BTM2133 METROLOGY

CHAPTER 4

Measuring Instruments
 MEASURING INSTRUMENT

Direct
measurement
Indirect
measurement
Linear
measurement
Precision

Non-precision

Type of
measurement
instrument

Precision
Angular
measurement
Non-precision
Linear measurement

 Direct measurement
 Rule
 Vernier caliper, height gage, depth gage
 Micrometer

 Indirect measurement
 Outer Caliper
 Inner caliper
 Divider
Linear measurement

 Precision instrument
 Micrometer
 Vernier caliper, height gage, depth gage

 Non-precision instrument
 Rule
 Divider
 Calipers
Angular Measurement

 Precision instrument
 Universal bevel protractor
 Dividing head
 Spirit level
 Sine bar
 Angle gage block Dividing head
 Auto collimator
 Non-precision instrument
 Protractor
 Adjustable bevel
 T-square
Graduated Scales and
Scaled instruments

• Rule is also called as graduated scales.

• The layout and inspection instruments (scaled instruments)

can be divided into three groups:

1st: rules with mechanical refinements to make them more

useful, such as the combination square.

2nd: related devices that are used with rules but are not rules
themselves, like caliper.

3rd: vernier instruments like vernier height gage which are the
highly precise refinements of steel rule.
Direct measurement

 Rules

Rules or graduated scales, are most

commonly used in layout and
inspection, the two opposite ends of the
production process.
The simplest and most commonly used
instrument is a steel rule, bar or tape
with fractional or decimal graduation.
Rules can be rigid or flexible.
 Steel Rule
 Steel rules are all narrow steel strips with one set or
more of graduated marks.
 These marks are referred to as a scale.
 The number of subdivisions of unit of length on a rule
is called discrimination.
 When you measure with a rule, you use the
interchange method of measurement because you
observe both ends of the part feature at the same
time.
 Measuring with a graduated rule is commonly called
direct measurement.
Discrimination
 Steel rule (reference point)
 You must consider three factors when using a
steel rule:
1. Which style of rule do the best job.
2. Which measurement divisions (scale) should be
used.
3. Which method of holding both rule and part
allows us to obtain the most precise
measurement.

 These factors help us to the best relationship

among the reference point on the part and the
graduations of the rule.
The role of error of steel rule

 Measurement errors with steel

rules come from:
i. Inherent instrument error or tool
ii. Observational error of eye
iii. Manipulative error of hand
iv. Bias
i. Inherent instrument

Can be eliminated by choosing a

quality steel rule.
Quality rules are engine engraved;
a machine called ruling engine
cuts each graduation.
Low cost rules are stamped or
printed, whereas engine engraved
are sharp.
ii. Observational error

 Parallax is important form of

observational error, in which an object
appears to shift when observer changes
his of her position.
 To combat parallax; always place the
scale edge of the rule as close as
possible The observer B would correctly measure
x as 16 division,
While A would measure 15 and C would
measure 17.
iii. Manipulative error

Many common manipulative errors

are caused by ‘cramping ‘- the use
of excessive force.
When you squeeze rule or other
instrument tightly, you may forcing
it against the part.
For reliable measurement, always
use a light touch.
Manipulative Error
iv. The problem of bias

Bias means that we unconsciously

influence each measurement we
make.
- Assume that the dimension need
to be 14 cm (5 ½ in).
- Because that graduation is easier
to read than 13.5 cm (5 31/64 in) or
14.5 (5 33/64 in) cm, you might
biased to read 14 instead of the
accurate measurement.
MICROMETER INSTRUMENTS

 Commonly used for measuring the thickness and

inside or outside dimensions of part.
 All micrometers are based on the relation of a
screw’s circular movement to its axial movement.

 Types of micrometer
1. Outside Micrometer
2. Inside micrometer
3. Depth micrometer
4. Others –e.g :
i. wire micrometer
ii. Screw thread micrometer
Outside micrometer
Outside micrometer (cont’)

 It is mainly used to measure the outside

diameter of a job or length of a small
part.
 It can measure dimension to an accuracy
of 0.001mm.
 The outside micrometers are available in
the measuring ranges from 0-25mm, 25-
50mm, 75-100mm and so on.
 The largest measuring range available is
575-600mm.
 Micrometer parts
 Frame: The C-shaped body that holds the anvil and barrel in constant relation to
each other.

 Anvil: The shiny part that the spindle moves toward, and that the thing to be
measured rests against.

 Barrel/sleeve: Also called the stock. The stationary round part with the linear
scale on it. Sometimes vernier markings.

 Lock-ring/lock nut/thimble lock/Clamp ring: The knurled part (or lever) that
one can tighten to hold the spindle stationary, such as when momentarily
holding a measurement.

 Screw (not seen): The heart of the micrometer. It is inside the barrel.

 Spindle: The shiny cylindrical part that the thimble causes to move toward the anvil.

 Thimble: The part that one's thumb turns. Graduated markings.

 Ratchet stop: Device on end of handle that limits applied pressure by slipping
at a calibrated torque.
Proper way to use micrometer
Inside micrometer
Inside micrometer

 The inside micrometer is used for measuring

large internal diameters (over 50mm) to an
accuracy of 0.01mm.

 It work on the same principle as that outside

micrometer.

 Spindle/ extension rod of different length are

provided in order to obtain a wide measuring
range.
 Depth micrometer
 The depth gauge micrometer is a precision
measuring instrument, used by engineers to
measure depth of holes, slots and recessed areas to
accuracy of 0.01mm.
 They come in sets with different length depth rods of
different ranges measurement.
 The micrometer head acts as reference surface and
is held firmly and perpendicular to the center line of
the hole.
 The ratchet is turned clockwise until the spindle face
touches the bottom of the blind hole.

 The scales are read in exactly the same way as the

scales of a normal micrometer.
 In using this instrument, it should be first ensured
that the edge of the hole is free from burrs.
Depth micrometer
Wire micrometer
To measure diameter of wire
Screw thread micrometer

It is designed to measure the pitch

diameter of screw thread to an
accuracy of 0.01mm.
 Screw thread micrometer
In order to measure the pitch
diameter, the pointed end of
the spindle and the sides of the
vee-envil should contact the
surfaces of the thread.
The reading on the micrometer
is read in the similar way as in
outside micrometer.
Reading a Micrometer
Advantages and disadvantages of
micrometer
 VERNIER INSTRUMENT
 Vernier instrument are used most tool-
rooms, die-making and laboratory work but
rarely for modern production inspection.

 Vernier instrument today includes:

1. Vernier caliper
2. Height gages,
3. Depth gages,
4. Gear tooth instrument
 1. VERNIER CALIPER
 It is a precision instrument which is used for
measuring external as well as internal diameters to an
accuracy of 0.02mm.

 Vernier calipers are slide calipers with a vernier scale

attached.

 The principle of vernier is that when two scales or

divisions slightly different in size are used, the
differences between them can be utilised to determine
the accuracy of measurement.
 Parts of a vernier caliper

1.Outside jaws: used to measure external lengths

2.Inside jaws: used to measure internal lengths
3.Depth probe: used to measure depths
4.Main scale (cm)
5.Main scale (inch)
6.Vernier (cm)
7.Vernier (inch)
8.Retainer: used to block movable part to allow the
easy transferring a measurement
Alignment consideration
 2. VERNIER HEIGHT GAGE
 It is mainly used for measuring heights of parts
to an accuracy of 0.02mm.

 The height gage is essentially a vernier caliper

with an entire surface plate as its fixed jaw.

 The surface plate is not part of height gage, but

the height make efficient use of the surface
plate, because the gage sits right on the plate.

 In order to measure the height, the work is

placed between the surface plate and the
measuring face.
Vernier height gage
Height gage attachment

1. Scriber
(the most important use of the scriber is
for layout rather than measurement) See
figure 4.10.

2. Depth gage attachment

(we can convert the instrument to a
depth gage with very large range, which
allow us to measure relative height
differences in inaccessible.
Scriber

Figure 4.10
Depth gage attachment

The depth gage

attachment gets into
otherwise inaccessible
places
The problem with height gage

 Instability
 wobble (tall, thin column sways freely- can
destroy the reliability of measurement

 Magnification of setup errors

 dirt, surface plate error, burr on height gage
base

 Magnification of instrument error

 wear and abuse can disturb the squareness
of the column to the base of the moveable jaw
to the column.
Height gage error
Vernier gear tooth caliper

 Used for measuring the thickness of a gear tooth at

the pitch circle of a gear.

 Consist of vernier caliper perpendicular to each

other.

 The horizontal caliper measures the tooth thickness

is similar to an outside caliper.

 Whereas the vertical caliper is adjusted for

measuring the distance from the top of tooth to the
pitch circle of the gear.
Vernier gear tooth caliper
How to read vernier instrument?

1. Read the number of the whole divisions on the

main scale that appear to the left of zero (0) on
the vernier.
2. Read the largest numbered graduation on the
main scale that lies to the right of the index (0)
on the vernier scale.
3. Read the largest whole mirror division to the
right index.
4. Find the vernier graduation that most exactly
coincide with any graduation on the main scale.

* Note: before using the instrument, it should be checked

for zero reading. The zero line on the vernier scale
should coincide with the zero on the main scale
Reading a vernier in inches
INDIRECT MEASUREMENT

 Indirect-reading instruments are typically

calipers or dividers without any graduated
scales.
 They are used to transfer the measured size
to a direct-reading instrument such as a rule.
 After adjusting the legs to contact the part at
the desired location, the instrument is held
against a graduated rule, and the dimension
is read.
 Accuracy of indirect measurement is
limited.
 Indirect measurement

Inside caliper Outside caliper Divider

 Indirect measurement
 Outside caliper
 Have their legs bent inward and hinged at the top.
 For checking or measuring outside dimensions or plate thickness.
 A steel rule must be used with the caliper when direct reading is
required.

 Inside caliper
 Have their leg bent outwards.
 For checking or measuring the internal dimensions of recesses, hole
diameters and parallel surfaces of inside dimension.
 A steel rule requires to obtain specific reading.

 Divider
 This tool used for transferring dimensions, marking out curves and
circles and for doing general layout work.
 ANGULAR MEASUREMENT
Bevel protractor
A bevel protractor is a
direct-reading
instrument similar to a
common protractor,
except that it has a
movable element

Will be discussed details in chapter 7

 Sine bar
 Measuring with sine bar
involves placing the part
on a inclined bar or plate
and adjusting the angle
by placing gage blocks
on a surface plate.
 After the part is placed
on the sine bar, a dial
indicator is used to scan
top surface of the part.

Will be discussed details in chapter 7

OTHER MEASUREMENT
INSTRUMENTS

 Feeler gage
 Screw pitch gage
 Dial indicator
 Profile projector
 Feeler gage
 A feeler gage is a simple tool
used to measure gap-widths.

 Feeler gauges are mostly used in

engineering to measure the
clearance between two parts.

 They consist of a number of

small lengths of steel of different
thicknesses with measurements
marked on each piece.

 They are flexible enough that,

even if they are all on the same
hinge, several can be stacked
together to gauge intermediate
values.
 ** clearance – a space between two
parts
 Screw pitch gage
 The use of screw pitch gage
provides quick and accurate
method of checking the thread
pitch of a fastener.

 The leaves of this measuring

tool are marked with the
various pitch.

 To check the pitch, simply

match the teeth of the gage
with the threads of the fastener.

 Then read the pitch from the

leaf.

Ref : J. Erjavec, Automatic Transmission, Thomson Delmar

Learning, 2004
 Dial indicator
 Dial indicators are simple mechanical
devices .

 Convert linear displacements of a

pointer to the amount of rotation of
an indicator on a circular dial.

 The indicator is set to zero at a

certain reference surface, and the
instrument or the surface to be
measured is brought into contact
with pointer.

 The movement of the indicator is

read directly on the circular dial.
 Profile projector
 Profile projector is also commonly called as optical projector or optical
comparator.

 It is an instrument which projects the large shadow of the profile of the

workpiece on a glass screen.

 From this projection of the workpiece, measurement can be made directly

or indirectly.

 The profile projector has a table that can be moved laterally and from
front to back.

 The workpiece is placed on the table and moved into position so that its
enlarged shadow comes on the screen.

Ref: Serving Ohio, Kentucky & Indiana, Manufacturing

technology, New Age Publishe, 2005
Profile projector

 Profile projector consist of:

i. Light source
ii. A lens system (to direct the light past
the workpiece)
iii. A staging table
iv. Projection optics (including both lens
and table)
v. Screen (where the workpiece image is
projected)
Profile projector
References

 Dotson C.L., Fundamentals of Dimensional

Metrology, Thomson Delmar Learning, 2006
 www.wikipedia.com
 www.technologystudent.com
 Webster.J, Outdoor Power Equipment, Thomson
Delmar Learning, 2000
 J. Erjavec, Automatic Transmission, Thomson
Delmar Learning, 2004
 Serving Ohio, Kentucky & Indiana,
Manufacturing technology, New Age Publisher,
2005
 R.S Khurmi, J.K. Gupta,A textbook of workshop
technology, S,Chand & Company LTD, 2001
 S.Kalpakjian & S.R.Schmid, Manufacturing
Engineering and Technology,Prentice Hall, 2001
 Assignment
 Explain the following measurement instruments in term of accuracy and
precision, applications and methods:
- dividing head
- profile projector
-screw thread micrometer

* assignment. Max pages: 6 pages

**Submit before X/XX/201X (Friday) 5.00 pm.
Any Question??

Thanks ☺