Micrometer

An instrument for making precise measurements that has a spindle moved by a finely
threaded screw. Word micro used for very small object up to micron (0.001 mm)

Principle
It works on nut and bolt principle.

C-Frame:
It’s a c shaped frame is a rigid part that has both holding points for a job or object to be
measured. Its size depends on micrometer measuring range so size of c frame
increases as range expands to bigger.
Zero adjust screw:
It’s a screw located back end of anvil shown in figure. if there is some error found before
the measurement during test.
Anvil:
As discussed above it is a small stationary cylindrical part of micrometer located in far
end of c-frame and acts as one holding point for measuring objects. So we can say it’s a
one of rigid measuring and holding point of micrometer.
Spindle:
A cylindrical long part which is mounted through all other parts sleeve, lock nut and
thimble. It is moveable part and has a connection with ratchet as we rotate the ratchet
clockwise or counter clockwise the spindle slides out or inward to adjust it with compare
to measuring object size.
Anvil Face and Spindle Face:
Faces of both anvil and spindle which are opposite to each other are the measuring
points of micrometer and hold the measuring object collectively.
Lock nut:
As we know the mechanism of micrometer based on precision ground threads of
spindle so the lock nut works as stationary nut for this mechanism, so rotation of this
mechanism into lock nut controls the spindle movement.
Sleeve:
It’s a barrel type cylindrical part which mounted on spindle and is main scale of
micrometer because main scale is engraved on the sleeve. Thimble rotates around that
sleeve and spindle. Its main function is indication of reading in millimeter in case of
imperial micrometer.

Thimble:
Thimble is also mounted on spindle and a scale is engraved around it perimeter of
thimble. Scale of thimble is to show the measurement value in fraction.
Ratchet:
It’s a knurled thumb gripe to rotate the spindle into desired direction for measuring
process, provided with ratchet action to avoid over tightening of micrometer across the
measuring object and also ensures equal pressure force of each measurement.
Least Count = Smallest division on main scale / Total number of division on
circular scale
If smallest division on main scale is 0.5 mm.
Total no. of division circular scale = 50
L.C = 0.50/50 = 0.01mm

How take Reading:

The main scale reading(MSR) is 2.5 mm and circular scale reading(SCR) is 38, and
least count (L.C) is 0.01 mm.
Total Reading = MSR + ( CSR×L.C)
Total Reading = 2.5 + (38×0.01)
Total Reading = 2.88 mm
Example 2:

Total Reading = MSR + (L.C×CSR)

Total Reading = 5.50 + 28×0.01 = 5.78 mm

Zero Error:
Correct reading = Obtained reading – Zero Error

where zero error can be either negative (the “0” marking on the thimble is above the

datum line)
Zero Error positive ( the “0” marking on the thimble is below the datum line )
Explanation

The reading on the bottom is the measurement obtained and the reading at the top is
the zero error. Find the actual measurement. (Meaning: get rid of the zero error in the
measurement or take into account the zero error)

Measurement with zero error: 1.76 mm

Zero error: + 0.01 mm (positive because the zero marking on the thimble is below the
datum line)

Measurement without zero error: 1.76–(+0.01)=1.751.76–(+0.01)=1.75 mm

Dial Gauge or Dial Indicator :

Dial gauges are used to measure the flatness and inclination of objects. It is used to
check round bar roundness. It checks the flatness of an object as compared to the
flatness of the standard object. In the mechanical field, dial gauges are used to check
the flatness and alignment of various jobs and work pieces.
This dial gauge is based on the principles of “rack and pinion.” The dial gauge can
measure up to a minimum of 0.01 mm readings. Therefore, its lowest count is 0.01 mm.
Parts of Dial Gauge
Casing:
There is a metal casing which is the outermost part of the dial gauge.
Graduated Scale:
Inside the casing, graduated scales are present, marking various readings. Pointer:
A Pointer exists that indicates the measured value on the graduated scale.. Small Dial
Gauge:
This small dial gauge is present insides the dial gauge. It also has graduation. This
small dial gauge has reverse reading. The readings of small dial gauges can be straight
or reverse depending on the mechanism used in the gear train for the movements of the
pointer to the small dial gauge.

Small dial pointer:

There is a small indicator that points to the measured value at the graduation of the
small dial indicator. It is also called a shorthand indicator.

Stem:
The plunger or spindle moves up & down inside this stem.
Contact Point:
This contact point will have contacts with the surface & will help in the motion of the
plunger. When the pointer of the external pointer completes its revolution, the pointer of
the smaller pointer wills move from 0 to 1, i.e., the smaller dial pointer will show 1 mm
when this larger pointer will exceed 100 reading in the larger dial pointer.
When the external pointer completes its ten rotations, the pointer of the smaller indicator
will return to zero. The small dial gauges are very helpful in taking a reading.
Least count of Dial Gauge Indicator:

100 lines reading in outers scale = 1mm = 1 full rotations on outer scale

Therefore, least count = 1 rotation on main scale / No of the division moved on the dial
scale.

Now,

1 Rotation On Main Scale = 1mm

No. of the division moved on dial scales = 100

Hence, Least Count = 1mm /100 = 0.01mm.

Reading Measurement:

When the larger dial pointer completes a full rotation, the smaller dial pointer will move a
unit that is equal to 1 mm. After taking the readings of the small dial indicator, the
readings of the external dial are taken. Explain that the external dial indicator has a
reading of 42.

After reading both the indicators we calculate the variations in mm using this formula:

Formula for variations (in mm) = short dial reading + (external dial reading x least count)

Now we have to assume,

Variation = 3 + (42 x 0.01)

= 3.42 mm
Exra Understanding:

Working Process:

When the dial gauge is placed on top of a workpiece, the dial gauge rod moves upward,
and the racks cut on it also move. The small gear S1 that attaches to the rack on the
rod starts rotating. When the rod moves upward, the small gear will rotate clockwise.

This smalls gear S1 is connected to a large gear G1. This larger gear controls
the G1 pointer P2, which is a pointer to the smaller dial gauge. When the smaller gear
S1 rotates clockwise, the larger gear G1 will rotate in the anti-clockwise direction, and
the pointer P2 connected to the larger gear G1 will rotate in the anti-clockwise direction.

G1 as this big gear An anti-clockwise direction will rotate, then the outer gear’s small
gear S2 will rotate clockwise, and so the outer dial P1‘s pointer will rotate in the
clockwise direction. In addition, the larger gear G2 will also rotate in a clockwise
response.
Now this larger gear is connected to the G2 helical spring, and the helical spring will
rotate in an anti-clockwise direction and accumulate rotational energy; and when the
work is completed, the helical spring will give its energy backs to the gear, and the
gears and pointers to their initial position Will come back As all gears will move in the
opposite direction

Combination Square:

A measuring tool consisting of a steel rule that slides through an adjustable protractor

head or level or a center head which can be fixed at any point on the rule by a lock bolt
and being usable as an inside or outside try square, a marking or depth gauge, level,
miter square, plumb, and straightedge.

Standard Head :

 Square, for marking and referencing 90° angles and checking if surfaces are flat
and square to one another.
 Mitre square, for marking and referencing 45° angles, such as in woodworking
for mitre joints.
 Spirit level, to check if a surface is level or similarly if a surface or edge is plumb
(vertical).
 Depth gauge or height gauge.
 Form of marking gauge for marking lines parallel to an edge, by setting the head
to a certain distance from the end of the rule.
 Protractor Head:

 Measuring and checking angles between surfaces, edges, and markings.

 Marking angles from an edge
 Directly transferring angles, like a bevel gauge (sliding T gauge), to minimize
measurement errors and inaccuracies.
 Measuring and marking angles relative to the horizontal by using the spirit level.

Centre Finder Head :

 Marking lines through the centre of circular or square objects, such as dowels.
Making multiple marks at different angles can be used to identify the point at the
center of the circle.
 Marking lines perpendicular to a curved edge (normal lines).
 Bisecting square corners to mark a 45° angle

Chapter # 05 Fix Measuring Tools:

What is Gauge:
The gauges are fixed design inspection tools, without a scale, which serve to check
the dimensions of manufactured parts. Gauges do not indicate the exact value of the
inspected dimension on the work. They are used for determining whether the inspected
parts are made within the specified limits.
Ring Gauges:
A ring gauge, is a cylindrical ring of a thermally stable material, often steel, whose
inside diameter is finished to gauge tolerance and is used for checking the external
diameter of a cylindrical object.
Ring gauges are used for comparative gauging as well as for checking, calibrating, or
setting of gauges or other standards
Types of Ring Gauges:
  Go Gauge
 No Go Gauge
 master or setting ring gauges.

Go ring gauges are designed to verify the upper tolerance limit of the outer diameter of
the part. If the go ring gauge fits over the outer diameter of the part, then this indicates
that the maximum allowable material condition for that part has not been exceeded,
meaning that the diameter of the part falls within the upper limit of its tolerance, and
therefore, the part is acceptable.

No-go ring gauges check the lower tolerance limit on the outer diameter of the part. If
the no-go ring gauge does not fit over the outer diameter of the part, then this indicates
that the minimum allowable material condition for the part has been satisfied, meaning
that the diameter of the part exceeds the minimum or lower limit of its tolerance, and
therefore, the part is acceptable.

The master gauges used to calibrate or set micrometers, optical comparators, or other

gauging systems. Working gauges are used in the shop for dimensional inspection and
periodically checked against a master gauge.

For weak student/understanding

Ring gauges are used to measure shafts to determine if they are within the specified
limits of size. The bore of the Go gauge is machined so it is fractionally larger than the
upper limit of size of the shaft.

The bore of the No Go gauge is machined so it is fractionally smaller than the lower limit
of size of the shaft. To use the ring gauges, you offer them up to the shaft and try to
slide them over the diameter. If the Go gauge slides over the shaft but the No Go does
not the shaft is within tolerance If both gauges fit over the diameter the shaft is to small
If the go gauge does not fit over the diameter the shaft is to large.

Plain Plug Gauges (not board content)

Plain plug gauges are used for checking plain or unthreaded holes and shafts.
These plain plug gauges are made of proper wear-resisting steel and the handles
are made of any suitable steel, such as light metal handles always for heavy
plain plug gauges or suitable non-metallic handles are provided for smaller plain
plug gauges.

The gauging surface of plain plug gauges are hardened to not less than 750 H.V
and suitably stabilized and groud and lapped.

The plain plug gauges are the double-ended type for sizes up to 63 mm and of
single-ended types of sizes above 63 mm. The plain plug gauges are designated
by ‘GO’ and ‘NOGO’ as applicable.

GO and NOGO plain plug gauges for sizes up to 10 mm.

Feeler Gauge

It is also known as a thickness gauge. Feeler gauges are often used to measure
the clearance between the components. These gauges are excellent for the
measurement of narrow slots, measuring clearance, determining small spacing,
and determining the fit between mating parts.
 Radius or Fillet Gauge

These gauge types are used to check the concave and convex radii on corners
or shoulders. It is also useful for layout work and inspection of components in
various industries. It is used as a template when grinding of cutting tools.

Screw Pitch Gauges

The screw pitch gauge is also called a thread gauge which looks related to a filler
gauge. Each strip or blade has several teeth, precisely shaped in standard thread
form.
Snap
Snap gauges, sometimes called gap gauges, are metrology tools that are used to
gage the diameter or thickness of a part or material.

These tools are versatile and are designed to provide a quick go/no-go decision
on cylinders, shafts, grooves, and other similar parts and features in machining
operations.

Snap gauges can be used for checking dimensions on both cylindrical and non-
cylindrical parts whereas ring gauges are for cylindrical parts only.
Gauge Block (Slips Gauges)
The individual gauge block is a metal or ceramic block that has been
precision ground and lapped to a specific thickness. Gauge blocks are stacked to
make up a desired length (or height).
Uses:
They are used as a reference for the calibration of measuring equipment used in
machine shops, such as micrometers, sine bars, calipers, and dial indicators (when
used in an inspection role). Gauge blocks are the main means of length standardization
used by industry.
Wringing:

The blocks are joined by a sliding process called wringing, which causes their ultra-flat
surfaces to cling together.
Air pressure applies pressure between the blocks because the air is squeezed out of
the joint.
Surface tension from oil and water vapor that is present between the blocks
Molecular attraction that occurs when two very flat surfaces are brought into contact;
this force causes gauge blocks to adhere even without surface lubricants, and in a
vacuum.
The process of wringing involves four steps
Wiping a clean gauge block across an oiled pad (see the accessories section).
Wiping any extra oil off the gauge block using a dry pad.
The block is then slid perpendicularly across the other block while applying moderate
pressure until they form a cruciform.
Finally, the block is rotated until it is in line with the other block.

Accessories:
The pictured accessories provide a set of holders and tools to extend the usefulness of
the gauge block set. They provide a means of securely clamping large stacks together,
along with reference points, scribers, and various shapes of blocks that act like caliper
jaws, either external or internal. Conical-tip ones ease measurement of center-to-center
distances between hole centers. A stack of gauge blocks with external caliper-jaw
accessories, all clamped together, acts as a quickly assembled custom-size go or no-go
gauge.
Grades:
reference (AAA): small tolerance (±0.05 μm) used to establish standards (00 grade)
calibration (AA): (tolerance +0.10 μm to −0.05 μm) used to calibrate inspection blocks
and very high precision gauging (0 grade)
inspection (A): (tolerance +0.15 μm to −0.05 μm) used as tool room standards for
setting other gauging tools
workshop (B): large tolerance (tolerance +0.25 μm to −0.15 μm) used as shop
standards for precision measurement.
Set of Blocks:
56 pieces with increment

Metric 103 Pieces

English 81 Piece