FACULTY OF MECHANICAL & AUTOMOTIVE ENGINEERING

TECHNOLOGY

DRM1613 METROLOGY
SEMESTER II – 2023/2024
PROJECT
GROUP 6

PROJECT TITLE : BENCH VICE

SECTION : RM01
LECTURER : MUHAMMAD HILMI BIN JALIL
SUBMISSION DATE : 7 JUNE 2024

NO MATRIX NO. NAME

1 RM23199 MUHAMMAD DANISH IRFAN BIN MOHD AZHAM
2 RM23257 IKMAL ARIF BIN THARIQ
3 RM22267 AMAR HARITH BIN MOHD NADZRI
4 RM22178 AL-MU’IZZUDDIN BIN SAFIAN
Task Distribu�on

BIL GROUP MEMBER ID NUMBER TASK DONE

1 MUHAMMAD DANISH RM23199 1. Explana�on
IRFAN BIN MOHD AZHAM on the
Measuring
Instrument and
Method
2. Calcula�on
of Means and
SD
3. Process of
Measurement
4. Conclusion
2 IKMAL ARIF BIN THARIQ RM23257 1. Reason for
Selec�ng the
3D model
2. Explana�on
on the
Measuring
Instrument and
Method
3. Process of
Measurement
3 AMAR HARITH BIN MOHD RM22267 1. Introduc�on
NADZRI on the project
and selected
3D model
4 AL-MU’IZZUDDIN BIN RM22178 -
SAFIAN
Introduc�on
This report is a summary of the project of making a bench vice that
was performed for subject metrology (DRM1613). The bench vice
project involves several stages, from design and material selec�on to
machining and assembly. Each stage requires me�culous
measurement and verifica�on to ensure that all parts fit together
perfectly and func�on smoothly. The primary instruments used in
this project include the vernier caliper, angle gauges, and profile
projector. These tools are indispensable for achieving high precision
in dimensions, angles, and profiles, which are cri�cal for the
performance of the bench vice.

This report provides a comprehensive overview of the measuring

instruments and techniques used, detailing their opera�on and the
role they play in the manufacturing process. The use of vernier
calipers allows for precise measurement of linear dimensions, angle
gauges ensure accurate angular measurements, and profile projector
facilitate the inspec�on of complex profiles. By employing these
metrology tools, the project aims to produce a bench vice that meets
stringent quality standards, ensuring reliability and efficiency in its
use.
Reason for Selec�ng 3D Model
Selecting a 3D model of a vice bench offers several advantages:

1. Complexity: A vice bench model typically includes various

components like the base, handle, and clamping mechanism,
making it ideal for demonstrating detailed assembly and
mechanical function.
2. Functionality: The vice bench is a practical tool used in various
industries, allowing for realistic and application-focused
projects.
3. Educational Value: Studying the 3D model of a vice bench
provides valuable insights into mechanical design, engineering
principles, and material properties.
Explana�on on the Measuring Instrument
and Method

Vernier Caliper
Purpose: A vernier caliper is a precision measuring instrument used
to accurately measure linear dimensions of objects. Its primary
purpose is to provide precise measurements of length, width, and
thickness of objects with high accuracy.
Method:
1. Prepara�on: Ensure the vernier caliper is clean and in good
condi�on.
2. Zero Adjustment: Close the jaws of the caliper and make sure
the zero mark on the vernier scale aligns with the zero mark on
the main scale.
3. Selec�on of Measurement Mode: Vernier calipers can measure
both internal and external dimensions. Choose the appropriate
mode depending on the object to be measured.
o External Measurement: Open the jaws of the caliper and
place the object between them. Close the jaws gently
un�l they firmly grip the object without deforming it.
o Internal Measurement: Use the small jaws at the botom
of the caliper to measure internal dimensions such as the
diameter of a hole or the width of a groove. Open the
jaws and place them inside the object, then close them
gently un�l they contact the walls of the internal feature.
 4. Reading the Main Scale: Read the main scale (in millimeters or
inches) to determine the whole number part of the
measurement. Note the number immediately to the le� of the
zero mark on the vernier scale.
5. Reading the Vernier Scale: The vernier scale consists of
mul�ple divisions that correspond to a frac�on of the smallest
division on the main scale. Find the line on the vernier scale
that aligns most closely with a line on the main scale. Note the
number on the vernier scale that lines up with a line on the
main scale.
6. Calcula�ng the Measurement: Combine the whole number
from the main scale with the frac�on indicated by the vernier
scale. This provides the accurate measurement.
o For example, if the main scale reads 5 mm and the vernier
scale aligns with the 0.2 mm mark, the measurement is
5.2 mm.
7. Recording the Measurement: Record the measurement
accurately, including units (millimeters or inches).
8. Verifica�on: To ensure accuracy, it's recommended to take
mul�ple measurements and verify consistency.

Radius Gauge
Purpose: A radius gauge, also known as a radius gage or fillet gauge,
is a precision measuring instrument used to measure the radius of a
curved surface or the fillet radius of a corner. Its primary purpose is
to ensure that manufactured components meet design specifica�ons
by accurately determining the radius of curvature.
Method:
1. Selec�on of Gauge: Choose the appropriate radius gauge based
on the expected radius range of the surface to be measured.
Radius gauges typically come in sets with various sizes of curved
notches or steps represen�ng different radii.
2. Prepara�on: Ensure that the surface to be measured is clean
and free from any debris or irregulari�es that could affect the
measurement.
3. Placement: Place the radius gauge perpendicular to the curved
surface or corner to be measured.
4. Selec�on of Notch: Select the notch or step on the radius gauge
that matches the curvature of the surface closely. It should sit
flush against the surface without any gaps.
5. Alignment: Ensure that the selected notch or step is aligned
with the curved surface or corner, allowing for accurate
measurement.
6. Visual Inspec�on: Visually inspect the fit between the notch or
step and the surface to ensure there are no gaps or overlaps. A
perfect fit indicates that the radius gauge matches the
curvature of the surface accurately.
7. Reading the Measurement: Once the notch or step is properly
aligned with the surface, note the size or label of the
corresponding notch or step on the radius gauge.
8. Recording the Measurement: Record the measured radius
accurately, including units if applicable.
9. Verifica�on: To ensure accuracy, it's recommended to double-
check the measurement using mul�ple radius gauges of
different sizes if possible.
Profile Projector
Purpose: A profile projector is a precision op�cal instrument
primarily used for the measurement and inspec�on of 2D profiles of
manufactured parts. Its purpose is to accurately magnify and project
the profile of a part onto a screen for detailed examina�on and
measurement.
Method:

1. Prepara�on: The part to be inspected is placed on the stage of

the profile projector. It should be cleaned and posi�oned
accurately.
2. Illumina�on: The light source is turned on, providing uniform
illumina�on of the part.
3. Focus: The projec�on lens is adjusted to focus the image of the
part onto the screen.
4. Magnifica�on: The desired magnifica�on level is set using the
magnifica�on system.
5. Projec�on: The profile of the part is projected onto the screen.
6. Measurement: Using the re�cle or addi�onal measurement
tools, dimensions and features of the part are measured and
inspected.
7. Analysis: The inspector analyzes the projected profile for any
devia�ons from the desired specifica�ons.
8. Documenta�on: Results of the inspec�on, including
measurements and any defects found, are documented for
quality control purposes.
Calcula�on of Means and Standard
Devia�on

i. Base

Top
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
125.00 125.00 125.00 125.00 0.0000
25.00 25.01 25.00 25.00 0.0047
60.00 60.01 59.00 60.00 0.4738
20.00 20.00 20.01 20.00 0.0047
40.00 40.00 40.00 40.00 0.0000
4.50 4.50 4.50 4.50 0.0005
 1.00 1.00 1.00 1.00 0.0000

Front
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
150.00 151.00 150.00 150.03 0.4714
60.00 60.00 60.00 60.00 0.0000
19.85 19.86 19.85 19.85 0.0047
19.85 19.86 19.85 19.85 0.0047

Right
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
30.00 31.00 30.00 30.33 0.4714
20.00 20.00 20.00 20.00 0.0000
8.00 8.01 8.00 8.00 0.0047
60.00 60.00 60.02 60.00 0.0094
37.30 37.31 37.30 37.30 0.0047
8.50 8.50 8.50 8.50 0.0000
4.45 4.45 4.45 4.45 0.0005

*All chamfered edges are 1.00 mm

ii. Fixed Jaw

1) Thread
Type: Metric Tap
Size: M64x6.0
Front
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
34.70 34.69 34.71 34.70 0.0082
60.00 60.01 60.00 60.00 0.0047
 38.00 39.00 38.00 38.33 0.4714
19.15 19.15 19.16 19.15 0.0047
7.20 7.20 7.20 7.20 0.0000
6.50 6.51 6.50 6.50 0.0047
5.15 5.14 5.16 5.15 0.0082
1.00 1.00 1.00 1.00 0.0000

Right
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
4.50 4.50 4.51 4.51 0.0047
25.00 25.01 25.00 25.00 0.0047
1.00 1.00 1.00 1.00 0.0000

*All chamfered edges are 1.00 mm

iii. Moving Jaw
Top
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
7.92 7.92 7.91 7.92 0.0047
4.92 4.91 4.93 4.92 0.0082

Depth:
1) 5.00 mm
2) 11.00 mm

Front
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
30.00 30.00 30.00 30.00 0.0000
19.00 19.00 19.00 19.00 0.0000
31.35 31.36 31.36 31.36 0.0071
5.15 5.16 5.15 5.15 0.0050
6.50 6.51 6.50 6.50 0.0071
17.35 17.40 17.35 17.37 0.0206
7.20 7.21 7.19 7.20 0.0071
19.15 19.15 19.20 19.17 0.0206
19.00 19.00 19.00 19.00 0.0000
30.00 30.00 30.00 30.00 0.0000
Right
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
25.00 25.50 25.00 25.17 0.2041
1.00 1.00 1.00 1.00 0.0000

Back
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
38.00 37.00 38.00 37.66 0.4714
34.70 34.70 34.71 34.70 0.0047
60.00 60.00 60.00 60.00 0.0000
18.91 18.92 18.91 18.91 0.0047
16.98 16.97 16.98 16.98 0.0047

Depth:
3) 14.00 mm
4) 15.00 mm

*All chamfered edges are 1.00 mm

iv. Turning Screw

1) Thread
Type: Metric Die
Size: M64x6.00
Front
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
29.36 29.35 29.36 29.36 0.0047
15.00 15.00 15.00 15.00 0.0000
 18.51 18.50 18.51 18.51 0.0047
1.00 1.00 1.00 1.00 0.0000

Right
1st, mm 2nd, mm 3rd, mm Mean, SD, σ
mm
15.00 15.00 15.00 15.00 0.0000
53.07 53.06 53.08 53.07 0.0082
105.00 105.01 105.00 105.00 0.0047
5.85 5.85 5.85 5.85 0.0000
2.00 2.00 2.00 2.00 0.0000
9.00 9.00 9.00 9.00 0.0000
v. Fillister

1st, mm 2nd, mm 3rd, mm Mean, SD, σ

mm
7.80 7.81 7.80 7.80 0.0047
4.60 4.61 4.60 4.60 0.6588
0.50 0.51 0.51 0.51 0.0041
6.40 6.42 6.40 6.41 0.0094
0.50 0.50 0.50 0.50 0.0000
4.75 4.75 4.70 4.73 0.0236
vi. Pin

1st, mm 2nd, mm 3rd, mm Mean, SD, σ

mm
59.00 59.10 59.05 59.05 0.0408
0.50 0.55 0.50 0.52 0.0236
4.00 4.50 4.00 4.05 0.0408
3.00 3.50 3.00 3.10 0.0817
Process and Measurement

Measuring with Vernier Caliper

Tools Required:
- Vernier Caliper

Steps:

1. Preparation:
o Ensure the vernier calliper is clean and free of debris.

o Clean the 3D printed workpiece to remove any dust or

par�cles.

2. Zeroing the Calliper:

o Close the jaws of the vernier calliper completely.

o Check the zero reading on the main scale and the vernier

scale. If not zero, adjust accordingly.

3. Measuring External Dimensions:

o Open the calliper jaws slightly more than the dimension to

be measured.
o Place the workpiece between the jaws.

o Close the jaws gently un�l they touch the workpiece

without compressing it.

o Read the measurement from the main scale and the

vernier scale to get the precise dimension.

 4. Measuring Internal Dimensions:
o Open the internal jaws of the calliper slightly more than

the internal feature to be measured.

o Insert the jaws into the feature (e.g., hole).

o Open the jaws un�l they touch the internal sides of the

feature.
o Read the measurement from the scales.

5. Measuring Depth:
o Use the depth rod at the end of the calliper.

o Place the end of the calliper on the top surface of the

feature.
o Extend the depth rod un�l it touches the botom surface.

o Read the measurement from the scales.

Measuring with Radius Gauge

Tools Required:
- Radius Gauge Set

Steps:

1. Preparation:
o Select the radius gauge set that includes the likely radii of

the features to be measured.

o Clean the 3D printed workpiece.

2. Choosing the Right Gauge:

o Inspect the feature (e.g., fillet or rounded edge) that you

need to measure.
 o Choose a radius gauge with a radius close to the
es�mated radius of the feature.

Measuring the Radius:

o Place the concave or convex edge of the gauge against the

rounded feature on the workpiece.
o Check for the fit: the gauge should match the curvature of
the feature without gaps.
o If the gauge does not fit perfectly, try the next closest size
un�l you find the one that matches.

3. Recording the Measurement:

o Once the correct gauge is found, note the radius indicated

on the gauge.
o Record the radius measurement.

Measuring with Profile Projector

Tools Required:
- Profile Projector Machine

Steps:

1. Prepara�on:

• Ensure that the profile projector is set up on a stable surface

and calibrated correctly.
• Select the appropriate lens for magnifica�on based on the size
of the object you are measuring.
• Clean the measuring stage and any components that will come
into contact with the object to be measured to ensure accurate
readings.

2. Place the Object:

• Carefully place the object to be measured on the measuring

stage of the profile projector. Ensure that it is posi�oned
securely and flat against the stage.

3. Focus and Magnifica�on:

• Adjust the focus and magnifica�on se�ngs of the profile

projector to obtain a clear and magnified image of the object's
profile on the screen.

4. Alignment:

• Align the object's profile with the crosshairs or grid on the

screen. This ensures that you are measuring the correct
dimensions.

5. Measurement:

• Using the built-in measuring tools or so�ware of the profile

projector, measure the dimensions of the object's profile. This
may involve measuring lengths, angles, radii, and other relevant
features.

6. Record Data:

• Record the measurements accurately, either manually or by

using the profile projector's data capture capabili�es.
7. Analysis:

• Analyze the measured dimensions against the specified

tolerances or requirements. Iden�fy any devia�ons or
discrepancies that may require further inves�ga�on or
adjustment.

8. Repeat as Necessary:

• If required, repeat the measurement process for different

sec�ons or features of the object to ensure comprehensive
dimensional analysis.

9. Documenta�on:

• Document the measured dimensions, analysis results, and any

relevant observa�ons for future reference or repor�ng
purposes.

10. Maintenance:

• A�er comple�ng the measurements, clean the profile projector

and measuring stage to maintain its accuracy and reliability for
future use.
Conclusion
In conclusion, the objec�ves of this project have been successfully
achieved. Through me�culous measurement using appropriate
instruments, we obtained accurate dimensions of our 3D model,
including length, angle, and diameter. Following proper methods
ensured consistency and minimized errors, laying a strong founda�on
for reliable results.

Moreover, this project provided valuable learning opportuni�es,

including mastering the use of 3D design so�ware like SolidWorks.
This newfound skill opens doors to endless possibili�es in the realm
of digital modelling and design.

Lastly, the collabora�ve effort and dedica�on of all group members

were integral to the project's success. Their coopera�on and
conscien�ousness exemplified teamwork at its finest, demonstra�ng
that collec�ve effort can overcome challenges and achieve great
outcomes.
References
1. KALAM
2. htps://byjus.com/physics/vernier-calliper/
3. htps://infinitalab.com/metrology-tes�ng-service/what-
are-radius-gauges/
4. htps://en.wikipedia.org/wiki/Op�cal_comparator
5. htps://youtu.be/twY9fza6aIg?si=BUYw09bp0zcy5IlK
6. htps://grabcad.com/library/bench-vice-262
APPENDIX
1) MUHAMMAD DANISH IRFAN BIN MOHD AZHAM (RM23199)

2) IKMAL ARIF BIN THARIQ (RM23257)

3) AMAR HARITH BIN MOHD NADZRI (RM22267)

4) AL-MU’IZZUDDIN BIN SAFIAN (RM22178)