Chapter outline

4. Linear, Angular, Surface and Form Measuring Instrument

1. Linear measuring instrument
2. Angle measuring instruments
3. Gages (Slip)
4. Limit gages
5. Surface and form measuring instrument
6. Comparators,

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 4. Measuring Instruments
What is instrument?
• instrument is a device that transforms a physical
variable of interest (measurand ) into a form that is
suitable for recording (measurement)
 An example is ruler
 The measurand is length of object
 The measurement is number of
units (meters, inches, etc.) that
represent the length

 In order for the measurement to have consistent meaning, it

is necessary to employ a standard system of units

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Classification of Conventional measuring instruments:
1. Linear measuring and angular Instruments,
2. Form and surface measuring instruments
3. Comparative Instruments
Measuring instruments are divided into two:
– Graduated measuring devices include a set of markings on a
linear or angular scale to which the object's feature of
interest can be compared for measurement
– Non-graduated measuring devices have no scale and are
used to compare dimensions or to transfer a dimension for
measurement by a graduated device

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4.1 Linear measuring Instruments
Rules and tapes: (Direct measuring)
• Rules (up to 1 metre) and tapes (measuring to 30 m)
are the simplest way of measuring larger dimensions.
• Measurement accuracy is typically have rulings at
0.5mm
• Accuracy is much dependent upon the measurer and,
at best, the inaccuracy is 0.5%.

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4.1 Linear measuring Instruments …
Vernier caliper: (Direct measuring)
• The vernier calipers incorporates a main scale and a sliding
vernier scale which allows readings to the nearest 0.02 mm to
measure outer dimensions, inside dimensions and depths.
• Digital version with computer interface are much easier to use
– Example: The reading is 34.60 mm.

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• Vernier gear-tooth caliper measures gear teeth
thickness using two Vernier scales.
• Vernier height gage - gives measurements over long
vertical ranges. It is also used for precision layout.

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 Electronic Gages
Fig - An electronic vertical length
measuring instrument, with a
sensitivity of 1 μm (40 μin.).

Fig - An electronic gage for measuring bore diameters. The

measuring head is equipped with three carbide-tipped steel pins
for wear resistance. The LED display reds 29.158 mm..
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Outside and Inside Micrometer: (Direct measuring)
• Uses an auxiliary scale marked on a rotary thimble (constant
pitch of 0.50 mm) subdivided into 50 equal divisions.
• Available in different shapes and sizes
• Accurate to 0.01 mm with resolution to 0.002 mm
• Most common are 25 mm–500 mm capacity
• Digital versions help avoid reading errors
– Example: The reading is 7.38 mm.

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Depth micrometer measures hole depth, slots, and other
recesses and come as a set with interchangeable rods
Inside micrometers
• Uses 12.5 or 25 mm travel hollow micrometer head and
set of precision length rods of inside dimensions from
50 to 600 mm
• Harder to use accurately because a true reading for
maximum parallel extension that just fits a hole
diameter is difficult

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• Disc/ flange micrometer measures form tools, cutting
edges, narrow slots, flanges and hard to reach areas.
• Screw /pitch thread micrometer - Measures pitch
diameter of a screw thread

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 Analog and Digital Measuring Devices

Fig. digital micrometer depth gage

Fig - (a) A vernier (analog) micrometer. (b) A digital micrometer with a

range of 0 to 25 mm and a resolution of 1.25μm. It is easier to read
dimensions on this instrument than analog micrometer. (c) Schematic
illustration for integration of digital gages with microprocessors for real-
time data acquisition for statistical process control.
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Calipers: (Indirect measuring)
• Used to transfer measurements from workpiece to a steel rule.
• Outside caliper measures outside surface or outside diameter.

• Rules are also used for transfer measurements with calipers.

• It is used for semi-precision and comparison measurement.

Inside caliper Outside caliper Divider caliper 12

 4.2 Angle measuring Instruments
• Angle protractor consists of two straight edges.
• Scale A attached to the straight edge C rotates inside a fixed
circular housing attached to the other straight edge B.
• The bevel protractor has a vernier scale on the housing and
allows the inaccuracy level to be reduced to 10 minutes of arc.
• The spirit level consists of a standard attached to a rotatable
circular scale mounted inside a square frame. The bubble in the
spirit level allows measure angle with accuracies of 10 min arc.

Fig - (a) Schematic illustration of a bevel protractor. (b)

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Vernier for angular measurement, indicating 14° 30´.
4.2 Angle measuring Instruments …
Combination set
• Combination set is used as a rule, a square, a
miter, a depth gage, a height gage, and a level. The
combination set consists of: blade, center head,
protractor head, combination square head, scribe,
and spirit level

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4.2 Angle measuring Instruments …
Sine bar
• The sine bar is a precision bar that has been hardened and
then ground and lapped to very precise dimensions.
• Sine bar is used for precise checking angles and machine
setups, typically used with gage blocks.
Square
• A square has two straight edges that form a right angle for
inspecting squarness and laying out work.

Fig - Setup showing the use of a sine bar for

precision measurement of work-piece angles.
4.3 Gages
• Gauge blocks/ slip gauges consist of rectangular blocks of
hardened steel that have flat and parallel end faces with high
accuracy in surface finish and flatness.
• They are used to check whether a particular dimension is within
the allowable tolerance rather than the dimension.
• Precision gage blocks are available in certain standard sizes or in
sets (containing different sized blocks)
• A number of gauge blocks are joined together to make up the
required dimension.
– Accessories provide a secure clamping large stacks together

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Gages ……
Gage blocks are used for:
• Calibration and inspection of precision instruments
• To set comparators/indicators
• Setting of sine bars
• Precision layout
• Machine setups
Grades:
• Gages are available in various grades depending on their use:
– Reference (AAA): (tol.± 0.00005 mm) to establish
standards
– Calibration (AA): (tol +0.00010mm - 0.00005mm) used to
calibrate inspection blocks and very high precision gauging
– Inspection (A): (tolerance +0.00015 mm - 0.00005 mm)
used as tool room standards for setting other gauging tools
– Workshop (B): large tolerance (tol +0.00025 mm -0.00015
mm) used as shop standards for precision measurement 17
 Angle gauge blocks
• 16 blocks –90° in 1 second increments
• Useful for measuring optical wedges
• Surfaces are optically flat and specular
– can use with an autocollimator
• Same is true of gauge blocks

Sides are not finished to same specs as angle faces but are
perpendicular to angle faces so angle readings are correct
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4.4 Limit Gages
(1) GO/NO‑GO plug gages
A type of "Go" or "No-Go" gage used to admit or refuse
the inside dimension of an object.
• One gage limit allows the part to be inserted while
the other limit does not
• GO limit - check dimension at max material condition
– Minimum size for an internal feature such as hole
– Maximum size for external feature (outside dia)
• NO‑GO limit - inspect minimum material condition

Fig - (a) Plug gage for holes with GO and NOT GO on opposite ends.
(b) Plug gage with GO and NOT GO on one end. 19
 (2) Snap gage:
Snap gage gages diameters, lengths, and thickness.
The adjustable limit snap gage is used to check
outside diameter.
There are a various types of snap gages:
→ adjustable snap gage.
→ adjustable roll snap gage.
→ dial indicator snap gage.

Fig - (d) Snap gage with adjustable anvils.

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(3) Ring gages
• Plug gage for checking size/ diameter/ taper of internal
threaded part.
• A type of "Go" or "No-Go" gage used to admit or refuse the
outside dimension being checked.
• There are three types of plug and ring gages: plain cylindrical,
cylindrical taper and thread plug gage
• They are mounted at the ends of an aluminum handle. "Go" in
one end and "No-Go" on the opposite end.

Fig - (c) Plain ring gages for

gaging round rods. Note the
difference in knurled surfaces
to identify the two gages.
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Application of Limit Gages
• Thread gages
• Form gages
• Screw pitch gages
• Radius and fillet gages
• Feeler gages
• Plate gages
• Wire gages
• Indicating gages (mostly surface gages, dial gages)
• Air gages

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4.5 Surfaces and Form Measuring instruments
Measurement of Surfaces
Two parameters of interest:
• Surface texture - geometry of the surface,
commonly measured as surface roughness
– Surface roughness - small, finely‑spaced deviations from the
nominal surface determined by material and process
• Surface integrity - deals with the material
characteristics immediately beneath the
surface and the changes to this subsurface that
resulted from the processes that created it
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Mechanical Gages: Dial Indicators
• Mechanical gages are designed to mechanically
magnify the deviation to permit observation
• Most common instrument in this category is the
dial indicator, which converts and amplifies the
linear movement of a contact pointer into
rotation of a dial
– The dial is graduated in small units such as 0.01 mm
– Applications: measuring straightness, flatness, parallelism,
squareness, roundness, and runout

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Dial indicator uses
• A dial indicator is used to measure shaft run out, shaft
thrust, gear backlash, flywheel face run out, flywheel
housing concentricity, and valve seat concentricity.
• There are 2 types of dial indicators:
a. Balanced reading (figures in both directions from the zero)
b. Continuous reading (numbered continuously)

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Dial Indicator Uses
• Test indicators – short range
• High sensitivity – used as null devices
• Long range – needle makes many
revolutions – has counter dial
• Used for rough centering, thickness
measurement
• Mounted in a stand – either stationary
while part moves or indicator moves
along a straightedge with part still
• Generally looking for minimum
indicator movement
• End result given as TIR – Total Indicator Also attached to bore & depth gages
Reading or Runout Digital & dial versions available
Can be fitted with various tips
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 Dial Indicator Uses

Fig- Three uses of dial indicators: (a) roundess, (b) depth, and (c) multiple-dimension gaging of a part.

Measuring Straightness
Fig - Measuring straightness manually with (a) a knife-edge rule and (b) a dial indicator.
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 Measuring Roundness and Runout

Fig - (a) Schematic illustration of out-of-roundess (exaggerated). Measuring roundess using (b) a V-
block and dial indicator, (c) a round part supported on centers and rotated, and (d) circular tracing.

Fig - Dial indicator setup to measure runout; as part is rotated about its center,
variations in outside surface relative to center are indicated on the dial. 28
 Measuring Profiles

Fig - Measuring profiles with (a)

radius gages and (b) dial
indicators.

Fig - Measuring gear-tooth thickness and

profile with (a) a gear-tooth caliper and
(b) pins or balls and a micrometer.

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4.6 Comparative instruments:
• Comparator are a form of Linear measurement
device which is quick and convenient for
checking and showing deviations in size
• They are classified according to the principles
used for obtaining magnification
1. Mechanical Comparators
2. Electrical Comparators
3. Optical Comparators
4. Pneumatic Comparator s

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4.6 Comparative instruments:
2) Mechanical Comparators

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4.6 Comparative instruments:
2) Electrical Comparators
4.6 Comparative instruments …
3) Optical Comparators
• Graphically displays (shadow graph) and measures dimensions
and shapes; Capable of magnifying an object hundreds of
times.

Optical Contour Projector

Fig - A bench-model horizontal-beam contour projector with a 16-
in. diameter screen with 150-W tungsten halogen illumination. 33
4.6 Comparative instruments …
4) Pneumatic Comparators Air Gages

(c)

Fig - (a) Schematic illustration of the principle

for an air gage. (b) Three types of plugs used
for air gaging. The gage on the right is an air
(b) snap gage. (c) A conical head for air gaging;
note the small air holes on conical surface.
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 Table - Types of Measurement and Instruments Used
.

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