QUALITY ASSURANCE

Common Measuring
Tools
MT 257
 Accuracy and Precision
• Accuracy
• Difference between the average of several
measurements made on a part and the true
value of that part

• Precision
• Getting Consistent results repeatedly

• Precision without Accuracy is no good

• Can use wrong gage and receive inaccurate,
repeatable results
 Measurements and Accuracy
• Accuracy of Measurement is dependent on:
• Calibration
• Check periodically
• Manipulation
• Knowing how to use
• Reading
• Avoid Parallax Error – Reading from an Angle
• Workpiece Geometry
• Cannot achieve accuracy with irregularities in shape
• Dirt and Burrs
• Keep clean
 Types of Measurement Errors
• Observational
• Misreading the measuring tool – •Gage Errors
Parallax Error •Precision & Accuracy loss
• Manipulative •Out of calibration error
• Holding tool or gage incorrectly
• Not locating datum properly
• Bias •Part Error
• Rounding off •Within-the-piece variation
•Dirty parts
• Gage Inaccuracy
•Poor surface finish
•Flaws
 Measuring Pressure
• Important for Accuracy
Attempt to use Constant Pressure
Ideally same as used to Calibrate tool

Care of Tools
• Avoid rough handling and dropping
• Check for damage and calibration
• Light film of oil to protect from rust
• Keep in toolbox
 Measuring Tools
• Selecting Proper Measuring Tool (Rule of Thumb) – 10 to 1 Rule
o 10x more accurate than total tolerance to be measured
o If Total Tolerance = 0.01 in. then use tool with 0.001 discrimination

• Avoid Unnecessary Accuracy

o If Casting Tolerance = 0.03 in. & Dial Gage graduated in 0.0001 in.
 The Steel Rule
• Know when and when not to use
• Cannot be used on dimension with tighter tolerance than discrimination
• Cannot use if tolerance = 0.01 in., Discrimination = 1 /64 = 0.016 in.
• Can use if tolerance = 0.06 in.

• Proper Reference is Important

• Reference in one of two ways
• Edge of rule firmly fixed
• Begin with 1-in. line
 The Steel Rule
• Hook Rules
• Designed to line up with the end of the Steel Rule (0 in.)
• Watch for looseness or wear to avoid errors
 Transfer Measurements
• Cannot be read directly

• Make contact with part Lock into Position

Measure with another tool

• Dimension has been “transferred” from part to transfer tool to scale on

tool used to make measurement
 Spring Calipers Outside & Inside

• Are Adjustable Calipers – Inside and Outside

Spring Calipers
• Used to Transfer a dimension
• to a line-graduated instrument (such as a
Steel Rule)
• How to use?
• Locate feature to be measured
• Transfer to Line-Graduated tool to find
Actual size of part
• Used widely on Castings or Forgings
 Gage Blocks
• Can be used to
• Setup a length dimension for a transfer measurement
• Set or calibrate fixed gages – Snap Gages
• Used as Special Attachments for various applications

• Three Standard Shapes

• Round
• Square
• Rectangular
 Gage Blocks
• How to use?
• Clean before use: Kerosene + cleaning solution
• “Wringing” (Rubbing) them together – Squeezes air out
• “Cementing” action occurs – Stick together
• Use fewest number of blocks in stack as possible
• Wrung blocks are called a Stack
 Wear Blocks 81-piece Square Gage Block Set

• Placed at ends of Stack to Protect the rest

of blocks from wear
• Come in Two Sizes
• 0.050 in. 0.100 in.
• Must place the same side out
• Use smaller blocks as wear blocks, if
necessary

Various
Increments of
Block Sizes
 Gage Blocks
• Stack up 3.6824 in.
• Use 0.1004
• 3.582
• Use 0.132
• 3.450
• Use 0.450
• 3.000
• Use 3.000
 MECHANICAL INDICATORS
• Variable Contact Instrument Tool
• Can detect the actual variation between dimension and reference

• Dial Indicator
• Amplification
• Indicator amplifies the
actual movement of the
tip to the dial face
 Balanced & Continuous Dial
• Balanced Dial • Revolution Counters
• Can be read directly in • Tells how many full
either direction from 0 revolutions the large
indicator needle has
made

• Continuous Dial
• Starts at 0 and
continuous in number
sequence all the way
around till reach 0
again

https://www.youtube.com/watch?v=vMtWwt8GQzw
 Contact Tips
• Variety of Contact Tips • Spherical tips used to give point contact
Wrong • Needle tips allow used to enter hole

Correct
 Contact Tips
• Ball Point
• Optimal for workpieces with deep indentations
 Contact Tips
• Spherical Point
• Optimal for use where workpiece needs to slide from side to side
 Contact Tips
• Conical Point
• Used for positioning the measurement point
• Not suitable for soft materials – can easily damage
 Contact Tips
• Flat Point
• Optimal for use on Convex Surfaces
 Contact Tips
• Knife Edge Point
• Suitable for measuring narrow groove diameter
 Contact Tips
• Needle Point
• Suitable for probing bottom of groove or hole
 Contact Tips
• Lever Point
• Suitable for use on perpendicular faces – Mold Cavities
• Lever can be adjusted to the required angle
 Cosine Error In Indicators
• Cosine Error
• Error is caused when an indicator tip is at an angle to the surface being
measured
• Tip must be parallel to the surface
 Cosine Error In Indicators
• Cosine Error
• Position of the body of the indicator makes no difference
• Tip must be parallel to the surface
 Cosine Error In Indicators
• Cosine Error
• There are times – because of the shape of a part – must use the indicator tip at an
angle to perform the measurement
• Can correct for the Cosine Error
• Reading will be too high
• Compensate by decreasing the reading by a Percentage
• The larger the Tip angle, the larger the Error

• Ψ = Angle of Tip
• Δ(%) = Change in
Reading
 Cosine Error In Indicators
• A measurement is made with the indicator tip at an angle of 15°
• The Reading shows 0.010

• What is the % Error?

• Δ(%) = ( 1 / Cos 15° – 1 ) x 100 = 3.5%

• What is the True Reading?

• 0.035 x 0.010 = 0.00035 , True Reading = 0.010 – 0.00035 = 0.0097

 Full Indicator Movement (FIM or TIR)
• If Feature Control Frame

• B surface should be parallel to A Surface

within 0.01 in.

• Measurement taken

• FIM = -0.003 to +0.004 = 0.007 in

• FIM is total value
 Dial Indicating Gages
• Dial Indicating Gages are Variable Gages
• Variable Gages - Detect the actual size - Not just tolerance

• Dial Calipers
• Useful for quick & accurate measurements
Dial Indicating Gages
 Dial Indicating Gages
• Reading the Micrometer
• Thimble
• Each Line = 0.001

• Numbers every 5 lines (0.005)

• One complete turn = 0.025

• So each revolution of Thimble is equal to one division on the Sleeve

 Dial Indicating Gages
• Reading the Micrometer

• = 0.100 + 0.025 + 0.015 = 0.140

 Dial Indicating Gages
• Dial Indicating Micrometer Key Features
• Constant Measuring Pressure (in the Anvil – Flat Top)
• Direct Reading in ten-thousands range
• Can be use as a Snap Gage – preset desired size, lock it, compare
 Types of Micrometers
• Standard Outside Micrometer
 Types of Micrometers
• Depth Micrometer
 Types of Micrometers
• Hub Micrometer
• Useful in Tight Places
 Types of Micrometers
• V-Anvil Micrometer
• Good for measuring diameters or detecting out-of-roundness
 Types of Micrometers
• Inside Micrometer set
• Good for measuring Inside Diameters
• Ranges from 2 in. to 12 in.
 Types of Micrometers
• Special Purpose Micrometer Applications
 Types of Micrometers
• Special Purpose Micrometer Applications
Calibrating Micrometers
Calibration Technique
Vernier Instruments

= 0.950 (bar) + 0.006 (plate) = 0.956

Vernier Instruments
Telescoping Gages
Small Hole Gages
 Attribute Gages
• Designed to either Go or Not Go – Quick Verification

• Tell you if part is “Good” or “Bad” but Not How Good or Bad

• Within or not within Tolerance

• Non-Adjustable
 Attribute Gages – Plug Gages
• Plug Gages
• Two plugs – Go member & NoGo member
• If Go goes in & NoGo does not
• Hole is Good
• FI Go doesn’t go in
• Hole is undersize
• If NoGo goes in
• Hole is oversize

• Can also be Thread Plug Gages

Attribute Gages – Flush Pin Gages
• Flush Pin Gages
• Position of pin give an idea of whether the par dimension is within limit

Undersize Oversize Good

 Radius Gages
• Used to measure Radii
• Sizes from 1/64 to 1/2 in. – increments of 64ths – 1/64, 1/32, 3/64, etc.
 Radius Gages
• Used to measure Radii
• Sizes from 1/64 to 1/2 in. – increments of 64ths – 1/64, 1/32, 3/64, etc.
Tapered (Adjustable) Parallels
• Two pieces that are inclined and joined
together by a dovetail slide and lock
screw

• Moved in opposite directions

• Can be set to specific width

• Used for Machine Setups
• Go-NoGo Gages
• Measurements
 Centerline & Center Master Gage
• Centerline Gage
• Clamp to Vernier caliper
• Center of cone in line with
measuring face of caliper

• Center Master – Measure Height

• Subtract reading at bottom from
reading at top
Internal Threads – Measuring Depth
• Turn Method
• Thread Plug Gag’s Lead to Verify Depth
• Lead – Distance Travelled in one Full Turn

• If 20 Threads per inch & 0.600 Deep

• Each thread = 0.05 in.
• Lead = 0.05
• Then should turn 0.600 / .05 = 12 times
Pitch Diameter
• Three Wire Method
• Use Three wires of the same diameter
• 2 on one side and 1 on the other

• Best Wire Size (W) = 0.57735 x Thread Pitch (P)

• Thread Pitch = 1 / # of threads per in.

• Micrometer Reading = M

• Pitch Diameter (E) = M + 0.86603P – 3W

Pitch Diameter
Question
•Measure a 1/4 in. – 20 thread,
•Assume M = 0.280 in.

Answer
•Thread Pitch (P) = 1 / 20 = 0.05 in.

•Wire Size (W) = 0.57735 x 0.05 = 0.0288 in.

•Pitch Diameter (E) = M + 0.86603P – 3W

•E = 0.280 + 0.86603 x 0.05 – 3 x 0.0288
•E = 0.2363 in.