UNIT 2

Measuring Instruments
Structure
2.1 Introduction
2.2 Vernier Calipers
2.3 Micrometer
2.4 Vernier Height Guage
2.5 Dial Indicator
2.6 Sign Bar
Learning Objectives
After studying this unit, the student will be able to
• Identify the required instrument from a given number of instruments
• Locate the function of parts of instrument.
Introduction
Manufacturing and assembly requires that all parts are made of accurate
size and shape. Therefore, the measurement and inspection is the most important
phase of manufacturing. The need of accurate measurement is necessary because,
it promotes interchnageability of the parts. Many tools and devices have been
signed for measuring and checking the parts. The most commonly used precission
measurement instruments are
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1. Vernier Calipers 2. Micrometer 3. Height Guage

4. Dial Indicator, 5. Sine bar
2.1 Vernier Calipers
Vernier Callipers are widely used for precision measurements of length,
thickness, depth and inside and outside diameters. They are manufacturered
with metric unit calibration to accuracies or least counts of 0.1, 0.02 or 0.05
mm.

Clamping Auxillary
L-Shaped Vernier head
Frame Scale Screws
Main Scale Beam

Fixed Jaw Fine adjustment

Movable Jaw
Screw
Internal External Mesuring
Measur- T ips
ing Tips

Fig. 2.1 Vernier Caliper

A vernier callipers essentially consists of a beam carrying the main scale,

inside and outside measuring jaws, a depth gauge bar and an adjustable gauge
bar and an adjustable vernier head which can be moved along the beam. Those
with higher accuracies are provided with an auxilary head connected to the main
head by a micrometering screw for fine adjustment. Both the heads are provided
with locking screws to lock them firmly at any desired position. The main head
carries the vernier divisions or vernier scale. A vernier callipers with an accuracy
of 0.02 mm is shown in the figure.
Principle of Vernier Callipers.
Vernier with 0.1 mm accuracy
In this, the vernier scale is 9 mm long and is divided into 10 equal divisions.
Each small division on the main scale measures 1 mm.
9
One division on vernier scale  0.9
10
One division of vernier scale is shorter than one division of main scale by
(1-0.9)=0.1mm.
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This is known as the Least Count or measuring accuracy of the instrument.

Vernier with 0.02 mm accuracy
In this, the vernier scale is 49 mm long and is divided into 50 equal divisions.
The main scale as usual carries small divisions of 1 mm length each.
49 98
One division on vernier scale  0.98mm
50 100
Or, it is shorter than one main scale division by (1-0.98)=0.02mm. This is
the Least Count or measuring accuracy in this case.
Reading the Vernier
Before commencing measuring, it should be ensured that the zero marks
on vernier and main scale coincide with each other when the two jaws are in
contact. If not, the difference should be carefully noted and duly accounted for
in the final reading. The methods of reading verniers are mentioned below :
Steps in taking reading
1. Note the number of divisions o main scale crossed by the zero mark on
vernier scale (say 23 divisions).
2. Note which vernier division is conciding with any of the main scale
division (say 8th division).
3. Multiply the second reading by least count and add to the first as follows
Final reading = 23+(0.1x8)=23.8mm
2.2 Micrometer
The micrometers are precision measuring instruments. These are available
in English system or metric system, but the metric system micrometers are mostly
used. The various types of micrometers are as follows.
(i) Outside micrometer, (ii) Inside micrometer,
(iii) Depth micrometer (iv) Vernier micrometer
(vi) Screw thread micrometer
We shall now discuss these micrometers, in detail, in the following articles.
(i) Outside Micrometer : It is mainly used to measure the outside diameter
of a job or length of a small part, to an accuracy of 0.01 mm. The main parts of
an outside micrometer, as shown in Fig. 2.2, are as follows.
(a) An U-shaped or C-shaped frame,
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(b)An anvil protruding 3 mm on the left hand side of the frame, and a
spindle of 0.5 mm pitch on the right hand side of the frame.

1. Frame 2. Anvial 3. Spindle 4. Lock Nut 5. Sleeve 6. Thimble 7. Ratchet

Fig. 2.2 Micrometer

(c) A clamping or locking screw, to lock the spindle, when the micrometer
is at its maximum reading.
(d) A barrel (sleeve) having reference line and fixed graduations.
(e) A tubular thimble fastened with the spindle and moves with the spindle,
with 50 divisions marked on it, and
(f) A ratchet screw, used to prevent excessive pressure on the spindle,
when the spindle near the work
The least distance which can be measured accurately with micrometer is
called least count of micrometer. It is the ratio of pitch of the spindle screw to
the number of divisions on the thimble Mathematically.
Pitch of the screw 0.5mm
Least count=   0.01mm
Number of divisions on the thimble 50

Reading a Micrometer
The micrometer reading is taken as discussed below:
1. Before taking a micrometer reading, the range of the micrometer and
zero error must be checked
2. The graduations on the barrel above the reference line are in 1 mm
intervals and are numbered 0,5, 10, 15, 20 and 25.
The graduations below the reference line are also in 1mm intervals, but
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each graduation shall be placed at the middle of two successive upper graduations
so as to read 0.5 mm, as shown in Fig. 2.3
3. Now hold the work between the faces o the anvil and spindle and note
the number of divisions on the barrel (or main scale) above and below the reference
line, and the number of divisions on the thimble coinciding with the reference
line.
Barrel

Thimble

Reference Line

Fig. 2.3 Reading of Macro Meter

4. The reading, as shown in Fig 2.3, is obtained as follows Number of

divisions above the reference line = 6
= 6 x 1 mm = 6 mm
Number of divisions below the reference line = 1
= 1 x 0.5 mm = 0.5 mm
Number of divisions on the thimble coinciding with the referenc line
= 21 = 21 x 0.01 mm = 0.21 mm
 Total 6 + 0.5 + 0.21 = 6.71
2.3 Vernier Height Gauge
It is mainly used for measuring heights of parts to an accuracy of 0.02 mm.
It is also used for scribing lines in layout work.
The principle of this instrument this instrument is similar to vernier called the
vernier height gauge, as shown in Fig. 2.4 are as follows.
1. A special base with accurately finished bottom.
2. A graduated beam, called the main scale,
3. A sliding vernier head carrying the vernier scale and clamp screw.
4. An auxiliary head having the fine adjustment and clamping screw and
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5. A measuring and scribing jaw.

Beam
Guiding Surface

Main Scale

Fine Adjustment
screw Auxillary head

Vemier Scale
Clamping screw
Scriber Carrier

Scriber
Vemier head

Measuring Face

Base

Fig. 2.4 Vernier Height

The vernier height gauge, commonly used, have the measuring range from
‘O’ to 300 mm. Before using this instrument, it should be checked for zero
error. For this, the vernier height gauge is placed on a surface plate and the
vernier head is brought down till the measuring jaw touches the surface plate. In
this position, the zero on the main scale should coincide with the zero on the
vernier scale. In order to measure the height, the work is placed between the
surface plate and the measuring face. The final adjustment depending upon the
sense of correct feel is made by the fine adjustment screw. The measurement is
read in the similar way as in the vernier caliper. For scribing lines, the scriber is
set at a specified “eight and moved along the work piece to be marked.
2.4 Dial indicator
This is a very useful dial test indicator which is used for accurate checking
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and measuring guage. With it we can know difference in surface. These are
made to check accuracy upto 0.0001’ in English system and 0.001 in millimeters.
A dial test indicator has been shown in Fig. 2.5 above it has the following main
parts:-

Fig. 2.5 Dial Indicator

1. Case of house 2. Cover 3. Bejel 4. Dial 5. Indicator 6. Revolution

fcounter 7. Rack and plunger 8. Stem 9. Contact Point 10. Dust Cap
11. Crystal
Working Princple of Dial Test Indicator: The working principle of dial
gauge has been shown in Fig. 2.6 only working of few parts has been illustruated
in it. A plunger (A) is fixed in is fixed in it. A small gear (B) is also united. This
gear as 10 teeth. The shaft on which gear (B) is fixed on the same shaft another
gear (C) with 100 teeth is united. Another gear (D) is united with gear (C). On
the axis of gear (D) needle fixed. Marking from 0 to 100 at equal distance is
indicated on the dial. To revert back the rack again to its original position, a
spring is also attached.

Fig. 2.6 Dial Test Indicator

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When there is pressure on the contact point of guage, rack moves up or

down. Thus, when one tooth of rack moves up or down a tooth of gear (B)
completes one full round. And with it, ngear (C) also moves one complete round.
Gear (C) with 100 teeth moves gear (D) 10 rounds because it has only 10 teeth.
In this way when gear (D) completes ten rounds, it means rack rises up 10 mm
or comes down. If gear (D) completes once round rack rises up or come down
10=1 mm. The needle fixed on the axis of gear (D) takes one round of the dial,
which contains 100 markings at equal distance from one another. Thus we can
say that when the needles moves on 100 marks rack rises up or comes down by
1 mm.
Therefore its least count 100 points = 1 mm
1
 One point of the dial=
100
=0.001 mm.

5. Sine Bar
It is used either to measure angles more precisely than bevel protractor or
for locating any work to a given angle within very close limits.

Fig. 2.7 Sine Bar

It is generally used in conjunction with slip gauges. A sine bar, as shown in

Fig. 2.7, consists of a hardened and ground steel bar which is stepped at the
ends. A roller is fastened in each step, with a screw. These rollers should touch
the both faces of the step. A sine bar is specified by the distance between the
centres of two rollers (L). The most commonly used sine bar has this distance as
100 mm.
In measuring the angles or locating any work to a given angle the use of sine
bar is made as follows :
(i) The work having tapered top and flat base is placed the surface plate.
(ii) One of the roller is placed on the surface plate, as shown in Fig. 2.6 (a)
while the other roller is made to rest on slip gauges of height H in such a way that
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the top of the workpiece coincides with the sine bar. Then the sine bar is set at
H
an angle 0 , which can be calculated as sinθ=
L

(iii)In order to obtain better results, both the rollers of the sine bar are
placed on slip gauges of height H1, and H2 as shown in Fig. 2.6 (b). In such
cases.
H  H2
sinθ= 1
l

Fig. 2.6 : (a) One Roller Placed on Slip Guages Sine Bar Fig. 2.6 : (b) Both the Rollers placed
on Slip Guages

Key Concepts
1. Vernier Caliper : Used to measure lengths upto an
accurancy of 0.02 mm.
In case of vernier caliper

Value of one main scale division

Least Count =
No. of vernier divisions

2. Micrometer screw gauge : Used to measure upto an accuracy

of 0.01 mm. In case of a micrometer
Pitch of the screw
Least Count =
No. of head scale divisions

3. Sine Bar : Used to measure the angles precisely,

4. Vernier height gauge : Used for marking accurately

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5. Dial Indicator : Accuarate checking and measuring the

flatness
Activities - I
Choose the proper instrument for the works given below :
Work Instument required
1. Measuring the
(i) depth of a Through hole
(ii) The thickness of a piece
(iii) Diameter of hole
(iv) Thickness of a piece upto 0.001 mm accuracy.
Activities - II
A job description is given in column 2.
Suggest suitable measuring instruments in column 3.

Sl.No. Job description Name of the measuring

instrument
(a) Checking and transfering angles
(b) Measuring angle.
(c) For checking straightness and flatness of surface
(d) To find the height, angle of a job
Short Answer Type Questions
1. What is least count of vernier caliper?
2. Write the working principle of micrometere.
3. What is the use of sinbar?
4. What are the uses of D.T.I?
5. Draw a neat sketch of vernier height guage.
Long Answer Type Questions
1. Explain the working of vernier caliper with a sketch.
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2. Draw a neat sketch of sine bar. How it is used for measuring the angle?
3. Explain the reading procedure of a micrometre with a sketch.
OJT / Project Work
1. Find out the radious of a 1mm Dia wire with micrometer
2. Find out the diameter of Cyclinder with varnier caliper
3. Mark out the given blue print with varnier height guage.