MEASURING INSTRUMENTS

Caring for measuring instruments.

Measuring instruments like micrometers, vernier calipers, digital and electronic

measuring instruments and height gauges are all precision instruments, and should be

treated with great care.

Take note of the following points:

• They should be used for their intended purposes only.

• When not in use, they should be cleaned and returned to their storage
cases.
• They should never be placed among other tools as they can be damaged
which will cause inaccuracy.
• They should not be handled for long periods at a time.
• Do not drop instruments, as they will cause them to be inaccurate.
• Contact of measuring faces of anvils must be avoided as this can cause
rusting.

1. Vernier Caliper

The Vernier caliper can be used to measure an internal measurement, an external

measurement, a step measurement, and a depth.
 It consists of a beam which accommodates a sliding component. The beam contains
the main scale and the sliding component holds the Vernier scale. It also has two sets
of jaws and a depth rod

Why is the Vernier scale necessary?

The vernier scale is used on several instruments and it is a clever way of improving
the precision of a reading on an instrument scale.
A vernier scale is visual aid to take an accurate measurement reading between two
graduation markings on a linear scale by using mechanical interpolation; thereby
increasing resolution and reducing measurement uncertainty by using vernier acuity to
reduce human estimation error.
The vernier scale is basically taking 1 division (1mm) on the main scale, then
magnifies it over a certain distance (49mm) and at the same time splitting it into a
number of divisions (50).

MAIN SCALE

VERNIER SCALE

Proving the accuracy of 50 Division Vernier Caliper

The vernier scale is basically splitting 1 division (1mm) on the main scale into 50
divisions (1mm/50 = 0.02mm) which means that 50 divisions would be .02mm apart.
The 50 divisions are therefore spread over 49mm on the vernier scale.
Therefore, the length of each division on the vernier scale is 49/50 = 0.98mm
This means that 1 division on the vernier scale is 0.02mm shorter than 1 division on
the main scale. This is visible when both zeros coincide or
when the vernier caliper is closed.
Therefore, if you line up the first division on the vernier
scale with a line on the main scale, then the vernier would
have opened 0.02mm proving that the caliper can be used to
measure 0.02mm.
How to take a reading using the Vernier Caliper
When no measurement is taken, it is commonly known as the vernier caliper
is closed, the zero on the main scale coincides with the zero on the vernier
scale. Let us consider the picture below to take a reading when a
measurement has been taken.

a) Determine where the zero line of the vernier scale cuts the datum line.
b) Take the nearest main scale reading to the left of this point. (3mm)
c) Now determine where a line from the vernier scale coincides with a line from the
main scale.
d) Take the nearest main division reading of the vernier scale to the left of this point.
(0,5mm)
e) Determine the number of subdivisions (on the vernier scale) between that nearest
main division and the point where the lines coincide. (4x0,02=0,08mm)
f) Now add the findings of lines b, d and e. (Ans = 3,58mm)

2. Vernier Protractor

As with linear measurement, vernier

scales can equally well be used to
determine angular measurement
accurately to the nearest 5’ of a degree.

Reading the vernier protractor

When no measurement is taken, the two zeros coincide. Interesting to note that
measurement can be taken to the left or right of the zero on the main scale.
The vernier scale accommodates application by have a scale both ways of the zero.
The vernier scale is basically taking 1 division (1⁰) on the main scale, then magnifies it
over a certain distance (23⁰) and at the same time splitting it into 12 divisions of 5’.
Let’s consider diagram (a)
a) Determine where the zero on the vernier scale
cuts the main scale, usually between two degrees.
(between 45⁰ and 46⁰)
b) Now check if we are using the LHS or RHS of the
main scale. (LHS)
c) Using (LHS) vernier scale, Now determine where
a line from the vernier scale coincides with a line
from the main scale. (35’)
d) Hence, the reading is 45⁰ 35’. Please note how the
answer is presented and not 45,35⁰

3. External Micrometer

The external Micrometer is designed for external measurements such as pins, shafts
and keys to an accuracy of 0,01mm
The micrometer consist of a C-frame with an anvil attached to it. The anvil is made of
tungsten carbide which is resistant to wear.
It contains a barrel which holds a sleeve and an internal thread.
The length of the scale on the sleeve is 25mm.
The circumference of the thimble is divided into 50 divisions.
The internal thread has a pitch of 0,5mm which means that if the thimble is rotated
a full revolution, the spindle will advance or retract 0,5mm.
A spindle lock is provided to prevent the spindle from moving after a measurement
has been taken.
The thimble is fitted with a ratchet to apply constant pressure when taking a
measurement.
Reading the external Micrometer

a) Determine where the front edge of

the thimble cuts the main scale.
(between 5 and 6mm)
Consider that the thimble needs to do two
revolutions to travel 1mm.
b) Is the thimble busy with 1st or 2nd
revolution. Is the halfway mark visible or not. If yes, then 0,5mm should be
added. (0,5mm)
c) Determine which line on the thimble coincides with the datum line.
(28x0,01=0,28mm)
d) Now add the findings of lines a, b and c. (Ans = 5,78mm)

4. Depth Micrometer

The depth micrometer is used for measuring the

depths of holes, slots, recesses, and similar
applications.
The micrometer principle is the same as for the other
instruments, however, the readings with this
instrument increase as the thimble is advanced,
resulting in the numbering of sleeve and thimble
graduations in the opposite direction to those on the
external micrometers. To take a reading, you must
note the 1mm and 0.5mm divisions is covered by the
thimble.

Reading the Depth Micrometer

a) Determine where the front edge of the
thimble cuts the main scale. (between 13
and 14mm)
Consider that the thimble needs to do two
revolutions to travel 1mm.
b) Is the thimble busy with 1st or 2nd
revolution. Is the halfway mark visible or
not. If yes, then 0,5mm should not be
added. (0,0mm)
c) Determine which line on the thimble coincides with the datum line.
(44x0,01=0,44mm)
d) Now add the findings of lines a, b and c. (Ans = 13,44mm)
5. Dial test indicator

The dial test indicator shown in Figure 4.58 is

very accurate instrument. It indicates any
variation that you cannot see with the naked eye.
A pointer on the graduated dial indicates the
amount of variation.

The plunger type has a plunger, which carries a

rack, which operates a system of gears for
magnification to the pointer. A dial is attached
to the outer rim and can be rotated so that zero can be set irrespective of the
initial pointer position. A clamp is also provided to prevent the dial from moving
once it has been zeroed. Dial divisions are usually 0,01mm with an operating range of
between 0mm and 10mm.
Because of the long plunger movement, the instrument is fitted with a secondary
scale and pointer for indicating the number of complete revolutions made by the
main pointer.

Uses of the dial test indicator

• Setting up work pieces accurately in a machine.
• Checking the run-out of a work pieces in a machine.
• Testing rectangular work pieces for parallelism.
• Testing shafts for roundness and straightness
• Testing components for concentricity.
• Testing the limits of size when used as a comparator.

Run-out is the condition when the diameter of the work-piece

is not running true to the centre of the machine whereas
concentricity is when the diameter of the work-piece is true to
its centre and usually checked between centres.

Some applications of the dial test indicator.

Reading the Dial Test Indicator

a) First consider the small dial on the DTI.

b) Determine how many revolutions the large dial has made. (7)
This means that the plunger has travelled 7mm.
c) Now consider the large dial.
Remember, when the plunger has travelled 1mm, the large dial will
make one complete revolution.
d) Determine the segment of a millimeter. (0,71mm)
e) Add the two values. (7+0,71 = 7,71mm)