale Coincidence
LC: Least Count

PROCEDURE:
1. The least count is to be determined as LC = (Value of 1 division of barrel scale
/ No. ofdivisions on thimble scale) = 0.5mm/50 = 0.01mm.
2. The component is placed between the spindle and anvil after the instrument is
adjustedfor zero error.
3. Component is held strongly without applying any pressure on the instrument.
4. Turn the thimble or ratchet to close the rods around the component to be measured.
5. Flip the locking lever to lock the rods in place.
6. The value of the main scale is noted down. The main scale division just
coincides withthe index line.
7. Take the thimble scale reading (TSR) which coincides with the reference
line on thesleeve.
8. The length and diameter can be calculated using the given Formula.

OBSERVATION TABLE:
Barrel Total Reading
Physical Thimble scale
Component scale (BSR) + (TSC
quantity Reading
Reading X LC)
measured (BSR)
(TSC X LC)

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