LESSON 1.

LINEAR MEASUREMENTS

 INTRODUCTION

Linear measurement applies to

measurement of lengths, diameter, heights
and thickness including external and
internal measurements. The line measuring
instruments have series of accurately
spaced lines marked on them e.g. Scale.
The dimensions to be measured are aligned
with the graduations of the scale. Linear
measuring instruments are designed either
for line measurements or end
measurements. In end measuring
instruments, the measurement is taken
between two end surfaces as in
micrometers, slip gauges etc…

This lesson presents the different types of linear measuring instrument that are
commonly used in the field. The later part is a set of questions that may require you to conduct
more research to cover other important concepts to meet the intended learning outcomes.

LEARNING OUTCOMES

After completing the lesson, you will be able to do the following:

1. Differentiate and identify graduated and non-graduated instruments in terms of its
limitations, functions and specific uses.
2. Demonstrate knowledge about the construction and principle of operation of the
different linear measuring instruments.
3. Perform linear measurement using callipers and micrometres with accuracy and
precision.

1
Classifications of Linear Measurements

The instruments used for linear measurements can be classified as:

1. Direct measuring instruments

2. Indirect measuring instruments

The Direct measuring instruments are of two types:

1. Graduated
2. Non Graduated

The Graduated Instruments

1. Vernier Callipers

This is a precise measuring instrument, comparatively low accuracy than the other
precision measuring instruments. The different types Vernier callipers are available to
measure internal, and external measurements.

Vernier Depth Gauges

Vernier depth gauge can be used to measure the depth of the holes. Here we can use
extension rods if necessary.

2
 Vernier Height Gauges

It is used to determine the height of the

objects. The Vernier Height gauge measures
the object height by using the underside of
the scriber as the datum. This datum may
be permanently fixed or height gauge will
have the provision to adjust the scale. see
the below picture:

2. Micrometers

Also known as Micrometer Screw gauge because a calibrated screw is used for precise
measurements in this instruments. We can measure the inside, outside diameters,
depths as well. This is also used in microscopes to measure the microscopic objects.

3. Dial indicators

Used to measure the small distances, angles. It is widely used in checking the tolerances
during the inspection of the machined component and deflection of the beams.

3
Non-graduated Instruments:

1. Caliper

Caliper is used to measure the diameters of the circular parts. The calliper consists two
legs hinged at the top. These legs are made of carbon and alloy steels.

There are two callipers(Outside, Inside Callipers)

Fixed Joint Calliper (Left: Spring type Caliper (Left: Outside, Right:
Outside, Right: Inside) Inside)

2. Trammel (Trammels heads)

Trammel’s heads are Clamped onto a rectangular bar for scribing arc’s and circles,
marking out sheet work.

4
3. Telescope gauges

This is used to measure diameters of holes or bores. This instrument having spring-
loaded plunges used together with a micrometre and has a handle that is attached to
two spring-loaded plungers. It can measure small to very large bores.

4. Surface Gauges

Used to find the centre of round section material. It is used to scribe parallel lines. This
surface gauge will have a magnetic base so that they can lock to the position. Mostly
this surface gauge is used along with the V-Block. The cylindrical object will be placed
on the V-Block to mark the parallel lines on the Object.

5
5. Straight Edges

Straight edges are used for drawing straight lines or checking their straightness. If it has
equally spaced markings along its length, it is usually called a Ruler

6. Wire Gauges

Wire gauge is used to measure the diameters of the wires. These wire gauges are in
circular or oblong shape and it is having notches along the edges of the shape (as shown
in below picture) and each notch is stamped with wire size number.

6
7. Screw Pitch Gauges

Also known as Thread Gauge or Pitch Gauge used to measure the pitch or lead of the
screw thread. Screw pitch gauges are not used in precision measurements rather it
allows the user to determine the profile of the given thread. We can quickly categorize
the thread by shape and pitch of the screw thread by using the Pitch Gauge.

8. Radius Gauges

Also known as Fillet Gauge. Radius gauge is used to measure the radius of the object.
These are also not used in precision measurements rather it allows the user to quickly
determine the fillet radius.

9. Thickness Gauges

Used to measure the thickness of the objects (Sheet metal). Thickness gauge will have
a stack of different thickness sheets and stamped with the thickness size. Thickness
gauges are not used in precision measurements rather it allows the user to quickly
determine the thickness of the sheets.

7
10. Slip Gauges

Also known for Gauge Blocks, Johansson Gauges, Jo Gauges.

These have come with a set of a box. The individual block is precision ground and lapped
specific thickness. These blocks are stacked together to make up the desired length.
See the below Example

8
Example:

Important Definition of Terms Related To Linear Measurements

Tolerance
The allowable deviation from a standard.
It is the difference difference between
between the upper limit and lower limit of
a dimension eg: the range of variation
permitted in maintaining a specified
dimension in a machined piece.”

Allowance. It is the difference between

the basic dimensions of the mating parts.
When the shaft size is less than the hole
size, then the allowance is positive and
when the shaft size is greater than the
hole size, then the allowance is negative.

Unilateral Tolerance. In this system, the dimension of a part is allowed to vary only on one
side of the basic size, i.e. tolerance lies wholly on one side of the basic size either above or
below it.

9
Bilateral Tolerance. In this system, the dimension of the part is allowed to vary on both the
sides of the basic size, i.e. the limits of tolerance lie on either side of the basic size.

Interference Fit. A negative difference

between diameter of the hole and the shaft
is called interference. In such cases, the
diameter of the shaft is always larger than
the hole diameter. It used for components
where motion, power has to be transmitted.

▪ Interference=(-clearance)
▪ Hole-Shaft<0 Interference exists between the high limit
▪ Hole< Shaft of hole and low limit of the shaft.

Transition Fit. Transition fits are a compromise

between clearance and interference fits. They
are used for applications where accurate
location is important but either a small amount
of clearance or interference is permissible. It
may result in either clearance fit or interference
fit depending on the actual value of the
individual tolerances of the mating components.

10