19M603 Metrology & Instrumentation

6MG2/G2B Even Sem 2023-24

Linear Measurement

Dr A Prabukarthi
Assistant Professor
Department of Mechanical Engineering
PSG College of Technology
Coimbatore-641004
Types of Measurement and Instruments Used
 Introduction

• Most people’s first contact with linear measurement is

with a steel rule or a tape measure.
• However, today’s engineer has a choice of wide range of
instruments to choose from right from purely
mechanically operated instruments to digital electronics
instruments.
• One has to only consider the nature of application and
cost of measurement to decide which instrument is the
best for an application.
• This class covers a broad range of linear measurement
instruments from a simple steel rule up to digital calipers
and micrometers.
 Design of Linear Measurement Instruments

• The measuring accuracy of line graduated instruments

depends on the original accuracy of line graduations.
Excessive thickness or poor definition of graduated lines
affect the accuracy of readings captured from the
instrument.
• Attachments can enhance the versatility of instruments.
However, every attachment used along with an
instrument, unless properly deployed, may contribute to
accumulated error. Wear and tear of attachments can also
contribute to errors.
 Contd..

• Instruments such as callipers depend on the feel of the

user for their precision. Good quality of the instrument
promotes reliability, but ultimately skill of the user
ensures accuracy.
• The principle of alignment states that the line of
measurement and the line of dimension being measured
should be coincident. This principle is fundamental to
good design and ensures accuracy and reliability of
measurement.
• Dial versions of instruments add convenience in reading.
Electronic versions provide digital readouts which are
even easier to read.
 Contd..

• One important element of reliability of an instrument is

its readability.
• If cost is not an issue, digital instruments may be
preferred. The chief advantage of electronic method is the
ease of ‘signal processing’. The readings may be
expressed directly in the required form without
additional arithmetic. The readings can be stored on a
memory device for further use and analysis.
• Whenever, contact between the instrument and surface of
the job being measured is inevitable, contact force should
be optimum to avoid distortion. The designer cannot
leave the fate of the instrument on the skill of the user
alone.
 Contd..

• Steel rule

– It should be made of good quality spring steel

– It should be machine ground on its faces and have

clearly engraved lines

– It should have graduations on both edges

– It should have minimum thickness

– It should be chrome plated

 Surface plate

• A surface plate is a hard, solid and horizontal flat plate,

which is used as the reference plane for precision
inspection, marking out and precision tooling set up.
• Since surface plate is used as the datum for all
measurements on a job, it should be finished to a high
degree of accuracy.
Contd..
 Care for Surface plate
• Measuring instruments should not be allowed to drop on its surface
• Kept covered while not in use
• Should be firmly supported and properly leveled
• Variations in local flatness of the surface should be checked occasionally
• Clean the surface before use
• Use the full area to avoid local wear

• Testing flatness
– Using two/three footed twist gauge
– Beam comparator
– Laser Beam
– Spirit level
– Engineer’s square (Try square)
– Interference
 Contd..

Engineer’s Parallels – used for setting the work

pieces at desired distance in milling, grinding and
shaper vices
- commonly made of tool steel, SS or CI
- 4 or 6 faces ground or lapped
- comes in pair
- classified as solid type, box type
and adjustable (tapered) type
- Grade A – high tolerance
- Grade B – low tolerance
V ‐ Blocks
 Contd..

V Block V Block with a stirrup clamp Magnetic V Block

Graduated Scales
Contd..
Contd..
Contd..
Depth Gauge
Contd..
Contd..
Contd..
Combination Set
Contd..
 Calipers

• Calipers
– Used to measure the diameter of a circular part
– Types
• Firm joint calipers
• Spring calipers
• Outside calipers
• Inside calipers
• Transfer calipers
• Odd leg calipers
Contd..
Contd..
 Feeler gauge

• Used to check the clearance between

the two mating parts.

• Consists of narrow strips of sheet

steel of different thickness
assembled together in a holder

• The strips should neither be forced

between the surfaces nor slide freely
 Screw pitch gauge

• Used to check the pitch of the screw thread

• They quickly determine the pitch by matching the teeth
of the strips with the teeth of the workpiece
 Radius gauge

• Employed for checking external and internal radii on a

curved surface
• Corresponding radius is permanently marked on each
blade
• Internal radius on one side and external radius on the
other side for convenience in use
 Wire gauge

• Used for finding diameters of wires by inserting the wire

in the notches provided
• Range from 0.1 to 10 mm
 Bore gauge

Telescopic gauges Small hole gauges

Vernier Instrument
 Vernier Caliper

1. Outside jaws: used to measure external length 2. Inside jaws: used to measure internal length
3. Depth probe: used to measure depth 4. Main scale (cm)
5. Main scale (inch) 6. Vernier (cm)
7. Vernier (inch) 8. Retainer: used to block/release movable part
Contd..
Contd..
Contd..
Contd..
Contd..
Height Gauge
Contd..
Contd..
Height Masters
Micrometer Instruments
Contd..
Conformity to ABBE’s Law
Contd..
Contd..
Contd..
Groove Micrometer
Outside Micrometers
Contd..
Contd..
Contd..
Contd..
Contd..
Contd..
Contd..
Metric Gauge Blocks
 History

• Developed by the Swedish inventor Carl Edvard Johansson

– Also called as Johansson Blocks

• Armourer inspector in a rifle factory

• Concerned with the expensive tools for measuring parts for the
Remington rifles

• Converted his wife’s sewing machine to grinding and lapping

machine

• Formed the Swedish company CE Johansson AB in March 1917

 Use

• Direct precise measurement

• Checking accuracy of the vernier callipers, micrometers

etc

• Setting up a comparator to a specific dimension

• Measuring angle of workpiece

• Angular setting in conjunction with sine bar

• Distance of plugs, spigots etc

• Check gap between parallel locations

 Wringing

• Defined as the ability of two surfaces to adhere tightly to

each other in the absence of external means

• They are not magnetized or clamped together

 Contd..
• Make sure that blocks are clean
• Wipe the surfaces of the blocks to be wrung gently across the oiled
Wring Pad Wipe these surfaces on the dry pad, removing as much
oil as possible
• Slide the surfaces of the blocks together. Apply pressure while
sliding the blocks.
• The blocks should slide together without any feel of bumps or
scratching, and should adhere to each other strongly after being
rotated into place
 Indian Standard

• Grade II – workshop grade

• Grade I
• Grade O
• Grade OO
• Calibration Grade

Nominal Size Grade 0 Grade I Grade II

mm micron micron micron

10 0.02 0.10 0.35
20 0.04 0.15 0.45
50 0.10 0.30 0.75
100 0.20 0.50 1.20
 Slip gauge set
M45 M87

Range (mm) Step (mm) Pieces Range (mm) Step (mm) Pieces

1.001 to 1.009 0.001 9 1.001 to 1.009 0.001 9

1.01 to 1.09 0.01 9 1.01 to 1.49 0.01 49

1.1 to 1.9 0.1 9 0.5 to 9.5 0.5 19

1 to 9 1 9 10 to 90 10 9

10 to 90 10 9 1.005 1
 Selection

• Start with the last decimal place and deduct this from

the required dimension

• Select the next smallest figure, find the reminder and

continue this procedure

• Try to figure out the minimum number of slips for

32.547 mm (Using M87 set)

 Procedure

• Last decimal – 0.007, choose

Range (mm) Step (mm) Pieces
1.007mm gauge
1.001 to 1.009 0.001 9
• Dimension left 32.547 –
1.007 = 31.54mm
1.01 to 1.49 0.01 49 • For second decimal plane of
0.04 choose 1.04mm
0.5 to 9.5 0.5 19
• Dimension left 31.54 - 1.04 =
30.5mm
10 to 90 10 9 • Select 0.5mm and 30mm
slip gauges to built the
1.005 1 required dimensions
 Selection of Slip gauge using M45 set

• Try to figure out the minimum number of slips for

Range (mm) Step Pieces 56.421 mm (Using M45 set)
(mm) • Always the last decimal point is to be considered first,
i.e. 0.001 mm. Since gauge of 0.001 mm is not available,
1.001 to 0.001 9 1.001 mm slip gauge is to be selected.
1.009 • The dimension left now is 56.421 – 1.001 = 55.42 mm.
• Now considering the second decimal place, slip gauge
1.01 to 1.09 0.01 9
with 1.02 mm height is selected. The dimension left is
55.42 – 1.02 = 54.4 mm.
• Next for 54.4 mm, slip gauge with 1.4 mm is to be
1.1 to 1.9 0.1 9
chosen and then 3.0 mm gauge. Finally, 50 mm gauge is
to be chosen.
• Thus, we have 50.000 + 3.000 + 1.400 + 1.020 + 1.001 =
1 to 9 1 9
56.421 mm.
• All these five slip gauges are wrung properly to get the
10 to 90 10 9 required dimension. If special set of gauges be used, the
combination in this case would have been 50.000 +
5.420 + 1.001 = 56.421 mm.
Master ring gauge
 Dial bore gauge

• Dial indicators, also known as dial gauges and probe

indicators, are instruments used to accurately measure small

linear distances, and are frequently used in industrial and

mechanical processes.

• They are named so because the measurement results are

displayed in a magnified way by means of a dial.

 Contd..

• Dial indicators may be used to check the variation in

tolerance during the inspection process of a machined

part.

• The tip of the probe may be interchanged with a range of

shapes and sizes depending on the application.

Contd..
Thank You
Pierre Vernier
• Pierre Vernier was a French
mathematician and instrument
inventor.
• He was inventor and eponym of the
vernier scale used in measuring
devices.