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Production Technoloy Lab 012110045519 1
Production Technoloy Lab 012110045519 1
Production Technoloy Lab 012110045519 1
LAB MANUAL
Subject: Production Technology
Semester-V
LIST OF EXPERIMENTS:
A-Performance
B- STUDY
Aim: - Linear Measurement Using Vernier Height Gauge & Micrometer (Internal &
External Depth)
Apparatus :- Vernier Caliper, Vernier Height Gauge, Micrometer, And Measuring Parts
This is just as vernier caliper, equipped with special base block and other
attachment which make the instrument suitable for height measurements. Along with the
sliding jaw assembly, arrangement is provided to carry a removable clamp. The upper
and lower surfaces of the measuring jaws are parallel to the base, so that it can be used
for measurements over or under surface. The vernier height gauge is mainly used in the
inspection of parts and work. With a scribing attachment in place of measuring jow, this
can be used to scribe lines at certain distance above the surface. However dial indicator
Can also be attached in the clamp and many useful measurements made as it exactly
gives indication when dial tip just touching surface. For all these measurement, use of
surface plate as datum surface is very essential.
PROCEDURE-
1. Take the material (sample) for which the value must be measured.
2. Check the vernier and main scale must coincide at 0
3. After checking the 0 mark put the sample piece and slowly leaves the measuring jaw
over the piece
4. Tight the screw and measure the main scale also vernier scale reading
5. The line coincide with the main scale that the VSR
6. By adding MSR with VSR*L
DIAGRAM OF VERNIER HEIGHT GAUGE
OBSERVATION TABLE FOR VERNIER HEIGHT GAUGE
VERNIER INSTRUMENTS:-
The three elements of venire caliper, viz. beam, fixed jaw, and sliding jaw permit
substantial improvements in the commonly used measuring techniques over direct
measurement with line graduated rules. The alignment of the distance boundaries with
the graduations of the rule is ensured by means of the positive contact member
The end of the screw forms one measuring tip and the other measuring tip is
constituted by a stationary anvil in the base of the frame. The screw is threaded for
certain length and is plan afterwards. The plain portion is called sleeve and its end is the
measuring surface. The spindle is advanced by turning thimble connected to the spindle.
The spindle is aside fit over the barre land barrel is the fixed part attached with frame.
The barrel is graduated in unit of 0.05cm.i.e.20division per cm, which is the lead of the
screw for one complete revolution. The thimble has got 25 divisions around its periphery
on circular portion. Thus it sub-divides each revolution of the screw in 25 equal parts;
i.e.each division corresponds to 0.002cm.
PROCEDURE
1. The whole movable jaw assembly is adjusted so that the two measuring tip just touch
two parts to be measured.
2. Then lock nut is tightened.
3. Final adjustment depending upon the sense of correct feel is made by the adjusting
screw.
4. Measuer the main scale readings i.e. the line coincide with o mark of vernier scale and
noted down the reading.
5. The measuring tip is so designed as to measure inside as well as outside dimension.
6. Calculate MSR, VSR and TSR
1. Take sample piece and slowly move the screw in clockwise direction and clock the nut
2. Now measure the circular part and line coinciding with the scale.
3. Calculate MSR, VSR and TSR. Take down the reading and follow the same
procedure.
OBSERVATION TABLE
It is used for measuring the depth of holes, slots and recessed areas. It has got one
shoulder which act as reference surface and is held firmly and perpendicular to the center
line of the hole. Here also for larger ranges of measurements, extension rod are used. The
screw micrometer depth gauge has range of 20mm or 25mm. The length of the
micrometer depth gauge varies from 0to 225mm.The rod is inserted through the top of
the micrometer. The rod is marked after every 10mm so that it could be clamped at any
position in using this instrument, firth it must be insured that the edge of the hole is free
from barrel
1. To measure the depth of any material, use the micrometer depth gauge.
2. Take the sample piece, the length of the rod varies from 0 to 225mm.
3. Various rods are used as per requirement at the certain limit that gauge will move as it
is by rotating screw in clockwise direction.
4. Tight the screw and measure the main scale and circular scale also adding the initial
value of rod this gives MSR, VSR and TSR by adding LC
5. Note down reading by following procedure.
OBSERVATION TABLE
RESULT
Linear measurement using vernier caliper, vernier height gauge and micrometer (internal
and external depth) are successfully completed.
EXPERIMENT NO 2
Aim:- Angular measurement using Combination Set, Bevel Protractor , Sine Bar and
Clinometers
.
Apparatus :- Combination Sets, Bevel Protector, Sine Bar and Clinometers.
Theory
BEVEL PROTECTOR
It is use for measuring &lying out of angles accurately and precisely within 5
minutes. The protector dial is slotted to hold a blade which can be rotated with dial to the
required angle and also independently adjusted to any desired length. The blade can be
locked in any position.
SINE BAR
The sine principle uses the ratio of the length of two sides of a right triangle in deriving a
given angle. It may be noted that devices operating on sine principal are capable of self
generation. The measurement is usually limited to 45 degree from loss of accuracy point
of view. The accuracy with which the sine principle can be put to use is dependent in
practice, on some from linear measurement. The sine bar itself is not complete measuring
instrument. Another datum such as surface plate is needed, as well as other auxiliary
instrument, notably slip gauge, and indicating device to make measurements.
(a) A Compound angle should not be formed by miss dignity of w/p with the sine bar.
This can be avoided by attaching the sine brand work against an angle plate.
(b) Accuracy of sine bar should be ensured.
(c) As far as possible longer sine bar should be used since4 many errors are reduced by
using longer sine bar.
Combination Sets :-
Precautions :-
Result :-
To Perform angular measurement using sine bare with slip gauge study of
clinometers , angle , gauge , combination set and bevel protractor is successfully
completed
EXPERIMENT NO:- 03
AIM :- Measurement Of Screw Thread Diameter Using The Floating flat form.
Measuring machine.
Measuring machine shown in the fig. Consists of three main units. First base
casting carries a pair of centers on which a threaded work piece is mounted. Another
carriage called as lower late is mounted on base. Which is exactly at 90 degree to base
but capable of moving parallel with the axis of thread. On this lower slide is provided
with another. Carriage called as top slide and capable of moving towards the center (i.e.
90 degree to the thread axis) on the one and f top slide there is one head having a large
thimble inability to read up to 0.002 mm and on the other and just opposite to it is a fixed
anvil which is spring loaded and its zero position is indicated dry fidrcial indicator. On
this top slide two supports one provides for supporting were and viz pieces for
measurement of minor dial and effect diameter.
WORKING:-
PA = OP - DA
= d/2 cosec x/2-d/2
= d/2 {cosec x/2-1}
V PQC,
Cot x/2 = PQ/QC
PQ = QC * COT x/2
AQ = PQ - PA
=QC Cot x/2 - d/2 (cosec x/2 -1)
=1/2 P
P =2 AQ
=2[QC Cot x2 - d2 (Cosec x/2-1)]
=2[P/4 Cot x/2 - d/2 (cosec x/2 - 1)]
Result:- thus screw thread diameter were calculated using floating platform diameter
Results:-
1) External diameter = R2 - R1 = -------------- mm.
2) Internal diameter = R2 - R1 = -------------- mm.
3) Pitch of threads = R2 - R1 = --------------- mm.
4) Threads angle = R2 - R1 = --------------- mm.
Precaution:-
1) Obtain clean picture of cross line and the cross thread seen through the
eyepiece.
2) For angular measurements lines must remain parallel to flank edge to
the tooth.
EXPERIMENT NO-5
Apparatus- Autocollimator
Theory-
Principal of Autocollimator: - it works on the principal that if the light source is placed
in the focus of a collimating lens then the light is projected as parallel beam. If this beam
is made to strike a plane reflector normal (perpendicular ) to the optical axis then it is
reflected back along its own path brought to the same focus.
But if reflector is titled through a small angle the parallel beam is reflector
through twice that angle and is brought to focus in same plane as a light source but to one
side at a distance x=2
F – Focal length of collimating lens
Construction: - A line diagram of injected reticule autocollimator consists of three parts
as micrometer, lighting unit and collimating lens.
Working: - when lamp is illuminated then ray from lamp passes through convener, target
reticule and stills on 45 transparent beam splitter. Beam splitter then reflector is placed
normal to optical axis which reflects the ray along its own path and an image is
transparent beam splitter and the image is seen through eye piece of microscopic on
external reflector. Now we tilt the plane reflector by a small angel the ray will reflect
back but twice the angle and in this condition we couldn’t fine the image on microscope
eye piece. Therefore in order to obtain an image operate micrometer microscope till the
image is seen or collected on an external reflector. Stop rotating micrometer, note down
the reading. The reading are directly in angular value that is in minutes 1, 2, 3 and 10 on.
Hence the difference in two reading of micrometer gives the value of ‘x’
Therefore we can calculate from equation x= 20
Where f is focal length of collimating lens.
Auto collimator is quite accurate and read unto 0.1 sec and used for distance.
Procedure:-
(1) Make the distance of 50mm internal on the w/p
(2) Set the cross wire so that two cross will coincide.
(3) Set the mirror so that the cross wire will be visible
(4) Move the reflector on next 50mm mark and adjust it to see reflection of cross
wire.
(5) Take the reading of reflected crosswire deviated or moved up or down. Measure
the distance between two crosswire
Result: - The mean deviation of surface is found out to be 0.024 mm upward and
downward
Conclusion:- Thus from the experiment we conclude that the surface provided was
not straight.
Precaution:-
Aim :- Linear Measurement Using Dial Gauge, Slip and Calibration of Dial Gauge.
Theory :-
The different component of dial gauge indicator is shown in fig. It consist
of plunger, removable contact pt, stem a transparent glass cover, calibrated dial pointer,
bezel camp or bezel locking nut. Revolution counter in order to counter in order to count
the no of revolution of a pointer, dust proof cap etc.
It consists of a plunger which slides in bearing and carries a rack
with it. The rack is meshed with pinion (P1) again pinion (P2) and gear (G2) are on same
spindle [because of which magnification is taking place]. The gear (G1) is meshed with
(P1) again pinion (P2) and gear (G2) are on spindle basically gear (G2) is meshed with
pinion (P3) on whose spindle pointer is attached. The pinion (P3) is meshed with gear
(G3) on which a light is here spring is attached in order to guide the movement of plunger
a rack guide is provided and to bring the plunger to its initial position a light coil spring is
attached to plunger.
Any linear displacement given causes rack to move upward during this
upward movement as rack is meshed with pinion (P1) and gear (G1) rotate by some
amount but as the no of teeth on gear (G1) is more compared to that of pinion (P2) which
is meshed with it rotate more time. Let us say if there is 100 teeth on gear G1 and 10
teeth on pinion P2 the 1st stage of magnification is 100/10=10 times again.
Therefore overall magnification can be calculated,
(G1XG2)/ (P2XP3)
EG : (100x100/10x10) = 100
In this way dial indicator works you can take diff readings by
keeping standard and object. Then comparison can be made.
The magnification is about 250-1000.
Dial gauge -
Dial gauges divided in two categories, type1 &type2for general engineering purpose
depending upon the movement of the plunger. These are manufactured in two grades
,grade a and grade b, with total plunger movement or lift of 3,5 and 10mm. Type1 dial
gauge has the plunger movement parallel tip the plane of dial and type 2 has the plunger
movement perpendicular to the plane of dial
Indicator gauge-
Dial indicator has been used with several auxiliary devices for a wide variety of length
measurement. Obviously dial indicator can be used for carrying the needed
complimentary function, resulting in a single tool, it is known as indicator gauge.
It must be remembered that indicator gauge are always comparator type measuring
instrument and require the use of a setting gauges for establishing the basic measuring
position
Slip gauge-
Slip gauges with three basic forms are commonly found. These are rectangular square
with center hole, and square without center hole.
Rectangular forms is the more widely used because rectangular block are less expensive
to manufacture, and adopt themselves better to application where space is restricted or
excess weight is to be provided.
For certain application squarely gauges, through expensive, are preferred. Due to their
large surface area, they wear longer and adhere better to each other when touch to high
stack.
PROCEDURE :-
For calibration checking.
1. The slip gauge is used for the purpose of checking the calibration.
2. A known slip gauge is taken and placed on the surface, the indicator gauge
which has
3.The least count of instrument is calculated
4. The deflection of the pointer is noted and the final reading is obtained
5. For measuring the dimension of a given sample , a known slip gauge is
matched with the given sample ;the comparator is put on the surface without disturbing
the reference setting
7. If the sample is greater then reference one, the pointer shows deflection which is
measured and reading is calculated.
OBSERVATION :
Slip gauge
For linear measurement least count = (0.2/200)=0.001 mm/div
For standard dimension
For specimen
Main scale reading =MSR = -------
Circular scale reading =CSR= ---------
Total reading (TR) = MSR + ( CSR * LC )
Total Height of specimen = -----------
Result
:- Thus we have completed the linear measurement using dial gauge and
calibration of dial gauge.
EXPERIMENT NO:- 7
Optical Flat
Optical flats are cylindrical in form with the working surfaces flat and are of two types:
Type A-It has only one surface flat. The working surface of this type of flat is indecently
by an arrow head on the cylindrical surface pointing towards the working surfaces.
Type B-It has both the surfaces flat and parallel to each other.
Type A are used for testing the flatness of precision measuring surface of flats, slip
gauges, measuring tables, etc. Type B are used for testing measuring surfaces of
micrometers, measuring anvils and similar length measuring devices for testing flatness
and parallelism.
These are generally made of either fused quartz or borosilicate glass. This glass is clear
and colorless and free from inclusions and defect like bubbles, internal strains and
extraneous matter.
The cylindrical surface of the optical flat are finished by grinding and the working
surfaces are finished by lapping and the polishing process. The finishing is done to such
an extent that straight and parallel interference b fringes are produced when the optical
flat is viewed under a monochromatic source of light by placing it in contact with
reference flat surface. Their edges are generally beveled to45 degree by a suitable
grinding or polishing process so that the edges are free from any chips.
Out measurement of length variation when reference plane of the measurement is
established and both indicator and object are located in a definite relation to the common
reference plane. These are achieved by means of appropriate gauging set-ups.when dial
indicator united with member which serve.
PROCEDURE :-
1. Start the optical flat m/c and place w/p on platform whose curvature is to be
measured.
2. Now the Optical flat is placed on it and observed the types of fringes appear on
the optical flat.
3. To take a current reading applying the finger tip at a center of optical flat and
observed the behavior of fringes made on optical flat.
4. By comparing behavior on the fringes with std-one & decided whether the surface
is convex concave or flat etc.
Result: - Thus we are studying the different types of flat or curvature of surface.
PRECAUTION :-
1) Take care while putting optical flat on surface that finished surface is on w/p
2) Handle the optical flat carefully while observing the curvature
3) Apply on the moderate pressure for proper contact
EXPRIMENT NO 8
1. Theory
2. Gauge
3. Classification Of Gauges
4. Taylor’s Principals
5. Problem
EXPERIMENT NO :- 10
• Chart
• Theory
• Process : Planning Sheet
• List Of Process Planning Sheet
• Steps Of Process Planning
• Preparation Of Tolerance Chart
1) Working Dimensions
2) Resultant
3) Intermediate Resultant
4) Tolerance Stack
EXPERIMENT NO :- 11
1. Control Chart
3. Process Capability
5. Problem
EXPERIMENT NO :- 12
Sampling Inspection
Acceptance Sampling by Attributes
Construction of O.C .Curve
1) Acceptance Quality Level (AQL)
2) Lot Tolerance Percentage Defective (LTPD)
3) Producer Risk
4) Consumer Risk
Sampling Plan
1) Single Sampling Plan
2) Double Sampling Plan
3) Sequential Sampling Plan
4) Numerical
Experiment No :- 13