3-5 Metrology

DAE Mechanical
Technology
2nd Year
2011-2012
Metrology
(MECH-252)
1. Lesson Plans
2. Operation Sheets
NAVTTC / TEVTA/ JICA
December 2011
This TLM has been developed in the "Project for Development of Center of Excellence of Technical Education", on
Mechanical Technology at Government College of Technology Railway Road (GCT RR), by a collaboration work
among National Vocational & Technical Training Commission (NAVTTC), Punjab Technical Education and Vocational
Training Authority (TEVTA) and Japan International Cooperation Agency (JICA).
Metrology
(MECH-252)
LESSON PLANS
Table of Contents
Introduction to Measurement
History of Measurements
Quality Control
SI UnitsISO Standards
FIT- Tolerance - Allowances
Surface Plates
Spirit level Engineering Parallel
Gauges
Gauges
Adjustable Measuring Tools
Micrometer
Dial Indicator
Angle measuring tools
Angle Measuring Tools
Precision Measuring instruments
Precision measuring instruments
Precision measuring instruments
Accuracy in measurements
Classification of Errors
Dial Instruments
Dial Instruments
Taper Measurements
Tool Marker Microscope
Profile Projector
Optical Flats
Mechanical comparator
Electrical / Electronics comparator
Digital Instrument
Digital instrument
Digital instrument
Coordinate Measuring Machines
Gear Testing Machine
Back Lash Measurement
Digital 3-D Scanner
Digital Read OUT
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
65
67
69
71
LESSON PLAN
TITLE OF TOPIC (Short, Description)
Introduction to Measurement
Subject (Course Title) MECH-252
Lesson No:
01
Name: Saeed Karim
Time: 40 mint
GENERAL OBJECTIVES:The student will be able to know about

the subject metrology
SPECIFIC OBJECTIVES:1. The student will be able to know
about the contents of subject
measurement.
Time
allocated
Expected Entry behaviors
TOPICS,NOTES (Brief)
With teacher student activities
Key points/Reminders/Sketch
Teaching Aids/Evaluation
METROLOGY :Metrology is science of measurements. Practice of metrology involves

precise measurement.
Scientific Study of measurements is
called metrology.
Metrology is mainly concerned
with,
Metrology is not concerned to length
i. Establishing the unit of
measurement but also concerned with
measurements.
industrial inspection.
ii. Developing methods of
measurement.
iii. Researching into the causes
of measuring errors and
eliminating these.
Time
allocated
Objectives of Metrology:The basic objective is to provide the
accuracy at minimum cost.
1. Thoroughly evaluation of newly
developed product.
2. To determine process capabilities.
3. To determine measurement
instruments capabilities.
4. To minimize the cost of inspection.
5. Standardization of measuring
methods.
6. Maintenance of accuracies of
measuring instruments.
Testing & Follow Up:-
(to see if leaner accompanied information or skill)
1) Explain Metrology.
2) Describe objectives of metrology.
Special Assignment:-
(Usually home work)

Prepare notes on objectives of metrology.
Tools Material & Aids:Board marker, Duster lesson Plan.
____________________________
Reference: -
(Author, title, publisher, page or chapter number, date of publication)

1) Engineering Metrology by R.K. Jane.
LESSON PLAN
History of Measurements
Lesson No:
02
Name: Saeed Karim
Time: 40 mint
GENERAL OBJECTIVES:i) The student will be able to know about

the History of Measurements.
ii) The student will be able to know about
the importance of Measurements.
SPECIFIC OBJECTIVES:-
1. The student will be able to

understand the importance of
Measurements.
Time
allocated
History of Measurements:It is well known saying that knowledge
about anything is complete only when
it is expressed in numbers and same
thing is known about it. Four thousand
years ago the parts of human body.
Later on, they were standardized.
Science of measurement has made

considerable progress when king
Henry decided that yard is the
distance from point of his nose to
the end of his thumb. In 1929 at a
meeting
of
international
commission of weight and
measure, a universal standard of
measurement was approved.
Time
allocated
Importance of Measurement:Measurement is very important in

today life. Quality and quantity can
never
be
achieved
without
measurement.
Measurement play key role in quality
control without measurement. We
cannot know about product whether
according to size or not.
1. We need measurement to make

thing with our design or other
design.
2. We need measurement to control
quality.
3. We need measurement for
scientific description.

1) Explain History of Metrology year wise.
(Usually home work)

Prepare notes on the importance of Measurements In modern
engineering
Tools Material & Aids:Board marker, Duster lesson Plan.
____________________________
Reference: -
(Author, title, page or chapter number, date publication)

1) Dimensional Metrology by T. Butch .
LESSON PLAN
Quality Control
Lesson No:
03
Name: Saeed Karim
Time:

the Quality Control.
SPECIFIC OBJECTIVES:1. The student will be able to know about
the Quality Control.
Time
allocated
Quality:1. Quality is fitness for use.
i.
Customer is king
2. Quality is conformance to
requirements.
ii.
Correcting and preventing loss.
iii.
Customer requirement.
3. Quality should be aimed at the needs

of customer, present and future.
Quality Means Meeting:Customer agreed requirement at

lower cost, first time and every time.
Time
allocated
Quality Control:-
Advantages:-
It is a scientific method of inspection by i.

adopting we get the best product in
minimum possible time with minimum ii.
cost.
iii.
Insured rapid inspection.

Fore casting trouble.
Increases output and reduces
waste.
iv.
Maintains complete record of daily

quality.
v.
More economical use of material.

1) Explain the purpose Quality Control.
(Usually home work)

Prepare notes on how does Quality Control increase production
Tools Material & Aids:Board marker, Duster, Lesson Plan.

____________________________
Reference: -
(Author, title, publisher, page or chapter number,publication)

1) Industrial inspection Method by Michelon
LESSON PLAN
SI UnitsISO Standards
Lesson No:
04
Name: Saeed Karim
Time:

SI Units and ISO Standards.
1. The student will be able to know about

SI Units and ISO Standards.
Time
allocated
SI Units :-
Fundamental units.
The 11th general conference of weights

and measure recommended a system of
fundamental and derived units for
international use. This system is named as
SI units.
Length (l)
Mass (m)
Time (t)
Temperature (T)
Current (I)
Luminous Intensity (Iv)
Amount of Substance (n)
Supplementary Units:Plan Angle(, , , )

Solid Angle ()
Time
allocated
ISO Standards:-
ISO 9000: QM & QA Selection & use
1970-European countries made quality

Standard.
ISO 9001: QA in design
1979-British standard institute presented

quality standard.
1987-ISO standards were presented and
approved.
ISO 9002: Prod. & installation

ISO 9003: Final inspection & Test
ISO 9004: Guide lines
ISO 8402: Quality Vocabulary

1) Explain about standards.
(Usually home work)

Prepare assignment showing quality standards.
____________________________
Reference: -
(Author, title, publisher, page or chapter number, publication)

LESSON PLAN
Lesson No:
4-A
Name: Saeed Karim
Time:
FIT- Tolerance - Allowances

limit system.
SPECIFIC OBJECTIVES:1. The student will be able to understand
and system of limits and tolerances.
Time
allocated
Allowance:-
Intentional difference between
mating parts
1. Clearance allowance
2. Interference allowance
FITS:-
Degree of tightness and looseness

between mating parts. Clearanceinterference Transition
difference between high limit and low

limit.
1. Unilateral
2. Bilateral
Tolerance:-
Time
allocated
Geometric Tolerance:-

1) Draw a sketch showing tolerance on difference parts .
(Usually home work)

Prepare notes on Geometric Tolerance.
____________________________
Reference: -

10
LESSON PLAN
Lesson No:
05
Name: Saeed Karim
Time:
Surface Plates

Surface Plates.
1. The student will be able to understand

about linear measurement s supporting
tools.
Time
allocated
CI Surface Plates:-
1. Commonly use
2. Made of cost Iron
3. Wear resistance
Glass Surface Plates:-
1. Light weight
2. Used for accuracy
3. Do not effect in temperature
1. Wear resistant very high

2. Low effect of temperature
3. Neglectable friction
Granite Surface Plates:-
11
Time
allocated
Straight Edge:Used to check straightness of parts

1. Flat type
2. Knife type

1) Why Surface Plates are used?
(Usually home work)

Draw neat sketch of different Surface Plates.
____________________________
Reference: -

1) Production Engineering by R.B. Gupta.
12
LESSON PLAN
Spirit level Engineering Parallel
Lesson No:
06
Name: Saeed Karim
Time:

supporting tools.

about the Spirit levels and surface
gauge.
Time
allocated
Spirit level:-
Used to check level of surfaces.
1. Spirit level
2. Engineers level
Engineers Parallel:1. Rectangular in shape

2. Used to check parallelism
3. Setting work pieces on machines.
13
Time
allocated
Universal Surface Gauge:1. All sides adjustable.

2. Scriber may be tilted in any position.
3. Most suitable tool for layout work.

1) Describe the use of Surface Gauge?
(Usually home work)

Draw neat sketch of different Surface Gauge showing all parts.
____________________________
Reference: -

1) Slop Theory by Anderson.
14
LESSON PLAN
Lesson No:
07
Name: Saeed Karim
Time:
Gauges

gauges.

about the use of different gauges.
Time
allocated
Ring Gage:-
Used to check external diameter of a

shaft or round objects.
1. Standard ring gage

2. Special ring gage
Two members go and not go.

Made in pairs
Go ring gage/ not Go ring gage
Used to check internal diameters of a

work pieces.
Plug Gage:-
Having two members Go and not go

on same gage.
15
Time
allocated
Snap Gauge: Fix type

Adjustable type
Go and not Go members
Radius Gauge:-
A thin, flat gage made of steel used

for measuring internal and external
radius.
Male radius or radius Female
radius or Fillet.

1) Describe the use of different Gauges?
(Usually home work)

Draw neat sketch of different Gauge showing all parts.
Tools Material & Aids:Board marker, Duster, Lesson Plan, gage.
_________________________________
Reference: -

16
LESSON PLAN
Lesson No:
08
Name: Saeed Karim
Time:
Gauges

gauges.
1. The student will be able to

understand about the use of
different gauges.
Time
allocated
Angle Gage:-
Consists of different blades.

Blades having different fix angle.
Screw Pitch Gage:-
Also called thread gage.

For checking pitch of threads.
Consists of different blades.
17
Time
allocated
Commonly known as wire gage or
SWG.
Standard Wire Gauge:-
Available in round and rectangle in

shape.
Feeler Gauge:-
Used to measure sizes of narrow

slots, gapes.
Consists of number of blades in
different sizes.

1) Explain the use of feeler Gauge?
(Usually home work)

Draw neat sketch of different Gauge identification.
_________________________________
Reference: -

1) Production Technology by R.B. Gupta.
18
LESSON PLAN
Lesson No:
09
Name: Saeed Karim
Time:
Adjustable Measuring Tools

universal Caliper.

about the use of different universal
Caliper.
Time
allocated
Vernier Caliper:-
Precision instrument used for
different measurements.
Fix jaw Sliding jaw
Lock- Depth bar main Scale, Vernier
Scale.
Based on relationship between two
different scales.
0.02 & 0.05 mm least count.
19
Time
allocated
Invented by French Engineer Pierre
Vernier in 1631.
Made of stainless steel.
Zero error cannot be removed.
Protect it from dust and dirt.

1) Take a work piece and measure its sizes.
(Usually home work)

Draw neat sketches showing Vernier measurements.
_________________________________
Reference: -

20
LESSON PLAN
Lesson No:
10
Name: Saeed Karim

Time:
Micrometer

Micrometer.

about the use Micrometer .
Time
allocated
Micrometer:-
Precision instrument
Used for outside dimensions.
Frame Main scale, Thimble scalelock Ratchet Anvil spindle.
Principle- Nut and Bolt Calibrated
screw 0.01 mm least count.
21
Time
allocated
Invented by Jean Palmer in 1848.
Made of wear resistant steel.
Slip gages are used for checking the

accuracy of micrometer used for
calibration.
Micrometer stands are used for better
results.
Protect it from dust and dirt.

1) Explain the use of Micrometer.
(Usually home work)

Draw neat sketches showing micrometer readings.
_________________________________
Reference: -

22
LESSON PLAN
Lesson No:
11
Name: Saeed Karim
Time:
Dial Indicator

Dial Indicator.

about the function of Dial Indicator .
Time
allocated
Dial Indicator:-
Precision tool used for comparing

size of object with standard and
deviation is shown on dial.
Spindle Bushing cover

Large hand Small hand
Central Lug- revolution counter dial.
Hold in stand for use.
23
Time
allocated
Used for checking parallelism
squareness, alignment roundness.
Using light pressure on contract

point of spindle, through gear train
and lever system shown on dial.
0.01 mm is least count.
Dont strike with other parts.

1) Explain the Dial Indicator.
(Usually home work)

Draw neat sketch of Dial Indicator.
_________________________________
Reference: -

24
LESSON PLAN
Lesson No:
12
Name: Saeed Karim

Time:
Subject (Course Title): MECH-252

GENERAL OBJECTIVES:i)
The student will be able to understand the

use fix angle measuring tools
SPECIFIC OBJECTIVES:1.
The student will be able to

understand about fix angle
measuring tools.
Time
allocated
Fix angle measuring tools:1. Combination square

Square head and grooved steel
rule.
2. Try square
commonly used for checking
squareness and 90o angle.
3. Double square
used for checking squarness and
900 angle from both sides.
25
Time
allocated
4. Die maker square commonly

used by die makers. Adjustable
type.
5. Engineers Square
checking for precision squareess
and 90o angle, adjustable type.
6. Center square
center head and grooved steel
rule.
For locating centre of round objects
and checking 450 angle.

Describe the difference between centre square and combination
square.
(Usually home work)

Draw neat sketches of six square for identification.
Tools Material & Aids:Board marker, Lesson Plan, Squares
Reference: -

Slop theory by Anderson__
26
LESSON PLAN
Lesson No: 13
Name: Saeed Karim
Time:
GENERAL OBJECTIVES:The student will be able to know the

use of angle measuring tools.
SPECIFIC OBJECTIVES:1.
The student will be able to understand

the use of fix angle measuring gauges.
Time
allocated
Angle gauges:
27
i.
Thread angle gauges

used for checking pitch of
thread ,also called screw pitch
gauge. Different size
blades/Leaves are fitted in sets.
ii.
Grinding gages
used for angle checking angle of
grinding wheels for accurate
grinding.
Time
allocated
iii.
Drill angle gage

also called drill gage for
checking the dia/size of drill bit.
iv.
Drill point gage

for checking the angle of twist
drill.
v.
Tool angle gage

also called v gage. v shaped,
checking for angle of cutting
tool.

Describe the use of drill point and Drill gage.
(Usually home work)

Draw neat sketches of gages for identification.
Tools Material & Aids:Board marker Lesson Plan Different pages
Reference: -

Production technology by R.B.Gupta.
28
LESSON PLAN
Angle Measuring Tools
Lesson No:
14
Name: Saeed Karim
Time:

the use of angle measuring tools.

about the use of adjustable angle
measuring tools.
Time
allocated
Adjustable Angle Measuring tools:-
29
1-Without graduation angle
Measuring Tools
i.
Sine Bar
a hard grinded steel bar having
same dia, two plugs fitted on both
sides, used for setting and
measuring angles.
ii.
Universal Bevel
Consists of stock and blade for
checking and transferring angles.
iii.
Combination Bevel
Consists of a stock and two blades
for checking angles.
Time
allocated
2-With graduation angle Measuring
Tools.
i.
ii.
iii.
iv.
Bevel protractor
0-900 and 900-0
Vernier Bevel Protractor
1/12o least count
Steel Protractor
0-180o
Dial Protractor
having dial
1/12o least count.

1) Explain the use of Dial Protractor.
(Usually home work)

Draw neat sketch of Vernier bevel Protractor.
Tools Material & Aids:Board marker, Duster, Lesson Plan, Protractors.
Reference: -

30
LESSON PLAN
Lesson No: 15
Name: Saeed Karim
Time:
Precision Measuring instruments.

GENERAL OBJECTIVES:i) The student will be able to know the use
Of precision measuring instruments.

the use of Vernier Height gage.
Time
allocated
Vernier Height gauge:-
31
i.
Used for measuring heights of

different work pieces.
ii.
Zero error can be

removed/ set.
iii.
Commonly available in
0-300 mm size with magnifying
glass.
iv.
Minimum resolution
0.02 mm.
v.
Straight and offset scriber.
vi.
Main scale can be moved up

and down.
Time
allocated
Vernier depth gauge:-
i.
ii.
iii.
iv.
v.
vi.
vii.
Used for measuring depth of

different work pieces.
Straight and hook type depth bar.
Hook type is also used for
measuring external size.
Least count 0.02 mm and 0.05m.
Base must touch on both sides of
work piece.
Magnifying glass should be used
for correct measurement.
Also called depth caliper.

Describe the use of hook type depth caliper.
(Usually home work)

Draw neat sketch of hook type depth Caliper.
Tools Material & Aids:Board marker, Duster, Lesson Plan, height and depth gage.
Reference: -

32
LESSON PLAN
Precision measuring instruments.
Lesson No: 16
Name: Saeed Karim
Time:
GENERAL OBJECTIVES:The student will be able to know the use of precision

Instruments.

the use of inside Micrometer and depth
micrometer.
Time
allocated
i.
Inside micrometer:-
ii.
iii.
iv.
v.
vi.
33
Commonly used for accurately

measuring internal size.
Extension rod and caliper
type.
50mm to 200mm extension rod
type.
Minimum resolution 0.01mm.
Spacing collars- lock and
extension rod are used for
measuring different size.
Reverse scale on caliper type
inside Micrometer.
Time
allocated
Key points/Reminders/Sketch Teaching

Aids/Evaluation
i.
ii.
iii.
Depth Micrometer:-
iv.
v.
vi.
vii.
Used for accurately measuring depths.

Fix and adjustable type.
Fix 0-25mm/
adjustable 0-100mm.
Least count 0.01mm.
Reverse scale.
Base must touch on both
sides of top of work piece.
Standers are used for zero
Setting of more than 25mm sizes.

Describe the use of depth micrometer.
(Usually home work)

Draw neat sketch of caliper type Inside micrometer.
Tools Material & Aids:Board marker, Duster, Lesson Plan,

Depth micrometer inside micrometer
Reference: -

34
LESSON PLAN
Lesson No:
17
Name: Saeed Karim
Time:
GENERAL OBJECTIVES:The student will be able to know the use of

SPECIFIC OBJECTIVES:1. The student will be able to understand

the use of thread
Micrometer- Vernier micrometer.
Time
allocated
Thread micrometer
35
i.
Used for measuring pitch of threads

accurately
ii.
Effective or pitch dia
iii.
Double vee type anvil and spindle.
iv.
Conical and vee type anvil and

spindle.
v.
Conical type anvil and spindle.
vi.
Least count 0.01m.
vii.
Also available in inch system.
Time
allocated
i.
Hot gauge micrometer.
ii.
iii.
iv.
Vernier micrometer.
v.
vi.
vii.
Used for measuring the size

Of hot work pieces.
Special type anvil and spindle for
hot work pieces.
Insulated frame and ratchet.
Thermal expansion.
Used for very accurately

measuring external dimensions
Vernier scale is engraved on
barrel.
Least count 0.001mm.
Care= never use as gage.

Name the micrometer used for very accurately
Measuring the external dimensions
(Usually home work)

Draw neat sketch of Vernier micrometer Showing Vernier scale
Tools Material & Aids:Board marker, Duster, Lesson Plan, Micrometers
Reference: -

1) Production technology by R.B.Gupta.
36
LESSON PLAN
Lesson No:
18
Name: Saeed Karim
Time:
Accuracy in measurements

GENERAL OBJECTIVES:The students will be able to know
1. The element of metrology.
SPECIFIC OBJECTIVES:The students will be able to

1. Understand the five basic elements of metrology.
Time
allocated
Element of Metrology
Standard:
Environment, thermal expansion,

There are five basic elements of metrology. holding method may affect standard.
These elements are necessary for talking
accurate measurement.
Work piece:
Neat and clean, free from dust and dirt.
Instrument:
Regular use of instrument friction,
magnetic force.
Person:
Improper handling, improper training,
lack of knowledge and skill, selection of
Tools.
Environment:
Improper temperature, light, vibration
effect accuracy of measurements.
37
Time
allocated
1. Difference in setting of work piece
and standard
Random Errors:
Error in measurements which are difficult to
control.
2. Difference in joint of measuring

instruments.
3. Friction
4. Invisible lines
5. Wear Tear in gauges
Testing & Follow Up: -

Explain random errors
Special Assignment: -
(Usually home work)

Prepare a chart showing classification of errors.
Tools Material & Aids:Board Marker, Lesson plans.
Reference: -

Metrology by M. Ghias
38
LESSON PLAN
Lesson No:
19
Name: Saeed Karim
Time:
Classification of Errors

GENERAL OBJECTIVES:The students will be able to know about
1. Measuring Errors
SPECIFIC OBJECTIVES:The students will be able to understand

1. Controllable errors
2. Random errors
Time
allocated
Classification of Errors:
There are two main types of measuring
Errors.
1. Control able or Systematic Error
39
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
Calibration
Mathematical
Ambient Errors
Alignment Errors
Environment
Reading Instruments
Elastic deformation
Parallax Error
Stylus Pressure
Time
allocated
2. Random Errors:
Error in measurements which are
difficult to control
i.
ii.
iii.
iv.
v.
Different in setting of work piece

and standard
Different in joint of measuring
instruments
Friction
Invisible lines
Wear tear in gauges

Explain random Errors
(Usually home work)

Prepare a chart showing classification of errors.
Tools Material & Aids:Board Marker, Lesson plans
Reference: -

40
LESSON PLAN
Lesson No:
20
Name: Saeed Karim
Time:
Dial Instruments

GENERAL OBJECTIVES:The students will be able to use
1. Dial caliper

1. Dial Caliper
2. Measurement with dial caliper
Time
allocated
Dial Caliper:
An instrument used for measuring
internal, external and depth with the help of
dial.
Easy to measure and read the scale
Main scale = 1.00 mm
Dial Caliper = 0.02 mm
Main scale Dial scale

Pointer Fix Jaw sliding Jaw
depth bar lock
41
Direct reading
Both metric and inch system
Time
allocated
Size available
0----150 mm
0---200 mm
0---300 mm
Provides highly repeatable inside
dimensions.

1. What is beast count of dial caliper?
2. Name the parts of dial caliper?
(Usually home work)

Prepare neat sketch of dial caliper showing measurement of 3040mm.
Tools Material & Aids:Dial Caliper (0-200 mm), Lesson Plan
Reference: -

Shop Theory by Anderson Mitutoyo catalogue
42
LESSON PLAN
Lesson No:
21
Name: Saeed Karim
Time:
Dial Instruments

GENERAL OBJECTIVES:The students will be able to use
1. Dial Thickness gauge
2. Dial bore gauge

1. Use of Dial instruments
Time
allocated
Dial Thickness gauge:

The instrument used for measuring
thickness of small parts with the help of dial.
Measurement thickness with

simple operation
Measuring faces high flatness,

parallel and excellent durability
Suitable for inspection small parts

on shop floor
Dial
Small pointer
Large pointer
Frame indicator contact point

Anvil spindle Lifting lever
43
Time
allocated
Dial Bore Gauge:

Used for inspection internal dimensions,
holes and bores.
Carbide tipped contact point for

durability
Easy zero adjustment
Interchangeable anvils having wide

range of measurement
Measuring diameter of small holes
Available in both inch and metric

system
Different ranges

Name the parts of dial thickness gauge
(Usually home work)

Draw neat sketch of dial bore gauge showing parts
Tools Material & Aids:Lesson Plan, Dial thickness gage, Dial bore gage
Reference: -

Mitutoyo catalogue
44
LESSON PLAN
Lesson No:
22
Name: Saeed Karim
Time:
Taper Measurements

GENERAL OBJECTIVES:The students will be able to know
1. Gauge blocks and sine bar

1. Use of gauge blocks and sine bar.
Time
allocated
Standard for measurement
Gauge Block:
i.
ii.
Slip gauges
Johnson gauges
Invented in 1950 by a metrologist Johnson.
Made of special hardened steel whose
two faces are used for accurate
measurement.
Used for calibration

Available in square and
rectangular shape
Cohesive and wiring type
AA, A, B according to tolerance
2, 1, 0, 00, and calibration grade
45
Time
allocated
Sine Bar:
A sin bar helps us learning something about
angles.
A steel bar has a cylinder near each
end form a hypotenuse
Designed with a distance between
the cylinders
Common size (5 10)
(12.7 25.4 cm)
Used for accurately measuring

angles

Describe grades of gauge blocks
(Usually home work)

Draw a neat sketch of sine bar forming triangle with a hypotenuse
of 5
Tools Material & Aids:Sine Bar (125 mm), Lesson Plan
Reference: -

Dimensional Metrology by Ted Busch Roger Horlow
46
LESSON PLAN
Lesson No:
23
Name: Saeed Karim
Time:
Tool Marker Microscope

GENERAL OBJECTIVES:The student will be able to know about tool
makers microscope
SPECIFIC OBJECTIVES: -
Expected Entry Behaviours
The student will be able

To understand the working of toll makers
microscope
Time
allocated
Tool makers microscope
The tool makes microscope is an optical
measuring machine equipped for external
and internal leng the measurement.
i) Centre stage for mounting cylindrical
components.
ii) Angel measuring oculars
iii) Double image ocular
iv) Optical feeder
v) Projections screen
Attachments
47
Time
allocated
Main parts
Rotatable- measuring stage swing able

head ocular projective screen micrometer
objective lens
The component being measured
illuminated by light method parallel bean of
light illuminates the lower side of work
piece which is than received by objective
lens in its way to prism that deflects the
lights rays in the direction of measuring
ocular and projection screen
Working

Name of the main parts of tool makers microscope
(Usually home work)

Draw neat sketch of tool makers microscope
Tools Material & Aids:Lesson plan duster board makers
Reference: -

Metrology by syed Skaykat Abbas
48
LESSON PLAN
Lesson No:
24
Name: Saeed Karim
Time:
Profile Projector

GENERAL OBJECTIVES:The student will be able to know about profile
Projector
SPECIFIC OBJECTIVES: The student will be able

To understand the use of profile projector and
profile measurment
Time
allocated
Profile Projector
Profile projectors are used to examine screen
threads, bevel greas and similar forms
49
i)
In profile projector work piece set at

an angle to the optical path or the
illumination beem must be moved to
the profile
Projection screens are of two types .
i)
Translucent
ii) opaque
Time
allocated
Diascopic projection
The greatest limitation of profile projection

is that we must ensure that the part
Is projection through films, transparencies and
feature being examining lies in the palen of
similar material
sharpens . this plane is part of screen that is
normal to the optical axis
Episcpoic projection
Importance
Is projection of the surface of opaque objects i) large number of part features are
examined in two dimension
which is used most often to examine engraved
simultaneously
surfaces, embossed patterns
ii) much measurement is direct which is
more reliable than transfer method

Describe two uses of profile projector
(Usually home work)

Draw neat sketch of profile projector
Tools Material & Aids:Lesson plan duster board makers
Reference: -

Dimensional Metrology by Ted Busch Roger Harlow
50
LESSON PLAN
Lesson No:
Name:
Time:
Optical Flats

GENERAL OBJECTIVES:The student will be able to know about optical
flats
To understand the use and application of
optical flats
Time
allocated
24-A
Saeed Karim
Optical flats
Optical flats is a transparent with one face
finished to near perfect flatners
51
The primary instrument that use light is
optical flat. Optical flat have one face
finished lightly prefect. When this face is
placed on another nearly flat surface, we
can see light bands, or fringes also know
as inter face which correspond to the
distance separating the two surfaces .
Time
allocated
There are four primary application of optics
1. magni fication the visual enlargement
of an object for precise measurement
2. alignment
using light rays to establish references
such as liners and planes
3. interferometry
using the leanomenon of light to
measure
4. using the known wave length o flights
as the absolute standard of length

Describe the use of optical flats
(Usually home work)

Draw neat sketch of optical flats
Tools Material & Aids:Lesson plan duster board makers sketch flexi
Reference: -

Dimensional Metrology by Ted Busch Rogerr Horlwo
52
LESSON PLAN
Lesson No:
25
Name: Saeed Karim
Time:
Subject (Course Title) MECH-236 a

Comparison measurement and mechanical
Comparator

To understand comparison measurement,
mechanical comparator its types and uses
Time
allocated
Mechanical dial comparators are indicator with
stands that incorporators their own reference
surface
Comparators are precision measuring

instrument used.
Comparative measurements between work
and standard
Types of mechanical comparators
i) cam and geor type
ii) rock and geor type
iii) high amplification
iv) Read type
High amplification and reed type are now is
use, other have obsolete.
53
Time
allocated
Parts
Base column arm indicator head
spindle lifter table
Principle
The movement of measuring tip attached
at the end of the pointer through a
mechanism of substituting a more accurate
linear to rotary transducer
Uses
i) Comparison
ii) Gauging

Describe the mechanism of mechanical comparator
(Usually home work)

Draw neat sketch of tool mechanical dial comparator with stand
Tools Material & Aids:Dial comparator flexi board marker
Reference: -

Dimension Metrology by Ted Busch Rahbar Metrology by Hafeez
Mughal
54
LESSON PLAN
Lesson No:
26
Name: Saeed Karim
Time:
Electrical / Electronics comparator

GENERAL OBJECTIVES:The student will be able to know about electrical
And electronics comparator

To understand the working of electrical and
electronics comparator
Time
allocated
Electrical comparator
This comparator is also known as
electromechanical measuring systems as this
employ an electromechanical device which
converts a mechanical displacement into
electrical input signal
55
Simple form of basic electric equipment.
Dial indicator mounted on stand
Switches are attached by the motions of
indicator spindle
Signal light limit indicator.
When indicator hand reaches prescribed
tolerance limits the preset switches close.
Yellow light signal undersize, red light
signal oversize, green light signal with in
tolerance limits.
Time
allocated
Electronic comparator
Electronic instruments are popular. It is better
to
use
an
inexpensive
instrument,
but
electronic instrument reduced time of checking

size, measuring size. The rate of measurement
make
electronic
instruments
perfect
dynamic measurement
of
Rapid operation even at light amplification.

Multiple amplification ranges in same
instrument
Limited self checking
Electronics comparator is based on the
principle of application of frequency
modulation or radio oscillation.
By using various adaptors, may be
application like external testing can be
made.
Measuring unit may be small having several
magnifications

Describe the use of the electrical comparator
(Usually home work)

Draw neat sketch of electrical or electronic comparator
Tools Material & Aids:Comparator flexi sketchs board marker
Reference: -

Dimensional Metrology by Ted Busch Roger Harlow
56
LESSON PLAN
Lesson No:
27
Name: Saeed Karim
Time:
Digital Instrument

GENERAL OBJECTIVES:The student will be able to know about digital
instrument
SPECIFIC OBJECTIVES: -
The student will be able

To understand about digital micrometer and
digital caliper.
Time
allocated
Digital micrometer
Digital matic micrometer mostly used for
outside measurement accurately. Reading is
displayed screen
57
Available in 0-25mm size, large size are
also available.
Easy to use and check sizes of different
parts.
May be used as gage having features like
that.
Dual conversion inch to mm and mm to
inch
0.001mm resolution
On /off button
Zero button
Micrometer stand is used for alignment
and proper holding stability.
Time
allocated
Digital caliper
Available in different sizes from 0-150to 0300 mm

Digital caliper used for measuring outside,
Easy to use and measure different sizes
inside and depth dimensions.
Dual conversion inch to metric systems and
metric systems to inch
Resolution 0.01mm
On /off button
Zero button for removing zero error
Used for three types of measurements with
the same instrument

What are the advantages of digital instrument. Describe in detail
(Usually home work)

Draw neat sketch of digital micrometer with stand
Tools Material & Aids:Lesson plane digital instruments board marker flexi
Reference: -

Catalogue
58
LESSON PLAN
Lesson No:
Name:
Time:
Digital instrument
27-A
Saeed Karim
GENERAL OBJECTIVES:The student will be able to know digital instrument
SPECIFIC OBJECTIVES: The student will be able to use

And understand digital indictor and digital
depth caliper
Time
allocated
Digital indicator
Digital indictor is used to check the variation
occurred in work pieces /jobs during production
process. It also indicator geometric uniformity of
dimension and contour
Available in 0-10mm and 0-25 mm sizes

Easy to use and check the variation of work
pieces.
May be used as gage having features like
that
Mounted on stand for use
inch
0.001mm resolution
Zero button
59
Time
allocated
Digital depth caliper
Available in 0-100mm size. Large size also

available
Used for accurately and easily measuring depth
Easy to use and measure depth
of work pieces size in displayed on screen
inch
0.01mm resolution
On / off button
Zero button for setting on zero

Name the parts of digital instruments
(Usually home work)

Draw neat sketch of digital indicator
Tools Material & Aids:Lesson plane, flexi digital instrument- board marker
Reference: publication)
(Author, title, publisher, page or chapter number, date of

Catalogue
60
LESSON PLAN
Lesson No:
Name:
Time:
Digital instrument
27-B
Saeed Karim

digital instrument

to understand about digital height gage
Time
allocated
Digital height gage
Digital height gage is used to easily measure the
height of different work pieces and layout
61
Commonly available in 0-300mm size
Placed on surface palate or lab table for
use
inch
0.01mm resolution
Zero button for zero setting
Straight and off set scribe may be used
Angle plate is used for alignment
Time
allocated
And supporting work piece on right angle
for measuring accurately

Name the parts of digital height gage
(Usually home work)

Draw neat sketch of digital height gage showing parts
Tools Material & Aids:Lesson plane, flexi digital height gage - board marker
Reference: -

Catalogue
62
LESSON PLAN
Lesson No:
Name:
Time:
Coordinate Measuring Machines
28
GENERAL OBJECTIVES:The student will be able to know about CMM
SPECIFIC OBJECTIVES: The student will be able to understand the

working of CMM
Time
allocated
Coordinate Measuring Machine
Coordinate measuring Machine are powerful
metrological instruments
CMM enable us to locate point coordinate on
the three dimension structure at the same time
that they integrate both dimension and
orthogonal relation ships
63
When a computer is added to the CMM it
creates an instrument that can
automatically perform complex angles is
that can learn measurements routines to
compare how a piece conforms to its
specifications.
The greater the complexity of the piece the
greater the benefits from a CMM
CMM provides so many measurements are
widely used for industrial application
Time
allocated
It is different to say when coordinate Metrologist use the term CMM to refer to
instruments that measurements that
measuring machine emerged as a district class
measure in two axis .
instruments but such metrology pioneer as C.E Cantilever type
Bridge type
Johansson and F.H Rolt Wrote about machines
Column type
that could measures in three axis. While the Horizontal type
Gantry type
instruments that these metrologist proposed
Modes of operation
were special purpose instrument, today CMM Manual
Manual computer assisted
and interfaced computer provide a variety of
Motorized computer controlled
measurement opportunities
Probes
All CMM consist of a probe and way to
move it along three axis relation to a work
piece

Name the parts of CMM
(Usually home work)

Draw neat sketch of CMM
Tools Material & Aids:Lesson plane, flexi - board marker
Reference: -

Dimensional Metrology by The Busch Roger Harlow
64
LESSON PLAN
Lesson No:
Name:
Time:
Gear Testing Machine
Subject (Course Title): MECH-
29
GENERAL OBJECTIVES:The students will be able to know about gear testing machine.
1. The students will be able to understand

about gear Inspection.
2. The students will be able to understand
inspection of Gears with machine.
Time
allocated
Gear Inspection:-
1-
To optimize the gear performance, an

accurate and precise inspection and testing
is necessary. The maximum life of gear train
depends upon the proper inspection and
testing of Gears.
2-
65
For a proper identification of

damaged areas during Inspection
operation, a magnifying glass, a
strong and clear light source and
reflector is to be used for best
results.
If the gears are not properly
inspected, it is obvious that gear
will fail and damage to other parts.
Time
allocated
A gear checking machine among other is

A vital aid in gear inspection process in gear supposed to check the following things.
i) Run out.
testing machine. It plays an important role in
ii) Pitch variation
any gear inspection operation.
iii) Accumulated pitch variation.
iv) Profile/involute
v) Lead
vi) Stop error
vii) Tooth thickness.
Gear Testing Machine:-

Write down the things which are inspected / tested during gear
inspection.
(Usually home work)

Draw neat sketch of a spur gear.
Tools Material & Aids:Lesson plan Flexi Spur gear Board Marker.
66
LESSON PLAN
Lesson No:
30
Name: Saeed Karim
Time:
Back Lash Measurement

GENERAL OBJECTIVES:The student will be able to know about back lash.
SPECIFIC OBJECTIVES:The students will be able to understand about back lash measurement
Time
allocated
Backlash:-
1- The amount of play between teeth
of mating gears is called backlash.
2- Difference between tooth thickness
and tooth space.
Standard Amount of Backlash:-
Min. backlash .03xModule

Average backlash .04xModule
Max. Backlash .05x Module.
67
Time
allocated
1- Excess depth of cut (than
standard/Theoretical working
depth) is employed to obtain
necessary backlash.
2- A pinion with 20teeth is to drive a
gear having 60 teeth and amount of
backlash is 0.15 MM is to be
obtained by cutting a gear tooth
than standard. Excess depth of cut
= .15x12 = .30 MM
How to obtain backlash:-

Calculate the back lash of two mating gears.
(Usually home work)

Draw neat sketch of two mating spur gears showing back lash.
Tools Material & Aids:Lesson plan Flexi, Board Marker
Reference: -

Technology of Machine Tool By SF Krar.
68
LESSON PLAN
Lesson No:
31
Name: Saeed Karim
Time:
Digital 3-D Scanner

GENERAL OBJECTIVES:The student will be able to know about 3D Scanner.
SPECIFIC OBJECTIVES:The students will be able to understand about

the use of 3D Scanner.
Time
allocated
3D scanner:Benefits:
Increase working with complex parts and
shapes.
Help with design of products to
accommodate someone else part.
If CAD models are outdated, a 3D scan will
provide an update version.
Replacement of missing and older parts.
69
A 3D scanner is a device that analyzes a

real-world object or environment to
collect data on its shape and possibly its
appearance (i.e. color). The collected
data can then be used to construct
digital, three dimensional models useful
for a wide variety of applications
Time
allocated
The purpose of a 3D scanner is usually to

create a point cloud of geometric samples
on the surface of the subject.
These devices are used extensively by

the entertainment industry in the
production of movies and video
games.
Other common applications of this
technology include industrial design,
orthotics and prosthetics, reverse
engineering and prototyping, quality
control / inspection and
documentation of cultural artifacts.

What are Benefits of 3D Scanner?
(Usually home work)

Draw neat sketch of 3D Scanner.
Reference: -

Internet - Wikipedia.
70
LESSON PLAN
Lesson No:
32
Name: Saeed Karim
Time:
Digital Read OUT

GENERAL OBJECTIVES:The student will be able to know about Digital Readout.

about the use of Digital Readout.
Time
allocated
Digital Readout:-
71
A digital read out (DRO) is a small

computer (display unit) usually with
an integrated keyboard and some
means of numeric representation.
It reads the signals generated by the
linear encoder (or less frequently by
rotary encoders) installed to several
machine's axes used to keep track of
workpiece position.
Time
allocated
The use of DROs are not limited to
manual equipment as CNC equipment can
usually be switched to manual operation
and in this case a form of DRO is simulated
on the Control Panel of a robotic machine.
This system is commonly fitted to
most machines in today's shops:
lathes, cylindrical grinders, milling
machines, surface grinders, boring
mills and other machine tools to allow
the operator to work faster and with
greater accuracy.

What are Benefits of DRO?
(Usually home work)

Draw neat sketch of DRO.
Reference: -

Internet
72
Metrology
(MECH-252)
OPERATION SHEET
Table of Contents
Practice of Graduated Tools Steel
Practice of combination Set
Practical of supporting tools
Practice of Guages
Practice of Small Hole and telescopic gauges
Practice of outside Micrometer
Practice of Intside Micrometer
Practice of Depth Micrometer
Practice On thread micrometer
Practice of Vernier caliper
Practice of vernier Height gauge
Practice of vernier depth gauge
Practice of Angle Measuring
Practice of Angle Measuring tools
Pracitice of Angle Measuring tools
Use of Sine Bar
Calculation to Tolerance
Practical of dial instruments
Use of Gauge Blocks
Practice of Electrical Comparator
Practice of Mechanical Comparator
Practice for digital Micrometer
Practice of digital caliper
Digital depth gage
Practice of digital Indicator
Practice of digital height gage
Practice of Gear Testing Machine
Back lash Measurement
Gear Tooth Measurement
Measurement by Thread Gauges
Practice of Measurement on CMM
Practice of Profile Projector
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
65
Operation Sheet No -1
Operation /job: - Practice of Graduated Tools Steel,
Hook, Rule Folding Rule Trammels
Subject: MECH-252
Objectives: - The Students will be able to
Use Rules and draw straight lines,
Introduction, Preparation & Motivation: Machines/Equipment/ Tools/ Materials: plate, Work pieces,
Technology: Mechanical
Time & Date:
Show sketches / Flexi of rules and trammels

Steel Rule, Hook rule, Folding Trammels Surface
Steps/Procedure/method
1.
2.
3.
4.
Name: Saeed Karim
Key Points/Precautions For Skillful Performance
Place the work piece on surface plate

Place the steel rule on work piece
Draw a straight line
Measure the length of line with rule
i. Use new rules

ii. Start measuring from one inch or 1 cm
iii. Degrees of rule should be straight and parallel
Application and Try Out :

Give exercise to students for practice
Safety Precautions:
1.
Use steel rule having clearly visible lines.
2.
Edges of steel rule should not be broken
3.
Start reading form 1 cm
Special Assignment:
Draw sketches of steel rule showing different measurements.
Drawing / Diagram / Sketch
Reference:
Shop theory by Anderson
Operation /job: Practice of combination Set
Subject: MECH-252
Name: Saeed Karim

Time & Date:
1. Use the combination set.

Introduction, Preparation & Motivation: -
Show flexi of combination set
Machines/Equipment/ Tools/ Materials: -
Combination set, work piece
1. Place the combination set on surface plate.

2. Fasten the center head / square head. bevel
protractor to blade
3. Set the work piece in any part of or finding center
/ checking squareness and measuring angles.
1.
2.
3.
4.
Blade / Grooved Steel rule,

Centre bead
Square bead
Bevel protractor
Students should be given exercise of finding centre of round objects
Safety Precautions:
1. Fasten the blade with parts carefully and properly
2. Use scriber pin for layout and working
Special Assignment:
Draw neat sketch of all the parts of combination set.
Reference:
Operation /job: Practical of supporting tools
Plates, Straight Edge, Levels Technology: Mechanical
Subject: MECH-252
Objectives: - The students will be able to use the difference
Name: Time & Date:
Surface plates and levels,

Introduction, Preparation & Motivation: plate, levels, straight edge.
Show flexi of CI surface plate tool makers surface
Machines/Equipment/ Tools/ Materials: engineers parallel
Different surface plates, levels straight edges
1.
2.
3.
4.
5.
Clean the surface plate

Check the level of plate with spirit level
Cheque the surface finish of surface plate with
master square and straight edge.
Place the work piece on surface plate for
measuring
Take the measurement
Application and Try Out:
I. Surface plate should be supported firmly

II. Load should be equally distributed on surface
plate.
III. Top should be truly cleaned
Students should be given exercise of checking level of surface plate.
Safety Precautions:
1. Protect to of surface plate against damage using cover.
2. Protect it against rust
3. Wiping cloth should be spread over surface plate for tools.
4. Cover when not in use
Special Assignment:
Draw neat sketch of all Plates, straight edge and levels
Reference:
Operation /job: Practice of Gauges
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. To use fix and adjust gages.

2.
Introduction, Preparation & Motivation: Show sketches / flexi and original gauges.
Ring Gauge plug gauge work pieces
1) Place the gauges on lab table

2) Place work piece on lab table
3) Set the gauge in work piece or set the work piece
in gauge
4) check size of work piece as per standard
a. Use both go and not go gauges for gauging

b. Ensure that gauging surface is hardened
Give exercise of gauging
Safety Precautions:
1. Clean work piece and gauging surface.
2. Check the work piece both in go and not go members.
3. Protect the gauges from dust, dirt and rust.
4.
Special Assignment:
Draw neat sketch of snap gauge for identification
Reference:
Engg. Metrology by R.K. Jane
Operation /job: -Practice of Small Hole and telescopic gauges
Subject: MECH-252
Name: Saeed Karim

Technology:
Time & Date:
1. Use the small Hole and Telescopic gauges.

2.
Introduction, Preparation & Motivation: Show small Hole and telescopic gauges.
Machines/Equipment/ Tools/ Materials: work pieces Micro meter.
Show Small Hole Gauge set Telescopic gauge set
1.
2.
3.
4.
5.
Place the gauges on Lab table

Place Work piece on lab table
Use Suitable size gauge.
Set the gauge in work piece properly
Measure the size on micro meter.
1. First approximate measure the size with Vernier

caliper.
2. Secondly select suitable size gauge
Application and Try Out : Give exercise of gauging

Safety Precautions:
1. Clean work piece and gauges.
2. Use carefully as there gages are sensitive
3. Set the gauge accurately
4. Read the size on metric micrometer.
Special Assignment:
Reference:
10
Operation /job: -Practice of outside Micrometer
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. Show sketches flexi of outside micrometer

Show sketches flexi of outside micrometer
outside micrometer (0-25mm) work pieces
1.
2.
3.
4.
5.
6.
Check zero error.

Hold the micrometer in stand.
Set the work piece in anvil and spindle
Read the size on main scale.
Read the thimble scale
Add above readings.
OneSmallDivisiononmasc
Tota ln o.ofdivisionthimble
L.C=
=0.01mm
Frame Anvil spindle Haim scale thimble scale ratchet

stop lock
Main supporting part of drill machine.
The student should be given exercise for reading micrometer.
Safety Precautions:
1. Micrometer must be held in stand.
2. Ratchet should be used while setting work piece for measuring
3. Do not use on moving ports
4. Cover after Use.
11
Special Assignment:
Reference:
12
Operation /job: Practice of Inside Micrometer
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. Use inside micrometer.

Introduction, Preparation & Motivation: type.
Machines/Equipment/ Tools/ Materials: mm)(25-50mm)
Show sketches flexi of Inside Micrometers caliper

Inside micrometer caliper types work piece (5-30
1.
2.
3.
4.
5.
Check and remove zero error

Set in the work piece properly using ratchet
Read the main scale
Read the thimble scale
Add above readings
Scale is reverse.
Haim scale=
1mm
Thimble scale = 0.01mm
The students should be given exercise of measuring internal sizes
Safety Precautions:
1. Set in work piece properly.
2. Read the hidden scale correctly
3. Read the thimble scale correctly
4. Store after use.
Special Assignment:
13
Reference:
Engineering Metrology by R.K. Jane

Metrology of M. Gluas
14
Operation /job: Practice of Depth Micrometer
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. Use depth micrometer.

Show sketches flexi of Depth micrometer
Machines/Equipment/ Tools/ Materials: pieces.
Depth Micrometer (0-100mm) standards work
1)
2)
3)
4)
5)
Clean the depth micrometer.

Check and remove zero error Using slandered
Insert required size rod in depth micrometers.
Set the depth micrometer over work piece
Measure the size.
L.C=
0.01
Reverse Scale
1-Mian Scale division =1.00 mm
1-small division =0.50 mm
1-Thmble division = 0.01mm
Base must touch on both sides of work piece
Application and Try Out: The students should be given exercises

Safety Precautions:
1. Fit rod and remove zero error
2. Before measuring ensure that edge of hole is free from burrs.
3. Measure and read the scale accurately.
15
Special Assignment:
Reference:
Machine tool technology By victor e. repp, villard j. meccarthy
16
Operation /job: Practice On thread micrometer
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. Use thread micrometer

Show sketches flexi of thread micrometer
Thread micrometer (V-anvil type)
1. Check and remove zero error.

2. Holde in stand
3. Set the bolt in V. Anil
4. Read the size on main scale
5. Read the size on thimble scale
6. Add above reading
One main scale division =1

One small scale division =0
One Thimble scale division is 0
Frame spindle v shaped anvil
The student should be given exercise for reading micrometer.
Safety Precautions:
1. Micro meter should be held in stand.
2. Set the threaded bolt in U-anvi
3. Do not use on moving ports.
4. Store in box after use .
Special Assignment:
Draw net sketches showing different sizes
17
Reference:
Metrology by Ghias.
18

Operation /job: Practice of Vernier caliper
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. To use Vernier caliper

Show sketches flexi and tools
Machines/Equipment/ Tools/ Materials: piece
Vernier caliper (0-200mm) magnifying glass work
1.
2.
3.
4.
5.
6.
Place tools and work pieces on lab table.

Check zero error
Set on work piece
Read main scale
Read vernier scale using magnifying glass
Add above reading
L.C=
One small division on main scale

Total no. of divisions on Vernier scale
1-main scale division =1.00mm

1-vernier division = 0.02 /0.0. mm
LC = 0.02 mm
Or 0.05 mm
Application and Try Out: The students should be given exercise

Safety Precautions:
1. Do not use vernier caliper having zero error
2. Use magnifying glass while reading vernier scale
3. Store in box after use.
19
Special Assignment:
Draw neat sketches of vernier caliper showing different size
Reference:
shape theory by Anderson.
Dimensional metrology by T. Bush
20

Operation /job: Practice of vernier Height gauge
Subject: MECH-252
1.
Name: - Saeed Karim

Time & Date:
Use Vernier Height
Show sketches flexi and height gauge.
Vernier height gauge angle plate workpiece
1.
2.
3.
4.
5.
6.
Place height gauge on surface plate

Place angle plate and work piece on lab table
Set zero
Set scriber on work piece
Read the size on main scale
Read the size on vernier scale using magnifying
glass
1-Mian Scale division =1.00 mm

1-vernier division = 0.02 mm
LC= 0.02mm
The students should be given exercise
Safety Precautions:
1.
Clamp the scriber properly
2.
Set the workpiece using angle plate
3.
Store in box after using
21
Special Assignment:
Draw neat sketch of bevel protractor showing angle of 60
Reference:
Machine tool technology by victor E Repp Villor J Mc Carthy
22

Operation /job: Practice of vernier depth gauge
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. Use the vernier depth gauge

Show sketches flexi and vernier depth gauge.
Machines/Equipment/ Tools/ Materials: magnifying glass
Vernier depth gauge (Hook Type) Workpiece
1.
2.
3.
4.
5.
Place depth gauge on surface plate

Place workpiece on suface plate.
Check zero error
Set the base of gauge on workpiece
Read the size
L.C=
0.02 mm
Or 0.05 mm
Base Main Scale

Vernier Scale Lock
Fine adjustment screw depth bar

Safety Precautions:
1. Before measuring ensure that edge of bde is free from burr.
2. Base must touch on both sides of hole.
3. Carefully read vernier scale
23
Special Assignment:
Reference:
Machine tool techonolgy by victer, E Repp Villor J Mc Carthy
24

Operation /job: - Practice of Angle Measuring
Tools Bevel Protractor
Subject: MECH-252
Name: - Saeed Karim

Time & Date:
1. The Bevel Protractor

Show sketches Flexi of bevel protractor
Bevel protractor Blade workpiece Magnifying glass
1.
2.
3.
4.
Place the tools on lab table

fasten the bevel protractor in blade.
set the protractor on workpiece
read the angle
10=60 minutes
Minimum angle measureem
Is 10

Safety Precautions:
1. Fasten the protractor in blade properly
2. Read the angle using magnifying glass
25
Special Assignment:
Reference:
Machine Tool Techonology by Victor, E Repp Villord J Mc Cartty.
26

Operation /job: Subject: Objectives: -
Practice of Vernier Bevel Protractor

MECH-252
The Students will be able to
1. Use the vernier bevel protractor
Name: - Saeed Karim

Time & Date:
Show chart flexi of vernier bevel protractor
Machines/Equipment/ Tools/ Materials: workpiece
Vernier bevela protractror magnifying glass
1.
2.
3.
4.
5.

Fasten the blade in vernier bevel protractor
Set the protractor on workpiece
Read main scale
Read vernier scale using magnifying glass
10 = 60 minutes
Minimum angle measurement
Is 0
Or 05 minutes
Magnify glass
Safety Precautions:
1. Fasten the protractor in blade properly
2. Read vernier scale carefully using magnifying glass
27
Special Assignment:
minutes
Draw neat sketch of vernier bevel protractor showing angle of 600-30
Reference:
Machine tool techonolgy by victer, E Repp Villor J Mc Carthy
28

Pracitice of Angle Measuring tools
Practice of steel protractor

MECH-252
Name: Technology: Mechanical

1. Use steel protractor
Time & Date:
Chart . flexi should be shown
Steel protractor magnifying glass, workpiece
1.
2.
3.
4.

Check the blade fitting lock
set the protractor on work piece
Read the angle
Minimum Angle measurement

Is 10
Lock Magnifying glass
Safety Precautions:
1. Check the blade fitting / lock before use
2. Lock the blade while measuring
29
Special Assignment:
Draw neat sketch of steel protractor showing angle of 1200
Reference:
30

Practice of Dial protractor

MECH-252
Name: - Saeed Karim


1.
Use the dial protractor
Time & Date:
Chart flexi should be shown
Dial protractor magnifying glass workpiece
1.
2.
3.
4.
5.
6.

check the dial scale and pointer
fasten the blade properly
set on workpiece
Measure main scale
Measure dial scale
10= 60 minutes
Main Scale =10
Dial Scale = 1/12 0 or
Or 05 minutes
Dial Scale pointer
Safety Precautions:
1.
Fasten the blade properly
2.
Read dial scale accurately
31
Special Assignment:
Prepare neat sketch of dial protractor showing 600-15
Reference:
32

Operation /job: Use of Sine Bar
Subject: MECH-252
1.
Use the Sine Bar
Introduction, Preparation & Motivation: Machines/Equipment/ Tools/ Materials: -
Name: - Saeed Karim

Time & Date:
Show the sketch of Sine bar
Sine bar (0-5), Guage block calculator
1.
2.
3.
4.
5.
Clean the sine bar and points of application on

the job
Set the sine bar
Set the gauge blocks under the sine bar
Set the Vernier bevel protractor to check the
angle of inclination of the job surface
Calculate the angularity using trigonometric
function
tan Perpendicular
Base
Sin Perpendicular
Hipotenuse
CoSin Base
Hypotenuse

Safety Precautions:
1. Clean surface, work piece, sine bar
2. Omit the air gap between gauge bloc
3. check angle of inclination with vernier bevel protractor before calculation
4. Calculate carefully.
Special Assignment:
Draw neat sketch of sine bar showing application
33
Reference:
Dimensional Metrology by Ted Busch Roger Horlow
34

Operation /job: Calculation to Tolerance
Subject: MECH-252
1.
Calculate tolerance and allowance
Time & Date:
Lesson Plan tolerance

Calculator Board marker duster
Tolerance
Difference between High limit and low limit
i. Unilateral + or
ii. Bilateral
Name: - Saeed Karim
i. Basic size
=40.00 mm
Tol
=0.20 mm
H.L
=
40.20
L.L
=
39.80
Total Tolerance = 0.40 mm
ii. Gauge tolerance
10% of total tolerance
10% of 0.40=0.04 mm
Subtract from high limit add in low limit
Safety Precautions:
1. Calculate the high limit and low limit carefully
2. Use calculator for decimal fraction
35
Special Assignment:
Draw neat sketch showing Unilateral and bilateral tolerance.
Reference:
Machine tool technology by
Victor E Reff
Villord J Mc Cortty
36

Operation /job: Practical of dial instruments
Subject: MECH-252
1.
Dial instruments
Time & Date:
Place all instruments on lab table

clean all the tools and work piece
Set the instrument on work piece
Read main scale
Read dial Scale
Add above readings
Show the sketches of dial instruments

Dial caliper dial thickness gauge dial indicator
1.
2.
3.
4.
5.
6.
Name: - Saeed Karim
LC=0.05mm
Or 0302 mm
Main scale =1.00 mm
Main scale= 40.00 mm
Dial scale = 0.36 mm
= 40.36 mm
Safety Precautions:
1. Set zero / Remove zero error
2. Set work piece properly
3. Read / pointer carefully
37
Special Assignment: Draw neat sketch of square gauge blocks also calculate the size for 64.75 mm
Reference:
Dimensional Metrology by T. Busch Roger Horlow
38

Operation /job: Use of Gauge Blocks
Subject: MECH-252
1.
To use the gauge blocks
Name: - Saeed Karim

Time & Date:
Show the sketch and flexi of gauge blocks
Gauge block set micrometer
Following procedure is used

i.
Write the desired figure on a piece of paper.
ii. Start at the top of gauge block set.
iii. Choose a block from complete mm in row
iv. Than choose decimal number block
v. Efforts should be made not to select more than
five blocks for on setting
The process of combining gauge blocks together to

make themselves adherings calle warnings.
44.051
1.001 - 1.001
43.050
1.05 - 1.05
42.00
4.50 - 4.500
37.50
12.50 - 12.50
25.00
25.000
44.051

Safety Precautions:
1.
2.
3.
4.
Clean the gauging surface using soft tissue

Place the blocks tag ether make + Sign slide upper block over lower block with circular motion
Blocks should be separated by same method
Do not pull the blocks
39
Special Assignment:
mm
Draw neat sketch of square gauge blocks also calculate the size for 64.75
Reference:
Dimensional Metrology by T. Busch Roger Horlow
40

Operation / Job: Practice of Electrical Comparator
Subject: Mech-252
Name:__ Saeed Karim

Technology___________
Time & Date:__________
Objective: The Student will be able to sue the electrical comparator
for comparison and gauging
Introduction, preparation & Motivation: Show sketch/flexi of electrical comparator.
Machines/Equipment/Tools/Material: Electrical comparator comparator stand power supply
unit Work pieces single light limit indicator
Steps/Procedure/Method
1.
2.
3.
4.
place for all the tools on lab table

clean all the tools
clamp the comparator on stand
set the comparator with signal light
limit indicator
5. set the zero
6. set the tolerance
7. place the work piece under spindle tip
8. Note the variation
9. Look at signal light
10. Repeat this practice
Key points/Precaution For Skillful

Performance
Power supply unit
Signal light limit indicator
Yellow light-- under size
Red light -- over size
Green light --within limits
Application and Try Out: The student should be given exercise for practice
Safety precautions:
1.
2.
3.
4.
Use comparator is dust proof lab

Use instrument oil on sliding surface.
Use light pressure while handling.
Electric gauge way show error if power supply is not proper voltage
41
Special Assignment: Draw neat sketch of Electrical comparator with single light indicator
Drawing /diagram /Sketch
References: Rahbor Metrology by Hafeez Mughal
42
Operation sheet - 22
Operation / Job: Practice of Mechanical Comparator
Subject: Mech-252
Name:__ Saeed Karim __

Technology:___________
Time & Date:___________
Objective: The Student will be able to sue the Mechanical comparator

for comparison and gauging
Introduction, preparation & Motivation: Show sketch/flexi of Mechanical comparator

Machines/Equipment/Tools/Material: Mechanical comparator dial comparator comparator
stand, Standard wrokpiece
1.
2.
3.
4.
5.
6.
7.
8.

Performance
Place all the tools on lab table

Clean all the tools
Clamp the comparator in stand
Set the comparator at standard / basic size
Set tolerance limits on dial comparator
Place the work piece under spindle tips
Note the variation
Repeat this practice
Adjust height of head and locket

Zero setting
Probe for lifting spindle
Application and Try Out: Give exercise to students for practice

Safety precautions:
1.
2.
3.
4.
Use comparator is dust proof lab under temperature control

Use instrument oil on sliding place
Use light pressure which handling.
Avoid unnecessary sliding of components on granite base and under spindle
43
Special Assignment:
Draw neat sketch of Mechanical dial comparator in stand
References: Rahbar Metrology by Hafeez Mughal
44
Operation / Job: Practice for digital Micrometer
Subject: Mech-252
Name:__Saeed Karim ___

Time & Date:___________
Objective: The Student will be able to use the digital

Instruments for measurements
Introduction, preparation & Motivation: Show sketch/flexi of Digital Instruments

Machines/Equipment/Tools/Material: Digital Micrometer work piece Micrometer stand
surface plate
1.
2.
3.
4.
5.
6.

Performance
Place the work piece on surface plate

Place the digital instruments on lab table
Mount the micrometer in stand.
Set the instrument on zero
Place the work piece in micrometer
Read the size on screen
Use micrometer stand for alignment and

holding stability
Use new batteries
0.01 resolution
frame Anvil spindle
Ratchet LCD - on / off button lock
Application and Try out: the should be given exercise for checking size with digital instrument
Safety precautions:
Micrometer must be hold in stand
Ratchet should be use while setting work piece for measuring
Do not use on moving parts
Cover after use
45
Special Assignment:
Draw neat sketch of digital micrometer showing reading 20.50mm
References:
46
Operation / Job: Practice of digital caliper
Subject: Mech-252

Time & Date:___________
Objective: The Student will be able to use digital caliper

Introduction, preparation & Motivation: Show sketch/flexi and instrument
Machines/Equipment/Tools/Material: Digital caliper (0-150mm) Work piece
1.
2.
3.
4.

Performance
Place all the tools on lab table

Check zero error
Set the work piece in between jaws
Read the size on LCD
1.
2.
3.
4.
Set zero before use

0.01mm resolution
Use new batteries for better results
More than one type of dimension with same
instrument
Application and Try Out: The student should be given exercises

Safety precautions:
1. Do not use digital caliper on moving parts
2. Set work piece between jaws accurately
3. Store in box/cover after use
47
Special Assignment: Draw neat sketch of digital caliper showing size 60.25mm
References:
48
Operation / Job: Digital depth gage
Subject: Mech-252
Name:__ Saeed Karim __

Time & Date:___________
Objective: The Student will be able to use digital depth gauge

Introduction, preparation & Motivation: Show sketch/flexi and digital depth gage
Machines/Equipment/Tools/Material: digital depth gage (0-100mm) Work piece
1.
2.
3.
4.
5.

Performance
Place tools and instrument on lab table

Clean tool and instruments
Set the zero
Set the digital depth gage over work piece
Read the size
0.01mm resolution
Base must touch on both sides of work piece
for measurement
Base, depth bar LCD

Safety precautions:
1. Before measuring ensure that edges of hole are free from burr
2. Carefully set the digital depth gage over work piece
3. Store / Cover when not in use
49
Special Assignment:
Draw neat sketch of DIGITAL Depth Gauge showing reading as 40.35 mm
References: Rahbar Metrology by Hafeez Mughal
50
Operation / Job: Practice of digital Indicator
Subject: Mech-252
Name:_Saeed Karim ____

Time & Date:___________
Objective: The Student will be able to use digital indicator

Introduction, preparation & Motivation: Show sketch/flexi digital indictor
Machines/Equipment/Tools/Material: digital indicator indicator stand work piece (0-25mm)
1.
2.
3.
4.
5.
6.

Performance
Place all tools and work piece on lab table

Clean all the tools
Set the digital indicator in stand
Place the work piece on stand
Set the pointer on work piece
Read the deviation in size on LCD
0.01 mm Resolution
Zero setting
Dual conversion
Application and Try Out: Students should be given exercises

Safety precautions:
Properly hold the digital indicator on stand
Set the pointer on work piece accurately
Use new batteries for better measurement
Store / cover after use
51
Special Assignment:
Draw neat sketch of digital indicator with stand showing deviation of 5.15mm
References:
52
Operation / Job: Practice of digital height gage
Subject: Mech-252
Objective: The Student will be able to use digital height gage

Time & Date:__________
Introduction, preparation & Motivation: Show sketch/flexi and digital height gage
Machines/Equipment/Tools/Material: digital height gage (0-300mm) work piece

Performance
1.
2.
3.
4.
5.
Place all the tools and instrument on lab table

Place height gage on surface plate
Place angle on surface plate
Set the scriber in height gage
Place the work piece with angle plate for correct
vertical position
6. Set the scriber on work piece
7. Read the size on LCD
0.01 MM Resolution
Offset scriber
Zero setting

Safety precautions:
Clamp the scriber properly
Properly set the work piece using angle palate
Store in a box after use
53
Special Assignment:
Draw neat sketch of digital height gage showing 100.40MM size
References:
54

Operation /job: - Practice of Gear Testing Machine
Subject: - Metrology (Mech. 252)
Objectives: -The students will be able to use gear testing machine
Name: - Saeed Karim

Time & Date:
Introduction, Preparation & Motivation: Machines/Equipment/ Tools/ Materials: Gear testing machine (Gears WD 40 Marking Gear Tap)
1- Clean the gear using WD-40

2- Check teeth surfaces using marking color and
Tap.
3- Check Surface area of gear for pitting spoiling
c racking.
4- Set the gear in gear testing machine.
5- Check the bare of gear.
6- Check the bearing bore.
7- Fill up the check list of gear inspection.
Gear Inspection by Gear testing machine
Application and Try out: Inspect a Spur gear and fill up checklist form.
Safety Precautions / Care:
1. Clean the gear before inspection.
2. Set the gear in machine properly.
3. Carefully fill up checklist.
55
Special Assignment:
Take a spare gear and prepare its check list.
Drawing/Diagram/Sketch:
References:
56

Operation /job: - Back lash Measurement
Objectives: - Students will be able to
Name: - Saeed Karim

Time & Date:
1. Calculate amount of back lash.
Machines/Equipment/ Tools/ Materials: Feeler gauge Spur gears WD-40
Back lash Measurement:1- Clean the teeth of driver and driven gears.
2- Mount both gears on driver and driven shaft sat
proper central distance.
3- Slightly rotate the driver gear.
4- Measure back lash between tooth profiles of
driver and driven gears using feeler gauge.
Application and Try out: Describe the other uses of feeler gauge
1. The tooth profile of gear should be clear from defects such as burs, pits etc.
2. Proper central distance should be maintained between shafts.
57
Special Assignment:
Take two Spur gears from advance machine shop of 2.5 Module and calculate back lash.
References: Technology of Machine Tool by SF Krar
58

Operation /job: - Gear Tooth Measurement
Name: - Saeed Karim

Time & Date:
1. Use gear tooth caliper and measure tooth size of Gear

Machines/Equipment/ Tools/ Materials: Gear tooth caliper WD 40 work piece

Gear Tooth Measurement by caliper Method:1- Clean the gear tooth properly using WD 40.
2- Hold the gear in fixture.
3- Open the vertical beam equal to addendum or
module and set on job.
4- Measure tooth thickness by using horizontal
beam of vernier tooth caliper.
Application and Try out: Measure the tooth thickness for spur gears of 1 Module and 2 Module.
1. Read the tooth thickness accurately.
2. Store tooth caliper in box after use.
59
Special Assignment:
Draw neat sketch of gear tooth caliper.
References: Technology of Machine Tool by SF Kror
60

Operation /job: - Measurement by Thread Gauges
Name: - Saeed Karim__

Time & Date:
1. Use thread gauges and measure different sizes

Introduction, Preparation & Motivation: Machines/Equipment/ Tools/ Materials: Screw pitch gauge Threading Gauge WD 40 Work piece
Measurements of Threads by Screw pitch Gauge

1- Clean the threads of Job and thread ring gauge.
2- Hold the job in proper fixture.
3- Check the size of thread by using thread ring
gauge.
Measurement of Threads By threads Ring

Gauges
1- Clean the threads of Job and thread ring gauge.

2- Hold the job in proper fixture.
3- Check the size of thread by using thread ring
gauge.
Application and Try out: Check the size of threads of given work piece by screw pitch gauge and
thread ring gauge
1. Use WD 40 to clean the threads.
2. Set the thread gauge on work piece properly.
3. Store the thread gauge after use.
61
Special Assignment:
Sketch the thread ring gauge
References: Technology of Machine Tool By SF Kror
62

Operation /job: - Practice of Measurement on CMM
Name: - Saeed Karim

Time & Date:
1. Use the CMM.

Introduction, Preparation & Motivation: Machines/Equipment/ Tools/ Materials: CMM, Different Work piece
789101112-
Turn on transformer.
Turn on air dryer.
Open compressed air valve.
Turn on machine power supply button.
Press start button.
The CMM starts initialization and moves with
reference to each axis.
13- Measure the size.
CMM
Co-ordinate Measuring Machine.
123456-
Clean the surface of measuring table.

Attach the temperature Sensor.
Calibrate CMM with master ball.
Place the work piece on measuring table.
Adjust moving speed.
Turn on Main Power supply.
Application and Try out: What are the functions of CMM?

1- Press the Emergency step button in case of emergency during operation.
2- Be sure to keep your hands and head at a distance from moving range.
63
Special Assignment:
Take a job and find its sizes
References: PITAC Lahore
64

Operation /job: - Practice of Profile Projector
Name: -Saeed Karim

Time & Date:
1. Use the Profile Projector.

Introduction, Preparation & Motivation: Machines/Equipment/ Tools/ Materials: Profile Projector with accessories work pieces.
Profile Projector:1234567-
Clean the tool and work piece.

Set the job in front of lens.
Focus the job.
Set the magnification.
Switch on project.
Set x-axis and y-axis for measurement.
Read the size of Lcd.
Application and Try out: What are the uses of profile projector?
1- Clean all the tools and job before measurement.
2- Focus properly for good results.
3- Handle the job in hand vise if not set on base.
65
Special Assignment:
Draw neat sketch and take a job from store and check its angles.
References: PITAC Lahore
66

3-5 Metrology

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3-5 Metrology

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DAE Mechanical

GENERAL OBJECTIVES:The student will be able to know about

Expected Entry behaviors

METROLOGY :Metrology is science of measurements. Practice of metrology involves

Testing & Follow Up:-

(to see if leaner accompanied information or skill)

(Usually home work)

Tools Material & Aids:Board marker, Duster lesson Plan.

(Author, title, publisher, page or chapter number, date of publication)

GENERAL OBJECTIVES:i) The student will be able to know about

Expected Entry behaviors

1. The student will be able to

Science of measurement has made

Importance of Measurement:Measurement is very important in

Testing & Follow Up:-

1. We need measurement to make

(to see if leaner accompanied information or skill)

(Usually home work)

Tools Material & Aids:Board marker, Duster lesson Plan.

(Author, title, page or chapter number, date publication)

GENERAL OBJECTIVES:i) The student will be able to know about

SPECIFIC OBJECTIVES:1. The student will be able to know about

Expected Entry behaviors

the Quality Control.

Quality:1. Quality is fitness for use.

Correcting and preventing loss.

3. Quality should be aimed at the needs

Quality Means Meeting:Customer agreed requirement at

It is a scientific method of inspection by i.

Insured rapid inspection.

Maintains complete record of daily

More economical use of material.

Testing & Follow Up:-

(to see if leaner accompanied information or skill)

(Usually home work)

Tools Material & Aids:Board marker, Duster, Lesson Plan.

(Author, title, publisher, page or chapter number,publication)

GENERAL OBJECTIVES:i) The student will be able to know about

Expected Entry behaviors

1. The student will be able to know about

The 11th general conference of weights

Supplementary Units:Plan Angle(, , , )

ISO 9000: QM & QA Selection & use

1970-European countries made quality

ISO 9001: QA in design

1979-British standard institute presented

ISO 9002: Prod. & installation

Testing & Follow Up:-

(to see if leaner accompanied information or skill)

(Usually home work)

Tools Material & Aids:Board marker, Duster, Lesson Plan.

(Author, title, publisher, page or chapter number, publication)

FIT- Tolerance - Allowances

Subject (Course Title) MECH-252

Expected Entry behaviors

and system of limits and tolerances.

Degree of tightness and looseness

difference between high limit and low

Testing & Follow Up:-

(to see if leaner accompanied information or skill)

(Usually home work)

Tools Material & Aids:Board marker, Duster, Lesson Plan.