Tafila Technical University

Faculty of Engineering
Department of Mechanical Engineering

Metrology Science LAB

“Experiment 3: Block Gauges”

Student Name: Ahmad Nader Ghawanmeh.

Student ID: 320180101053.
Instructor Name: Dr. Rashid Abdul Latif Lotfi Abdullah.
2. Objectives:

▪ To familiarize the student with the types, applications of block gauges.

▪ To learn how to use block gauges in calibration.

3. Apparatus:

1-Set of block gauges.

2-Surface plate.
3-Outside micrometer.
Gauge blocks
▪ Accurate measurements of length can be accomplished only through comparison with a
standard, preferably one that is traceable to a primary standard.
▪ Working standards for the measurement of length, such as line standards and end
standards are essential to manufacturing. Two marks engraved on a dimensionally stable
material define length on a line standard. The length of an end standard is the distance
between its flat, parallel end faces.

▪ Gauge blocks are the most often used length standards. These are small, steel blocks,
usually rectangular in cross section, having two very flat and parallel surfaces that are
a certain specified distance apart. Gauge blocks (figure 3.1) are usually made of alloy
steel or cemented carbide, hardened (to increase wear resistance) and carefully heat
treated to relieve internal stresses and minimize subsequent dimensional change.

▪ The measuring surfaces of each bock are ground and then lapped to produce very flat
and smooth surfaces that are parallel within a few tenths of a micrometer. When such
surfaces are slid together with a slight contact pressure, the adhere with a significant
force (adhesion is due to molecular attraction and atmospheric pressure); this procedure
of combining gauge blocks is called wringing.

▪ Gauge blocks usually come in sets of various sizes and by wringing you can obtain
various combinations.

Figure 3.1-gauge blocks set.

▪ Gauge blocks also called slip gauges-are made in five grades or classes or accuracy:
Grade 00, Calibration Grade, Grade 0, Grade I & Grade II.

▪ Calibration grade has the highest level of accuracy in normal engineering practice
and it is intended for calibrating other blocks. They are used where tolerance are < 2µm
and are not intended for general gauge inspection.

▪ Grade 0, I, II are intended for general use. Grade 0 is intended for high precision
uses, grade I is for general purpose manufacturing gauge (they are used with sine bars),
and grade II is intended for rough setting purposes and checking components.

▪ Instruction for wringing together two slip gauges:

1. Surfaces must be clean and free from burrs. They should be washed in petrol,
benzene, carbon tetrachloride or other dielectric-greasing agents and dry on a
clean cloth. Then be wiped with clean soft chamois leather.
2. Slip gauges then should be held across one another at right angles and wring them
with a rotary motion; this reduces the amount of surface rubbing.
3. A minute amount of grease or moisture must be present between the surfaces for
them to wring satisfactorily. Unless a very firm is obtained, there is always a
possibility that the wringing film may be a micrometer thick.

▪ It is advisable to take the following points into consideration: In order to prevent

damage to gauge blocks:
1. Protect from dust, dirt and moisture.
2. Avoid magnetization.
3. Handle lapped faces as little as possible to prevent etching from finger acid. Wipe
all finger marks with clean soft chamois leather.
4. Always wipe faces immediately before use even when use is continuous.
5. Always replace clean gauges in their box and close it after use. If gauges are not
in frequent use they should be coated to prevent corrosion.
6. Do not handle gauges above the open box; they may cause damage to other
gauges if dropped.

Figure 3.2 method of wringing slip gauges

5. Calibration

▪ Calibration is the act or result of quantitative comparison between a known standard

and the output of the measuring system measuring the same quantity. In a way, the
process of calibration is in effect the procedure for determining the scale of the
measuring system.

▪ For example, by application of a range of known values for the input and observation of
the system output, a direct calibration curve can be developed for the measurement
system. On such a curve the input, x, is plotted on the abscissa against the measured
output, y, on the ordinate.

▪ A calibration curve forms the logic by which a measurement system's indicated output
can be interpreted during an actual measurement. The calibration curve can be the basis
for fixing the output display scale on a measurement system.

Figure 3.3 Calibration of a micrometer using block gauges

6. Procedure

1. Use the provided metric unit slip (block) gauge set, list the slips to be wrung to
produce the following overall dimensions using the minimum number of blocks
gauges.
2. Use the block gauges set to calibrate the provided micrometer, calculate the error
in each reading, draw the calibration curve.
7. Results:

Table 1: Experiment Results

Reading No. Input Data Output Data Error
(mm) (mm)
1 5 4.95 1
2 5.15 5.21 1.16504854
3 5.3 3.3 37.7358491
4 5.45 5.5 0.91743119
5 5.6 5.65 0.89285714
6 5.75 5.78 0.52173913
7 5.9 5.88 0.33898305
8 6.05 6.09 0.66115702
9 6.2 6.18 0.32258065
10 6.35 6.33 0.31496063
11 6.5 6.55 0.76923077
12 6.65 6.7 0.7518797
13 6.8 6.82 0.29411765
14 6.95 7 0.71942446
15 7.1 7.14 0.56338028
16 7.25 7.22 0.4137931
17 7.4 7.45 0.67567568
18 7.55 7.6 0.66225166
19 7.7 7.72 0.25974026
20 7.85 7.88 0.38216561

▪ Figure 3.4 represents plotted data between output and input using Microsoft office
excel:
Input Data vs Output Data
9
8 y = 1.1577x - 1.091
7
6
Output Data

5
4
3
2
1
0
0 1 2 3 4 5 6 7 8 9
Input Data

Figure 3.4 Plotted Results

▪ And in the next page the results plotted Manually and the equations are showed on
both charts.