Dial Indicators

Introduction
• Dial indicators are small indicating devices
using mechanical means such as gears and
pinions or levers for magnification system.
• Basically used for making and checking linear
measurements.
• Many a times they are also used as
comparators.
• When a dial indicator is used as an essential
part in the mechanism of any set up for
comparison measurement purposes, it is called
as a dial gauge.
 Uses
By mounting a dial indicator on any suitable base
and with various attachments, it can be used for
variety of purposes as follows.

1. Determining errors in geometrical forms,

e.g., ovality, out of roundness, taper etc.
2. Determining positional errors of surfaces,
e.g., in squareness, parallelism, alignment
etc.
3. Taking accurate measurement of
deformation (Extension, or compression) in
tension and compression testing of
materials.
4. Comparing two heights or distances
between narrow limits (as a comparator)
Requirements of a good dial indicator
• It should be Robust in design and construction
• Pointer movement should be properly damped so
that it will not oscillate when readings are being
taken.
• To avoid damage to the instrument, movements of
plunger larger than the specified amount on the
scale should be controlled by some means.
• The instrument should be useful for the movement
of the measuring plunger in either direction without
affecting the accuracy.
• Operating pressure required on measuring head to
obtain zero reading must remain constant over
whole range.
 Advantages of Dial Indicators
1. The instrument can be easily used and read even by unskilled worker.
2. Contact pressure is low and uniform.
3. It is not subjected to problems such as gauge wear, temperature
variations etc.
4. It is best suited in mass production for precision dimensional control.
5. It can detect small dimensional variations that are beyond the range of
conventional gauges.
6. The instrument is accurate and economical.
7. It is versatile i.e., can be easily and rapidly used for different types of
precision measurements e.g., testing roundness, flatness, taper etc, by
using simple attachments.
8. It is portable, easy to handle and can be set very quickly.
9. It eliminates the uncertain human ability to ‘feel’ or judge and the
measuring pressure between the spindle and work automatically
remains constant.
Classifications:
• According to their shape
1. Sector shaped: The range is very
much limited and hence these
instruments are used for extreme
accurate measurement.

2. Circular: These are commonly

used.
Can also be classified as:
1) Plunger Type:
a) Back Plunger:
The plunger is at right
angles to the dial. It is
not widely used.
a) Plunger parallel to
the plane of dial

2) Lever Type
Dial Indicator with Lever Mechanism
Dial Indicator with Gear and Pinion Mechanism
Draw back (Limitations) of Dial Indicators

1. Wear of the plunger bearing surfaces, gear bearing points etc.

causes an error in the measurement.
2. Accuracy of the instrument is reduced due to backlash in gear
and pinion or gear train.
3. As the plunger moves inside, the contact pressure of the plunger
increases. The variations in the plunger contact pressure also
introduces error in the measurement.
Constructional features of Dial Test
Indicators.
Scale:
• Calibrated in 10 bigger divisions.
• Each bigger division is divided into 10 smaller divisions.
• One small division = 0.01 mm.
• 10 big divisions = 1.0 mm.

Range:
• 10 mm
• The dial gauge is mostly used to detect and magnify small
variations from a known size.
Rotatable Bezel:
• It is incorporated in most of the dial indicators for making the
final zero setting at any position throughout the full circle. A
clamp for locking it in any position is also provided.
Contact points:
• The dial gauges and all other indicating type instruments are
equipped with spherical hardened steel contact points.
• The contact points may be of various shapes as shown in figure.
Tolerance pointers:
Lever attachments:
• These are very useful to facilitate
the work of machine setting.
• The right angle offset attachment
shown in figure enables to make
internal measurements.
• This attachment transfers motion at
right angles to the indicator spindle
directly.

Dials:
• May have 200, 100, 80, 60, 50, 40
or 20 graduations.
Stands and holders for dial gauges
Using the Dial Indicator for Brake Align
correction plates (shims) for lateral runout
 Lever type Dial Test Indicator
• It has only a limited range (limited by
the scroll length), which usually
allows about 1.5 revolutions of the
pointer to be made.
• It is for this reason that a revolution
counter is not provided in this type of
dial indicator.

Uses: This instrument is more compact

than the plunger type and it is most
commonly used for both inspection and
machine setting.
• With the ball tip placed inside a small
bore, concentricity, roundness or
machine setting can be conveniently
checked.
General care of dial indicators
Pocket thickness gauge:
• It is a small handy instrument used to
measure thickness of paper, leather,
wire, plastic, sheet metal etc. to an
accuracy of 0.01 mm.

Dial Pipe gauge:

• This instrument is specially designed
for easy measurement of wall thickness
of pipes.
• The minimum inside diameter of
measurable pipe with this instrument is
3.5 mm.