Shop Practice No.

2
INSIDE AND OUTSIDE CALIPER
OBJECTIVES:
1. To be able to make inside and outside caliper.
2. To practice different bench work practice.
3. To be able to select the proper hacksaw, files in cutting and filing
operations.
4. To be able to apply cold forming method in this project.

METHODS AND ANALYSIS:

The most common incorrectly used and abused tools in the
machine shop are the hacksaw and files. It will take time and practice
for the student to be more proficient in their use. Bench work practice
will accelerate student to think ways to make their work easier and
safe working attitude.

MATERIALS:
2 pcs. flat bar 7 x 1 x 1/8
1 pc. 3 tail cut in two pieces use for rivets

TOOLS AND EQUIPMENT

Bench metal vice to hold the materials to be bent.
Hack saw to cut metals.
Ball-peen hammer for pounding metals to bend and for riveting
purpose.
Half Round File- used for filing curved surfaces.
Flat File- used for general filing of metals such as steel.

PROCEDURE:
1.
2.
3.
4.
5.
6.

7.
8.
9.

Cut the flat bar, 1/8-inch thickness by 1-inch width by 8-inches

length shown in figure 1.
Measure 1-inch length in both sides and mark it and place a
diagonal line between the units as shown in figure 2.
Cut the metal on its diagonal line and round the two ends as
illustrated in figure 2.
Joint the two to produce work piece through the 1/8-inch board
hole by riveting process.
Bend the two tips of the work piece at 90 as in figure 4 to
produce an inside caliper.
For the outside caliper, bend the curvature of the outside
caliper by lightly pounding the metal in the anvil until the
desired curvature is attained.
Join the two metals (same in No. 4) to produce an outside
caliper.
Finishing and smoothing of the work piece is done by filling.
Finish.

FIGURES IN MAKING INSIDE AND OUTSIDE CALIPERS

Bend the tip at

90o

Figure 4 Inside Caliper

8.0000
1.00
00

42

PRELIMINARY DRAWING AND DATA SHEET

(OUTSIDE CALIPER)

TOP VIEW

ISOMETRIC VIEW

FRONT VIEW

RIGHT SIDE VIEW

*Drawings are not to be scaled

(INSIDE CALIPER)

ISOMETRIC VIEW
TOP VIEW

FRONT VIEW

*Drawings are not to be scaled

QUESTIONS:

RIGHT SIDE VIEW

1.

2.

3.

4.
5.

What is the meaning of 24 teeth hack saw blade?

The hacksaw is used to cut steel and other metals. Blades
have 14, 18, 24, 32 teeth per 25mm (inch). A 24 teeth hack
saw blade is used for cutting steel plate up to 5/6 mm.
What procedure is recommended if a saw blade breaks
or becomes dull in a partially finished cut?
The blade should be replaced and the work should be rotated
one half turn so that the old cut is at the bottom. The new
blade will bind in an old cut and the set of the new teeth will
be ruined fast.
Describe and state the purpose of:
Single-cut files
Single cut files have rows of teeth that cut parallel to
each other at an angle of 65 degrees from the centerline.
The purpose of this file is for sharpening tools, finishfiling and draw-filing. They are also the best tools for
smoothing the edges of sheet metal.
Double-cut files
Double-cut files have rows of teeth crisscrossed so the
teeth become diamond shaped. The first row of teeth is
called the overcut. On top of these rows, a second set of
teeth is cut at a different angle to the file axis. This row is
known as the upcut and is finer than the overcut. Doublecut files are generally used for rough work and fast
removal of material.
Name the most commonly used degrees of coarseness
in which files are manufactured.
Most commonly used are the bastard, second cut, and smooth.
List four important aspects of file care?
a. A new file should be broken in by using it first on brass,
bronze, or smooth iron.
b. Never use a new file to remove the fins or scales on cast
iron.
c. Using a clogged file will scratch the work. This is called
pinning. One way to help prevent pinning is by rubbing
chalk between the teeth before filing,
d. The best method to clean the file is to use a file scorer and
file cleaner brush.

6.

How can pinning of a file be kept to a minimum?

Too much pressure results in pinning, which causes scratches.
Keep file clean and push brass, copper or wood through the
teeth to remove pins. Applying chalk to the face of the file will
lessen the pinning.
7.
What is cold forming?
Cold forming is the process of forging metals at near room
temperatures. In cold forming metal is formed at high speed
and high pressure into tool steel or carbide dies.
8.
Why is there a need of adjusting the blade tension of a
hacksaw?
The reason why most people have difficulty when sawing
metal is that there is too much flex in the blade. When cutting,
the blade must be rigid and under considerable tension to cut
properly. If it twists or kinks during the sawing process great
amounts of friction are generated and much energy is lost.
Therefore, proper installation of the blade is very important.
Don't just tighten the adjusting nut until the blade doesn't fall
off; continue tightening until the saw frame starts to bend
under the tension on the blade. That will keep it in correct
adjustment for sawing.
9.
Why is there a need to place a handle in file?
The end part of a file also known as the tang is a dangerous
part that may cause injuries to the user. The need of a file
handle ensures that the tang will not cause an injury to the
user
10. Give at least seven (7) types of files used by a
machinist. Make a simple drawing of each type and
their uses.
a) Round File
Round files are used for filing circular openings or concave
surfaces. Round files taper slightly toward the point. Bastardcut files 6 inches and longer are double-cut. The second-cut
files, 12 inches and longer, are double cut. All others are
single-cut.

b) Triangular File
Triangular file is triangular in section and very useful when
filing tight corners or angles. The sharp edges allow the file to
fit into corners when filing.

c) Square File
The square file is quite thin and fits into corners well. They can
be used to file slots in metal or for filing where there is little
space.

d) Half Round File

Half-Round File is used for filing curved surfaces. A normal
hand file with its flat cutting edges is unsuitable for filing
curved surfaces. However, the half round file has a curved
surface which is especially useful for filing internal curves.

e) Flat File
It is use to file flat surfaces. It is also the most common type of
file for all types of work except inside curves, the flat file
tapers in both width and thickness toward the head.

f) Pillar File
Pillar files are similar to hand files in general shape, but are
much narrower. They are double-cut with one uncut edge.
Pillar files are used to file in slots and keyways

DISCUSSION:
The method used in this project is cold forming. The students
were given 2 flat bars and from that, they need to construct the inside
and outside calipers. The students used a hacksaw in cutting the flat
bars. The students exercised their creativity skill in placing the metal
so that it can be easily cut. In order to form the desired shape, the
students used a ball-peen hammer to strike the flat bars in a room
temperature. The students skill in filing were tested once again. They
used a half-round file and flat-file in filing a curved and flat surfaces

respectively. This activity would help them enhance their skills that can
be used for upcoming experiments.

CONCLUSION:
In doing this shop practice, sufficient knowledge of different hand
tools are needed. This would help the students finish their work faster
and efficiently, and since this is the first time that the students will be
working on cold forming. Proper practices should also be performed to
ensure the safety of the students. The students should avoid using a
file without a handle. Presence of mind together with some PPEs is also
needed when performing operations in the drilling machine.

RECOMMENDATION:
The students recommend that the school should ensure that each
student should be given their PPEs because working in this kind of
environment is dangerous. Students are prone to lacerations and other
injuries. The student also recommend that the tools should always be
checked to ensure that it is capable of doing its job. Some of the blades
of the hacksaw are dull and needed to be replaced.

REFERENCES:
http://www.craftsmanspace.com/knowledge/calipers-measuringtools.html
http://www.technologystudent.com/equip1/hfile1.htm
https://www.goconqr.com/en/p/3199065-hand-cutting-toolsflash_card_decks

Mapua Institute of Technology

Muralla St. intramuros, Manila
Department of Mechanical and Manufacturing
Engineering

SHOP PRACTICE NO. 2

INSIDE AND OUTSIDE CALIPER

Caliwliw, Jantzen Brix

Program/Year: ME-3
Course Code/Section: ME137L/A2
Student Number: 2014100354

GRADE

Group Number: 2

Engr. Jose V. Hernandez

Instructor