Measuring Instruments – Overview

(Metrology)

Measurement
Skills

Mile-Storm-L2-Phase1- Rev 1.0

LEVEL – 2 ( Phase -1) 1
 MEASUREMENT AND INSPECTION
Measurement
Procedure in which an unknown quantity is compared to a known standard, using an
accepted and consistent system of units
 It may involve to scale the length of a part or may require a measurement of force
versus deflection during a tension test
 Measurement provides a numerical value of the quantity within certain limits of
accuracy and precision

Inspection

• Procedure used to determine whether a part or product feature (dimension)

conforms to design specification or not
• Many inspections rely on measurement techniques, while others use gaging methods
 Gauging is usually faster than measuring, but not much information is provided
about feature of interest

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 METROLOGY

Its defined as the science of measurement Concerned with seven fundamental quantities

 Length (meter)
 Mass (kilogram)
 Time (second)
 Electric current (ampere)
 Temperature (degree Kelvin)
 Light intensity (candela)
 Matter (mole)

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 ACCURACY AND PRECISION
Accuracy (Correct) - degree to which a measured value agrees with the true value of the quantity
 A measurement procedure is accurate when it is absent of systematic errors
 Systematic errors - positive or negative deviations from true value that are consistent from one
measurement to the next

Precision (Consistent ) - degree of repeatability in the measurement process

 Good precision means that random errors in measurement procedure are minimized

(a) (b) (c)

Figure (a) high accuracy but low precision;

Figure (b) low accuracy but high precision;
Figure (c) high accuracy and high precision. 4
 MEASURING INSTRUMENTS
REQUIRED:-

VERNIER CALLIPER

STREIGHT EDGE

MICROMETER
FEELER GAUGE

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 SCALE / RULER
 Ruler or rule is an instrument used to measure distances or to rule straight lines.
 Calibrated instrument used for determining measurement is called a MEASURE.

1 Inch = 2.54 cm
1 Inch = 25.4 mm
1 Thou = 1 Inch / 1000 = 0.001 Inch
1 Thou = 25.4 mm / 1000 = 0.0254 mm
4 Thou = (0.025 x 4) mm = 0.1mm
40 Thou = (0.025 x 40) mm = 1mm 6
 FEELER GUAGES
• Feeler gauges are Hardened steel blades of different
thicknesses
• Each blade marked with its size in millimeters and/or
inches.
 Useful for:- measuring small slots or grooves ,
measuring clearances of machinery.
 Two or more feeler gauges can be stacked together to
make up a desired thickness.
 If the feeler gauge feels too loose when measuring a
gap, select next size up.
 Repeat until the feeler gauge has a slight drag between
both parts.
 If the feeler gauge is too tight, select a smaller size.

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 USE OF FEELER GAUGE

MEASURING OF PISTON RING END GAP

 Clean the cylinder walls.

 Insert the piston ring in the cylinder.
 Push the piston ring using a piston until the ring is reached to the piston pin
boss.
 Take care, the end gap should not be located at the direction of the axis or
perpendicular direction of crankshaft.
 When the piston ring is inserted in the cylinder, the piston ring with facing the
mark towards cylinder head.
 Measure the piston ring end gap

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 PISTON RING LATERAL GAP

1. Insert the feeler gauge until it reaches into the ring groove.
2. Check at least at 3 - 4 points.

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 WARPAGE / DEFORMATION
1. Remove and clean the foreign matters from the surface
2. Measure at the 7 positions using a straight edge and filler gauge as shown in
below picture.
3. Measure the clearance between cylinder head surface and the straight scale,
4. avoid the coolant passage and the oil passage.

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 VERNIER CALIPER

 The Vernier is used for measuring the length of an object,

the outer diameter (OD) of a round or cylindrical object,
the inner diameter (ID) of a pipe, and the depth of a hole.
 least count - 0.02 mm

How to measure :-
 Read the “0” position of the Vernier scale
on the main scale to get a rough reading.
Rough reading = 18mm

 Look along the Vernier scale until one of

the Vernier division coincides with the
main scale = 0.23mm
 Accurate reading =
= 18 + (0.02 X 23)
= 18.46mm±0.01 mm
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 Measuring steps

1. Note the number of divisions crossed on main scale (say 9 as show in fig)
2. Note the number of Vernier divisions coinciding with any division on main
scale (say 3 shown in fig)
3. Multiply second reading by least count and add to the Main Scale reading
4. Final reading will be 9 + (0.02 X 3) = 9 + 0.06 = 9.06

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 VERNIER CALIPER
 Outer Dia / Length measurement

 Inner Dia / Length measurement

 Depth measurement

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 Precautions

0
01 2 3 4

Read the scale from proper position


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 MICROMETER
 A micrometer is a precision measuring tool used in science,
engineering, machining to measure the diameter, thickness or
length of an object.
 least count - 0.01 mm

How to measure :-

 Measure the Main scale reading – MSR = 8mm

 Measure the head scale reading – HSR = 0.12mm

 Total Reading = 8.12mm

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 Read the Micrometer Scale

25
0
10
5 20

15

10

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 Read the Micrometer Scale

1. Note the number of divisions in millimeters.

2. Note the Sub-divisions(0.5mm) crossed on the sleeve.
3. Note the number of divisions of beveled edge of thimble coinciding with datum line
on the sleeve.
4. Write them in above order and add up to get the final reading.

In the previous fig; there are 10mm divisions crossed and one 0.5mm division crossed
and the 6th divisions of thimble coincide with datum line. Thus
10 main divisions = 10.00 mm
1 Sub-divisions = 0.50 mm
16 divisions on thimble = 0.16 mm
Final reading = 10.66 mm

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USE OF MICRO METER

OD MEASUREMENT

SHIM MEASUREMENT

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USE OF MICRO METER

Measuring Cam Lobe

Measuring Crank Main

Journal Dia

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 DIAL INDICATOR

 Dial indicator is used to measure runout as part is rotated about its

center, variations in outside surface relative to center are indicated on the
dial.
 Used to measure: the bend or run-out, projection / depth on surfaces

 least count - 0.01 mm

How to measure :-
 Step 1 - Read the whole millimeters. The short needle
is between the 4 and the 5, so the reading is 4.00 mm.

 Step 2 - Read the tenths. The long needle is between the

0.20 and the 0.30 mm, so the reading is 0.20 mm.

 Step 3 - The long needle is 6 small divisions past the 0.2,

so the reading is 0.06 mm

Total = 4.26 mm.

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 USE OF DIAL GAUGE

Run out check

Valve Depression Check

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 USE OF DIAL GAUGE

Liner projection from Block

surface

Cam shaft bend checking

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USE OF DIAL GAUGE

Thrust bearing end play

Pin of the dial gauge must be

inline with crankshaft.

Measurement of Crankshaft
bend

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 USE OF DIAL GAUGE
Measurement of backlash

Pin of the dial gauge must be 90

deg. Angle with the touching
portion of the teeth.

Main shaft & counter shaft pre load

Base of the MST 515 must

not touch the bearing/shim.

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 DIAL BORE GUAGE

 Dial bore gauge determines if diameter is

worn, tapered, or out-of-round according to
specifications

 least count - 0.01 mm

How to measure :-
Using dial bore gauges
 Select appropriate-sized adapter to fit internal diameter of bore.
 Install it to the measuring head.
 Fixture is set to size desired and dial bore gauge is placed in it.
 Dial gauge bore is then adjusted to proper reading.
 Hold the gauge in line with the bore and slightly rock it to ensure it is centered.
 Read the dial when it is fully centered and square to the bore.
 Store a bore gauge carefully in its storage box.
 Make sure the gauge is at a 90-degree angle to the bore and read the dial.
 Take multiple measurements.

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 USE OF DIAL GAUGE

Measurement of cylinder bore

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DIGITAL MULTIMETERS

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 DIGITAL MULTIMETERS

Negative Probe Positive Probe

Meter

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 TORQUE WRENCH

Relation between Nm, Kg -m, Lb-ft:

1 kg-m = 9.8 Nm (10Nm app.) = 7.23 Lb-ft.

1kg-m = 9.8 Nm (10Nm app.) = 7.23 Lb-ft.

 Using Torque wrench to tighten bolts requires Certain rules.

 These rules help provide proper torque value and provide a good joint.
 The grip and motion of torque wrench contribute to the amount of load the bolts deliver.

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 ANGULAR TORQUING
WHY ANGULAR TORQUE? PROCEDURE
• The angular torque degree force ensures that the bolts are torque tightened up to yield point
and the 2 stage ensures that the clamping load for each bolt is a very close tolerance or
according to manual.

• To avoid unwanted torque loss due to uneven thread or bolt vs body friction and to confirm
required tightness between two mating surface, we use Angular Torque tightening method.

a
60
120

b
* Moving corner ‘a’ up to ‘b’ point will tight it 120deg. Angle.
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THANK YOU
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