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MEE361:Metrology
Dr Tunji Owoseni
Department of Mechanical Engineering
Kwara State University, Malete
Section 1.0
Metrology: meaning and its aspects
Accuracy and precision
General concept of measurement
Errors in measurement
 Systematic or controllable errors
 Random errors

Objectives metrology and measurements

Sep. 2022 2
Metrology

Metrology literally means the science of measurement.

It is also concerned with industrial inspection and its various
techniques.
It has two aspects namely:
 Reference standard metrology
 Engineering Metrology

Sep. 2022 3
Metrology
Reference standard metrology—the enforcement,
verification, and validation of predefined standards.

Engineering Metrology—the measurements of length,

angles, and other quantities that are expressed in linear and
angular terms. This is termed dimensional metrology.
 Dimensional measurements at the required level of accuracy are the
essential link between the designers’ intent and a delivered product.

Sep. 2022 4
Metrology
Metrology deals with establishing the units of measurements and
their reproduction in the form of standards, ascertaining the
uniformity of measurements, developing methods of measurement,
analysing the accuracy of methods of measurement, establishing
uncertainty of measurement, and investigating the causes of
measuring errors and subsequently eliminating them.

Sep. 2022 5
Accuracy
Accuracy is the degree of agreement of the measured dimension with
its true magnitude.
 It can also be defined as the maximum amount by which the result differs from the
true value or
 As the nearness of the measured value to its true value, often expressed in
percentage.
True value may be defined as the mean of the infinite number of
measured values when the average deviation due to the various
contributing factors tends to zero. In practice, realization of the true
value is not possible due to uncertainties of the measuring process and
hence cannot be determined experimentally.
Positive and negative deviations from the true value are unequal; they
will not cancel each other.

Sep. 2022 6
Accuracy
Two terms are associated with accuracy, especially when one strives for
higher accuracy in measuring equipment: sensitivity and consistency.
Sensitivity means the ability of the measuring equipment to detect small
variations in the quantity being measured. It can be calculated as the ratio
of the change of instrument indication to the change of quantity being
measured.
Consistency means the ability of the measuring instrument to return the
same readings all the time.

Sep. 2022 7
Accuracy

Figure 1.1: Relationship of accuracy with cost

Sep. 2022 8
Precision
Precision means the degree of repetitiveness of the measuring
process.
 It represents the degree of agreement of the repeated measurements of a
quantity made by using the same method, under similar conditions.
 Precision refers to the consistent reproducibility of a measurement. If an
instrument is not precise, it would give different results for the same
dimension for repeated readings.
The ability of the measuring instrument to repeat the same results
during the act of measurements for the same quantity is known as
repeatability.
 Repeatability is random in nature; it does not assure accuracy, though it is a
desirable characteristic.

Sep. 2022 9
Precision
Accuracy gives information regarding how far the measured value
is with respect to the true value, whereas precision indicates quality
of measurement, without giving any assurance that the
measurement is correct.
In most measurements, precision assumes more significance than
accuracy.
It is important to note that the scale used for the measurement must
be appropriate and conform to an internationally accepted standard.

Sep. 2022 10
 Concept of Measurements

1. Measurand, a physical quantity such as length, weight, and angle to be

measured
2. Comparator, to compare the measurand (physical quantity) with a known
standard (reference) for evaluation.
3. Reference, the physical quantity or property to which quantitative comparisons
are to be made, which is internationally accepted
In order to determine the length (a physical quantity called measurand) of the component, measurement is
carried out by comparing it with a steel scale (a known standard).

Figure 1.2: Elements of

measurement

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Basic Measurement Devices

Surface Plates

Test Stands

Dial Gages

Micrometers and Verniers

Gauge Blocks

Sep. 2022 12
Measurement Units

Imperial

International standard unit (SI Unit)

 What are they?

Sep. 2022 13
 Unit Prefixes
Metric Prefixes Symbol Multiples and Submultiples Factor
Exa E 1,000,000,000,000,000,000 1018
Peta P 1,000,000,000,000,000 1015
Tera T 1,000,000,000,000 1012
Giga G 1,000,000,000 109
Mega M 1,000,000 106
Kilo k 1,000 103
Hecto h 100 102
Deca da 10 10
Deci d 0.1 10-1
Centi c 0.01 10-2
Milli m 0.001 10-3
Micro µ 0.000001 10-6
Nano n 0.000000001 10-9
Pico p 0.000000000001 10-12
Femto f 0.000000000000001 10-15
Atto a 0.0000000000000000001 10-18
Metrology
Sep. 2022 14
 Errors in
Measurement

What is error?
Sep. 2022 15
Error and its Types
Error is a measure of the uncertainty associated with
measurements.
Error is the difference between a measurement result and
the value of the measurand.
Uncertainty describes the reliability of the assertion that
the stated measurement result represents the value of the
measurand.

Sep. 2022 16
Error and its Types

Systematic or Controllable Error (S/CE)—a type of error

that deviates by a fixed amount from the true value of

measurement.

Systematic errors cannot be eliminated by statistical

techniques. Minimization of systematic errors increases

the accuracy of measurement.

Sep. 2022 17
Reasons for occurrence of S/CE
Calibration errors
Ambient conditions
Deformation of workpiece
Avoidable errors
 Datum errors
 Reading errors
 Errors due to parallax
 Effect of misalignment

Sep. 2022 18
Error and its Types
Random errors provide a measure of random deviations when
measurements of a physical quantity are carried out repeatedly.
 Specific causes for these variations cannot be determined
 the variations are unpredictable and uncontrollable by the experimenter and are
random in nature.
 They are of variable magnitude and may be either positive or negative.

If the repeated measurements are plotted, they follow a normal or

Gaussian distribution.
Random errors can be statistically evaluated, and their mean value and
standard deviation can be determined.

Sep. 2022 19
 What are the sources of
random error?

Sep. 2022 20
 Systematic Errors vs Random Error

Sep. 2022 21
 Methods of Measurement

Sep. 2022 22
Why do measurement?
Measurements are conducted to determine the magnitude
of the value and the unit of the quantity under
consideration. E.g., the temperature of a rod is 3 °C, in this
case the digit 3, represents the magnitude of the measured
temperature and the unit of measurement is Celsius.
The required accuracy and the amount of permissible error
would determine the choice of the method of
measurement.
How many methods of measure are there?

Sep. 2022 23
Task 1
Describe each of the
following terms; state
examples for each.
 Device

 Instrument

 Equipment

Sep. 2022 24
Measurement procedures
Direct method
 This involves direct comparison between the measured quantity

and the primary or secondary standard. The following items are

used in direct measurement scales, vernier callipers, micrometers,
bevel protractors, etc. In the direct method, a very slight difference
exists between the actual and the measured values of the quantity.
This difference occurs because of the limitation of the human
being performing the measurement.

 Direct method is employed widely in the production field.

Sep. 2022 25
Measurement procedures
Indirect method
 In this case, measurement of the quantity is carried out directly
and then the value is determined using a mathematical model.
Some examples of indirect measurement are:
 angle measurement using sine bar,
 measurement of strain induced in a bar due to the applied force,
 determination of effective diameter of a screw thread, etc.

Sep. 2022 26
Measurement procedures
Fundamental or absolute method
 In this case, the measurement is based on the measurements of

base quantities used to define the quantity. The quantity under

consideration is directly measured, and is then linked with the
definition of that quantity.
Comparative method
 Here, the desired quantity compares to a known value of the same

quantity or a quantity practically related to it. i.e. the quantity is

compared with the master gauge; its deviation from the master
gauge is recorded after comparison. Commonest examples are
comparators, dial indicators, etc.

Sep. 2022 27
Measurement procedures
Transposition method
 This method involves making the measurement by direct

comparison, wherein the quantity to be measured (V) is initially

balanced by a known value (X) of the same quantity; next, X is
replaced by the quantity to be measured and balanced again by
another known value (Y). If the quantity to be measured is equal
to both X and Y, then

An example of this method is the determination of the mass of a

body by balancing it against known weights.

Sep. 2022 28
Measurement procedures
Coincidence method
 This is a differential method of measurement wherein a very

minute difference between the quantity to be measured and the

reference is determined by careful observation of the coincidence
of certain lines and signals. Measurements on vernier calliper and
micrometer are examples of this method.

Deflection method
 This method involves the indication of the value of the quantity to

be measured directly by deflection of a pointer on a calibrated

scale e.g. measurement or pressure.

Sep. 2022 29
Measurement procedures
Complementary method
 The value of the quantity to be measured is combined with a known value
of the same quantity. The combination is so adjusted that the sum of these
two values is equal to the predetermined comparison value. E.g. the
determination of the volume of an (irregular) solid by liquid displacement.
Composite method
 The actual contour of a component to be checked is compared with its
maximum and minimum tolerance limits to know the cumulative errors of
the interconnected elements of the component. This method is very reliable
to ensure interchangeability and is usually effected through the use of
composite GO gauges. The use of a GO screw plug gauge to check the
thread of a nut is an example of this method.

Sep. 2022 30
Measurement procedures
Null measurement method
 In this method, the difference between the value of the quantity to
be measured and the known value of the same quantity with which
comparison is to be made is brought to zero. Examples of the null
method are the measurements of
 electrical quantities like emf, voltage, resistance, capacitance
etc.
 nonelectrical quantities that are converted into electrical
quantities by means of potentiometers and bridges e.g.
temperature, pressure, strains, etc.

Sep. 2022 31
Measurement procedures
Contact method
 In this method, the surface to be measured is touched by the sensor
or measuring tip of the instrument. Care is taken to ensure constant
contact pressure in order to avoid errors due to excess constant
pressure. Examples of this method include measurements using
micrometer, vernier calliper, and dial indicator.
Contactless method
 Indicates, there is no direct contact with the surface to be measured.
Examples of this method include the use of optical instruments, tool
maker’s microscope, and profile projector.

Sep. 2022 32
 Standards of
measurement

Evolution, forms and application

Sep. 2022 33
Meaning of standard

A standard is an object, system, or experiment that bears a

defined relationship to a unit of measurement of a physical
quantity.

Standards are the fundamental reference for a system of

weights and measures, against which all other measuring
devices are compared.

Sep. 2022 34
Roles of standard
Standards make it possible to perform trade in national and
international arenas. It ensures fair international trade and commerce.
It also helps accomplish complete interchangeability of manufacture.
When a manufacturer adheres to accepted standards, the manufacturer
can convince the customers about the quality of the articles of trade
like products.
It also helps manufacturers globally in achieving consistency,
accuracy, precision, and repeatability in measurements and in
supporting the system that enables the manufacturers to make such
measurements.

Sep. 2022 35
 36

Task 2
Sep. 2022

Compare and contrast between material standard and

wavelength standard
State the disadvantages of material standard
Line and end measurement
Line standard/measurement
 This when the distance between two engraved lines is used to measure
length. Its commonest examples are yard and metre.
 Rules with divisions marked with lines are used widely.

End standard/measurement
 This is when the distance between two flat parallel surfaces is considered
a measure of length.
 The end faces of the end standards are hardened to reduce wear and
lapped flat and parallel to a very high degree of accuracy.
 The end standards are extensively used for precision measurement in
workshops and laboratories. The commonest examples are measurements
using slip gauges, end bars, ends of micrometer anvils, vernier callipers, etc.

Sep. 2022 37
 Reflect!
Which of line standard and end standard
applies to measure the distance
between two edges?

Sep. 2022 38
Between line
and end
standards

Sep. 2022 39
Task 3
Write five characteristics for each of
line and end standards

Sep. 2022 40
Transfer from line standard to end
standard

1. Basic length of primary line standard

2. Basic length of primary line standard with end 4. End standard of known length as obtained
blocks from the standard

3. Comparison of blocks (a + b) and (c + d)

Sep. 2022 41
Calibration of standards
Brookes level comparator
Displacement method
Calibration of end bars

Sep. 2022 42
 • The Brookes level comparator is used to calibrate
Brookes level standards by comparing with a master standard.
comparator • End standards can be manufactured very
accurately using a Brookes level comparator.

Sep. 2022 43
 • The displacement method is used to compare an
edge gauge with a line standard.
Displacement
• Displacement method (a) With line standard only
method (b) With line and end standards combined

Sep. 2022 44
Calibration • Calibration of end bars (a) Comparison of metre
bar and end bars wrung together (b) Comparison
of end bars of individual end bars

Sep. 2022 45
Numerical examples
1. It is required to obtain a metre standard from a calibrated line standard using a
composite line standard. The actual length of the calibrated line standard is 1000.015
mm. The composite line standard comprises a length bar having a basic length of 950
mm and two end blocks, (a + b) and (c + d), each having a basic length of 50 mm. Each
end block contains an engraved line at the centre.
Four different measurements were obtained when comparisons were made between the
calibrated line standard and the composite bar using all combinations of end blocks: L 1
= 1000.0035mm, L2 = 1000.0030mm, L3 = 1000.0020mm, and L4 = 1000.0015mm.
Determine the actual length of the metre bar. Block (a + b) was found to be 0.001mm
greater than block (c + d) when two end blocks were compared with each other.

Sep. 2022 46
Numerical examples
2. A calibrated metre end bar, which has an actual length of 1000.0005mm, is to be
used in the calibration of two bars X and Y, each having a basic length of 500mm.
When compared with the metre bar, the sum of L X and LY is found to be shorter by
0.0003mm. When X and Y are compared, it is observed that X is 0.0004mm longer
than Y. Determine the actual length of X and Y.
3. Three 200 mm gauges to be calibrated are measured on a level comparator by
wringing them together and then comparing them with a 600mm gauge. The
600mm gauge has an actual length of 600.0025mm, and the three gauges together
have a combined length of 600.0035 mm. When the three gauges are
intercompared, it is found that gauge A is longer than gauge B by 0.0020mm but
shorter than gauge C by 0.001mm. Determine the length of each gauge.

Sep. 2022 47
DIY
1. It is required to calibrate four length bars A, B, C, and D, each having
a basic length of 250mm. A calibrated length bar of 1000mm is to be
used for this purpose. The 1000 mm bar has an actual length of
999.9991 mm. It is also observed that
a) LB = LA + 0.0001 mm
b) LC = LA + 0.0005 mm
c) LD = LA + 0.0001 mm
d) LA + LB + LC + LD = L + 0.0003 mm
Determine LA, LB, LC, and LD.

Sep. 2022 48
DIY
2. A calibrated end bar having an actual length of 500.0005 mm is to be used to
calibrate two end bars A and B, each having a basic length of 250 mm. On
comparison, the combined length LA + LB is found to be shorter than the 500mm
end bar by 0.0003 mm. When the two end bars A and B are intercompared with
each other, A is found to be 0.0006 mm longer than B. Determine L A and LB.
3. Three 200 mm end bars (P, Q, and R) are measured by first wringing them together
and comparing with a 600 mm bar. They are then intercompared. The 600 mm bar
has a known error of 40 µm and the combined length of the three end bars is found
to be 64 µm less than the 600 mm bar. It is also observed that bar P is 18µm longer
than bar Q and 23 µm longer than bar R. Determine the lengths of the three end
bars.

Sep. 2022 49
Answers to the DIY
1. LA = 249.999725 mm, LB = 249.999825 mm, LC =

250.000225 mm, LD = 249.999625 mm

2. LA = 250.0004 mm, LB = 249.9998 mm

3. 3. LP = 200.0056667 mm, LQ = 199.9876667mm, LR

= 199.9826667 mm

Sep. 2022 50
 Sep. 2022

Linear
measurements

51
Section 2.0
Linear measurement: meaning and associated matters
 Design of linear measurement instruments
 Surfaces for measurement: surface plate and v-block

Scaled Instruments
Vernier Instruments
Micrometer Instruments
Slip gauges

Sep. 2022 52
Linear measurement: meaning and associated
matters

 The linear measurement is the distance between two given

points or objects.
 Linear measurement is done either by direct or indirect
measurement.
 Measuring instruments are designed either:
 for line measurements (e.g., steel rule or vernier calliper) or
 for end measurements (e.g., screw gauge).

Sep. 2022 53
Design of linear measurement Instruments

 Linear measurement instruments have to be designed to meet

stringent demands of accuracy and precision.
 The instruments should be simple to operate and low priced to
make economic sense for the user.
 The instrument should have proper attachments to make it
versatile to capture dimensions from a wide range of
components, irrespective of the variations in cross-sections and
shapes.

Sep. 2022 54
Design considerations for linear measurement
Instruments
 The measuring accuracy of line-graduated instruments depends on the
original accuracy of the line graduations.
 Excessive thickness or poor definition of graduated lines affects the accuracy of
readings captured from the instrument.
 Any instrument incorporating a scale is a suspect unless it provides
compensation against wear.
 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.
 Use attachments when their presence improves reliability more than their added
chance for errors decreasing it.

Sep. 2022 55
Design considerations for linear measurement
Instruments
 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
measurements.
 Dial versions of instruments add convenience to reading. Electronic
versions provide digital readouts that are even easier to read.
 However, neither of these guarantees accuracy and reliability of measurements
unless basic principles are adhered to.

Sep. 2022 56
Design considerations for linear measurement
Instruments
 The instrument should have enhanced readability.
 The smallest division on a micrometer is several times larger than that on a steel
rule of say 0.1 mm resolution, which is difficult to read. However, the micrometer
provides better least count, say up to 0.01 mm, compared to the same steel rule—a
micrometer is more reliable than a vernier scale but it has a lesser range than
verniers.
 If cost is not an issue, digital instruments may be preferred.
 Electronic method allows ease of signal processing to express readings directly in
the required form without additional arithmetic e.g. readings may be expressed in

either metric or British units, and can also be stored on a memory device for further
use and analysis.

Sep. 2022 57
Design considerations for linear measurement
Instruments
 Whenever a contact between the instrument and the surface of the job
being measured is inevitable, the contact force should be optimum to
avoid distortion.
 The designer cannot leave the fate of the instrument on the skill of the user alone. A
proper device like a ratchet stop can limit the contact force applied on the job
during measurements, thereby avoiding stress on the instrument as well as
distortion of the job.

Sep. 2022 58
 Surfaces for
measurement

Surface plate and V-block

Sep. 2022 59
 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.

It is made from cast iron, granite, and glass

Sep. 2022 60
 Granite Surface plate
Natural granite that is seasoned in the open for thousands of years is
free from warp age or deterioration.
It is twice as hard as cast iron and not affected by temperature
changes.
It is not vulnerable to rusting and is non-magnetic.
it is free from burrs or protrusions because of its very fine grain
structure.

Sep. 2022 61
V-blocks
V-blocks are extensively used for inspection of jobs with a circular cross
section.
Generally, the angle of the V is 90°, though an angle of 120° is preferred in
some cases.
V-blocks are made of high-grade steel, hardened above 60 HRC (6.83
GPa), and ground to a high degree of precision.
V-blocks are manufactured in various sizes ranging from 50 to 200mm.
 The accuracy of flatness, squareness, and parallelism is within 0.005mm for V-blocks of
up to 150mm length, and 0.01mm for those of length between 150 and 200mm

Sep. 2022 62
Magnetic V-block V-block with a stirrup V-block
clamp

V-blocks

Sep. 2022 63
Scaled Instruments

Combination set

Depth gauge

Sep. 2022 64
 Scaled Instruments

Types of callipers: (a) Outside calliper (b) Inside

calliper (c) Divider (d) Hermaphrodite calliper
Sep. 2022 65
Vernier Instrument

• Vernier instruments based on the vernier scale Forward vernier

principle can measure up to a much finer
degree of accuracy. In other words, they can
amplify finer variations in dimensions and can
be branded as ‘precision’ instruments.
• The minimum length or thickness that can be
measured with a vernier scale is called the
least count.
Backward vernier

Sep. 2022 66
Vernier
Instrument: Types

Type A
• Vernier calliper
• Dial calliper
• Electronic digital calliper

• The recommended measuring ranges for

vernier callipers are: Type B
0–125, 0–200, 0–250, 0–300, 0–500,
0–750, 0–1000, 750–1500, and 750–2000
mm.

Sep. 2022 67
 Dial and Digital calliper
The accuracy of the reading mechanism of the dial calliper is a function of
length of travel, unlike the vernier calliper that has the same accuracy
throughout its length.
 A dial calliper is also subject to malfunctioning because of the delicate nature of the dial
mechanism.

A digital calliper can be interfaced with a dedicated recorder or personal

computer through a serial data cable.
 The digital interface provides secured storage for a series of readings, thereby improving
the reliability of the records. It can be connected to a printer to provide a printed record
or can be directly interfaced with a computer of a statistical control system.

Sep. 2022 68
Vernier
• Vernier depth gauge
Instrument: • Vernier height gauge
Types

Vernier depth gauge Vernier height gauge

Sep. 2022 69
Vernier
• Vernier depth gauge
Instrument: • Vernier height gauge
Types
Vernier depth gauges can have an accuracy of up to 0.01mm. Periodic
cleaning and lubrication are mandatory, as the main scale and fine
adjustment mechanism are always in motion in the process of taking
measurements.
Unlike in depth gauge, the main scale in a height gauge is stationary
while the slider moves up and down. The vernier scale mounted on the
slider gives readings up to an accuracy of 0.01mm.
 Vernier height gauges find applications in tool rooms and inspection departments.
Modern variants of height gauges such as optical and electronic height gauges are
also becoming increasingly popular.

Sep. 2022 70
 A micrometer can provide better least counts and
Micrometer accuracy than a vernier calliper. Better accuracy results
because of the fact that the line of measurement is in
Instruments line with the axis of the instrument, unlike the vernier
calliper that does not conform to this condition. This
fact is best explained by Abbe’s principle, which states
that ‘maximum accuracy may be obtained only when
the standard is in line with the axis of the part being
measured’.

Conformity to Abbe’s law (a) Micrometer (b) Vernier calliper

Sep. 2022 71
Micrometer Instruments
• Micrometer has better accuracy than verniers, but it has a
shorter measuring range and can only be used for end
measurement.
• The ranges of micrometers are normally 0–25, 25–50, or

0–50 mm. The maximum range of micrometers is limited

to 500 mm.
• Precautions to reading a micrometer.
• The thimble must be read in the correct direction.

• The other precaution concerns the zero position on the

thimble. When passing the index line on the main scale,

there is a chance to read an extra 0.5mm.
• This is caused by the fact that the next main scale

graduation has begun to show but has not yet fully

appeared. This is avoided by being careful to read only
full divisions on the barrel.

Sep. 2022 72
 Micrometer Instrument: Types
Types of outside micrometers (a) Disk type (b)
Screw thread type (c) Dial type (d) Blade type

Sep. 2022 73
 • Universal micrometer It has interchangeable anvils
Micrometer such as flat, spherical, spline, disk, or knife edge. It is
called universal because of its modular design. The
Instrument: micrometer fitted with the required accessories can
Types function as an outside micrometer, a depth micrometer, a
step micrometer, etc.

Sep. 2022 74
 • A micrometer that we considered hitherto can
Vernier provide an accuracy of at best 0.01mm or
10µm. Placing a vernier scale on the
Micrometer micrometer permits us to take readings up to
the next decimal place. In other words, one can
accurately measure up to 1 µm or 0.001mm,
which is an excellent proposition for any
precision workmanship.

• Reading on the barrel gives the main reading,

while the vernier scale and the thimble scale
gives the additional decimal readings.

Sep. 2022 75
 • A micrometer that we considered hitherto can
Vernier provide an accuracy of at best 0.01mm or
10µm. Placing a vernier scale on the
Micrometer micrometer permits us to take readings up to
the next decimal place. In other words, one can
accurately measure up to 1 µm or 0.001mm,
which is an excellent proposition for any
precision workmanship.

• Reading on the barrel gives the main reading,

while the vernier scale and the thimble scale
gives the additional decimal readings.

Sep. 2022 76
Other • Digital micrometer
Micrometer • Inside micrometer calliper
Instrument • Inside micrometer
• Micrometer depth gauge
Types

Sep. 2022 77
 Slip Gauges
• The accuracy of the previously de described
instruments depends on the accuracy of the
workmanship involved in their manufacture.
Any minor misalignment or error in a screw
often leads to errors in measurement.

• Slip gauges, also called gauge blocks, can

counter some of these limitations and
provide a high degree of accuracy as end
standards. In fact, slip gauges are a direct
link between the measurer and the
international length standards.

Sep. 2022 78
Grades of Slip Gauges
• Slip gauges are classified into grades depending on their guaranteed
accuracy. The grade defines the type of application for which a slip gauge is
suited, such as inspection, reference, or calibration.
• Slip gauges are designated into five grades, namely:
• Grade 2 This is the workshop-grade slip gauge. Typical uses include setting up machine
tools, milling cutters, etc., on the shop floor.
• Grade 1 This grade is used for tool room applications for setting up sine bars, dial
indicators, calibration of vernier, micrometer instruments, and so on.
• Grade 0 This is an inspection-grade slip gauge. Limited people will have access to this slip
gauge and extreme care is taken to guard it against rough usage.
• Grade 00 This set is kept in the standards room and is used for inspection/calibration of high
precision only. It is also used to check the accuracy of the workshop and grade 1 slip gauges.

Sep. 2022 79
Grades of Slip Gauges
Calibration grade
 This is a special grade, with the actual sizes of slip gauges
stated on a special chart supplied with the set of slip gauges.
 This chart gives the exact dimension of the slip gauge, unlike
the previous grades, which are presumed to have been
manufactured to a set tolerance.
 Calibration grade are the best-grade slip gauges because even
though slip gauges are manufactured using precision
manufacturing methods, it is difficult to achieve 100 %-
dimensional accuracy.

Sep. 2022 80
Standard sets of Slip Gauges
Slip gauges are available in standard sets in both metric and inch units. In
metric units, there are sets of 31, 48, 56, and 103 pieces. For instance:
A set of 56 slip gauges consists of the following:
One piece of 1.0005mm
Nine pieces ranging from 1.001 to 1.009mm in steps of 0.001mm
Nine pieces ranging from 1.01 to 1.09mm in steps of 0.01mm
Nine pieces ranging from 1.0 to 1.9mm in steps of 0.1mm
25 pieces ranging from 1 to 25mm in steps of 1.0mm
Three pieces ranging from 25 to 75mm in steps of 25mm
A set of 103 pieces consists of the following:
One piece of 1.005mm
49 pieces ranging from 1.01 to 1.49mm in steps of 0.01mm
49 pieces ranging from 0.5 to 24.5mm in steps of 0.5mm
Four pieces ranging from 25 to 100mm in steps of 25mm

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Wringing of Slip Gauges
Wringing is the phenomenon of
adhesion of two flat and smooth surfaces
when they are brought into close contact
with each other.

If the surfaces are clean and flat, the thin

layer of film separating the blocks will
have negligible thickness. This means
that stacking of multiple blocks of
Technique of wringing slip gauges
known dimensions will give the overall (a) Step 1 (b) Step 2 (c) Step 3 (d) Step 4
dimension with minimum error.

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Combining Slip Gauges
Recall that gauge blocks are in standard sets of 31, 48, 56, and 103 pieces. While
figuring out the slip gauges that are required to make up a given dimension, adopt a
procedure that save time and ensure the use of the minimum number of gauges.

In addition, the accuracy up to which a dimension can be built depends on the

gauge that can give accuracy up to the last possible decimal place.

Thus, whenever we need to build slip gauges to the required height/dimension, the
primary concern is the selection of a gauge that gives the dimension to the required
decimal place. This is followed by selection of gauges in the order in which they
meet the dimension from the next last decimal place towards the left until the entire
selection is complete.

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