Engineering Metrology

and Instruments

Content
Introduction.
- Important concepts.
Measuring Instruments.
1) Length measuring Instruments.
1.1) Rules and tapes.
1.2) Vernier caliper.
1.3) The Micrometer.
1.4) Calipers.
2) Angle measuring Instruments.
3) Gages.
4) Comparative length-measuring instruments.
4.1) Dial indicator.
Table for various Measuring Tools.

Engineering metrology

 Introduction:
Engineering Metrology:
- Measurement of dimensions such as length, hickness, diameter, taper, angle,
flatness, profile and others.
Post-Process Inspection:
- Measurements taken after the part is produced
- Term inspection checking dimensions and determining whether it complies
with specifications.
In-process, On-line or Real-Time Inspection:
- Checking part characteristics while part is being produced.
Important concepts:
-

Range of measurement:
The physical variables that are measured between two values.One is the higher
calibration value H, and the other is Lower value L, The difference between H,
and L, is called range.
Sensitivity:
Is the smallest difference in dimensions that the instrument can detect.
Accuracy:
The ability of a measurement to match the actual value of the quantity being
measured.
Precision:
The degree to which the instrument gives repeated measurements of the same
standard.
The difference between precision and accuracy can be shown by the spread
of shooting of a tar-get (as shown in Diagram below).

Engineering metrology

Error:
The deviation between the results of measured value to the actual value.
Correction:
The numerical value which should be added to the measured value to get the
correct result.

Measurements Standards:
Two Standards
English Speaking Countries (English System):
Pound-mass, Foot, Second
Metric System (SI System International):
Kilogram, Meter, Second
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Measuring Instruments:
-

classification of measuring instruments:

1- Length measuring Instruments.
- Direct measuring.
- Indirect measuring.
2- Angle measuring Instruments.
3- Instruments for surface finish.
4- Instruments for deviations.

1) Length measuring Instruments:

1.1)

Rules and tapes: (Direct measuring)

Rules and tapes are the simplest way

of measuring larger dimensions. Steel
rules are generally only available to
measure dimensions up to 1 metre.
Beyond this, steel tapes (measuring to
30 m) or an ultrasonic rule (measuring
to 10m) are used.
The steel rule is undoubtedly the
simplest instrument available for
measuring length.
Measurement accuracy is only modest using standard rules, which typically have rulings
at 0.5mm intervals, but the best rules have rulings at 0.05mm intervals and
a measurement resolution of 0.02 mm. When used by placing the rule against an object,
Engineering metrology

the measurement accuracy is much dependent upon the skill of the human measurer and,
at best, the inaccuracy is likely to be at least 0.5%.

1.2)

Vernier caliper: (Direct measuring)

The vernier calipers found in the laboratory incorporates a main scale and a sliding
vernier scale which allows readings to the nearest 0.02 mm. This instrument may be used
to measure outer dimensions of objects (using the main jaws), inside dimensions (using
the smaller jaws at the top), and depths (using the stem).

How to read vernier calipers?

When a length is measured the zero point on the indicating scale is the actual point of
measurement, however this is likely to be between two data scale points. The indicator
scale measurement which corresponds to the best-aligned pair of indicator and data
graduations yields the value of the finer additional precision digit.
- Example:
The reading is 34.60 mm.
In figure shown, the first
significant figures are taken as
the main scale reading to the left
of the vernier zero, i.e. 34 mm.
The remaining two digits are
taken from the vernier scale
reading that lines up with any
main scale reading, i.e. 60 on
the vernier scale.
Engineering metrology

1.3)

The Micrometer: (Direct measuring)

The micrometer screw gauge is used to measure even smaller dimensions than the vernier
calipers. The micrometer screw gauge also uses an auxiliary scale (measuring hundredths
of a millimeter) which is marked on a rotary thimble. Basically it is a screw with an
accurately constant pitch (the amount by which the thimble moves forward or backward
for one complete revolution).
Take as an example: the micrometers which have a pitch of 0.50 mm (two full turns are
required to close the jaws by 1.00 mm). The rotating thimble is subdivided into 50 equal
divisions. The thimble passes through a frame that carries a millimeter scale graduated to
0.5 mm. The jaws can be adjusted by rotating the thimble using the small ratchet
knob. This includes a friction clutch which prevents too much tension being
applied. The thimble must be rotated through two revolutions to open the jaws by 1 mm.

How to read Micrometer?

In order to measure an object, the object is placed between the jaws and the thimble is
rotated using the ratchet until the object is secured. Note that the ratchet knob must be
used to secure the object firmly between the jaws, otherwise the instrument could be
damaged or give an inconsistent reading. The manufacturer recommends 3 clicks of the
ratchet before taking the reading. The lock may be used to ensure that the thimble does
not rotate while you take the reading.
- Example:
The reading is 7.38 mm.
In figure shown the last graduation visible to the
left of the thimble is 7 mm and the thimble lines
up with the main scale at 38 hundredths of
amillimeter (0.38 mm); therefore the reading is
7.38 mm.
Engineering metrology

1.4)

Calipers: (Indirect measuring)

These are used to transfer the measured dimension from the workpiece to a steel rule.
This avoids the necessity to align the end of the rule exactly with the edge of the
workpiece and reduces the measurement inaccuracy by a factor of two. In the basic
caliper, careless use can allow the setting of the caliper to be changed during transfer
from the workpiece to the rule. Hence, the spring-loaded type, which prevents this
happening, is preferable.
Types of calipers:
1- Inside caliper: are used to measure the internal size of an object.
2- Outside caliper: are used to measure the external size of an object.
3- Divider caliper: are used in the process of marking out suitable workpieces.

Inside caliper

Outside caliper

Divider caliper

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2) Angle measuring Instruments:

Measurement of angles is one of the less common measurement requirements that
instrumentation technologists are likely to meet. However, angle measurement is required
in some circumstances, such as when the angle between adjoining faces on a component
must be checked. The main instruments used are protractors and a form of angle
measuring spirit level.
In some circumstances, a simple protractor of the sort used in school for geometry
exercises can be used. However, the more sophisticated form of angle protractor shown
in the figure provides better measurement accuracy. This consists of two straight edges,
one of which is able to rotate with respect to the other. Referring to the figure, the
graduated circular scale A attached to the straight edge C rotates inside a fixed circular
housing attached to the other straight edge B. The relative angle between the two straight
Engineering metrology

edges in contact with the component being measured is determined by the position of the
moving scale with respect to a reference mark on the fixed housing B. With this type of
instrument, measurement inaccuracy is at least 1%. An alternative form, the bevel
protractor, is similar to this form of angle protractor, but it has a vernier scale on the fixed
housing. This allows the inaccuracy level to be reduced to 10 minutes of arc.
The spirit level shown in Figure is an alternative angle-measuring instrument. It consists
of a standard spirit level attached to a rotatable circular scale that is mounted inside an
accurately machined square frame. When placed on the sloping surfaces of components,
rotation of the scale to centralize the bubble in the spirit level allows the angle of slope to
be measured. Again, measuring inaccuracies down to 10 minutes of arc are possible if a
vernier scale is incorporated in the instrument.

Engineering metrology

3) Gages:
Gauge blocks, also known as slip gauges, consist of rectangular blocks of hardened steel
that have flat and parallel end faces. These faces are machined to very high standards of
accuracy in terms of their surface finish and flatness. The purpose of gauge blocks is to
provide a means of checking whether a particular dimension in a component is within the
allowable tolerance rather than actually measuring what the dimension is. To do this, a
number of gauge blocks are joined together to make up the required dimension to be
checked.

The pictured below 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 and scribers.
Slip gauges are made from a select grade of carbide with hardness of 1500 Vickers
hardness. Long series slip gauges are made from high quality steel having cross section
(35 x 9 mm) with holes for clamping two slips together.

Engineering metrology

Grades:
They are available in various grades depending on their intended use:

reference (AAA): small tolerance ( 0.00005 mm or 0.000002 in) used to

establish standards
calibration (AA): (tolerance +0.00010 mm to -0.00005 mm) used to calibrate
inspection blocks and very high precision gauging
inspection (A): (tolerance +0.00015 mm to -0.00005 mm) used as tool room
standards for setting other gauging tools
workshop (B): large tolerance (tolerance +0.00025 mm to -0.00015 mm) used as
shop standards for precision measurement

Plug gages:

(a) Plug gage for checking size or diameter of internally threaded part.
(b) Plug gage for checking taper of internally threaded part.
(c) Ring gage for checking size or diameter of externally threaded part.

Ring gages:

(a) The Metric Trapezoidal Ring Gage.

(b) American Standard Adjustable Ring Gage.

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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.
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4) Comparative length-measuring instruments:

4.1) Dial indicator:
A dial indicator is used to measure shaft runout, shaft thrust,
gear backlash, flywheel face runout, flywheel housing
concentricity, and valve seat concentricity. You can mount a
dial indicator on a test stand or, with clamps and a magnetic
base, directly on the equipment to be measured. Figure
shows a typical dial indicator with mounting accessories,
Most dial indicators have components such as a bezel,
indicator pointer, tool post and clamp, magnetic toolholder,
and sensor button that are used in taking measurements.

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Engineering metrology

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Various Measuring Tools

Word

Meaning

Context

More Information

Blade micrometer is a
measuring device that
blade
has a thin blade to
micrometer
reach inside narrow
recesses.
Blade micrometer is used for measuring
The blade micrometer measures narrow where the standard micrometer spindle could
grooves and keyways.
not be accommodated.

Combination set is
used as a rule, a
combination
square, a miter, a
set
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.

Combination set

Comparator
graphically displays
and measures
comparator dimensions and
shapes that would be
difficult to measure
with regular tools.

Optical measurement is a different and

valuable aid to quality control. Capable of
magnifying an object hundreds of times.

Also known as shadow graph

Depth micrometer
depth
measures depth of
micrometer holes, slots, and other
recesses.

Measuring a depth of a slot.

Engineering metrology

These micrometers come as a set with

interchangeable rods to accommodate various
measurements.

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Dial indicators check

alignment of machine
components; show the
variation of the object
being measured.
There are 2 types of
dial indicators:
dial
indicators

a. Balanced reading
(has figures in both
directions from the
zero)
b. Continuous reading
(numbered
continuously)

Dial indicators can be used to make

linear measurements.

Continuous reading dial indicator

Disc micrometer
disc
measures forming
micrometer tools, cutting edges,
narrow slots.
The disc micrometer is also called a
flange micrometer.
Gage block set is also
known as "Jo Blocks".
Precision-round
gage block
square or rectangular
set
blocks are made of
steel, chrome, or
tungsten carbide.

Micrometer is used to
measure materials. It
is available in metric
micrometer and inch systems. The
most common are the
outside and inside
micrometers.

This micrometer finds its application in

measuring flanges and hard to reach areas.

Gage blocks are used for:

The measuring surfaces are lapped and

polished to 200 milionths of an inch.

The most commonly used precision

instrument.

Engineering metrology

- calibration and inspection of precision

instruments
- to set comparators/indicators
- setting of sine bars
- precision layout
- machine setups

Available in different shapes and sizes

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outside
caliper

Rules are also used for transfer

measurements with calipers. It is used for
semi-precision and comparison measurement.
They depend on "feel" to measure a part.

Outside caliper
measures an outside
surface.

The outside caliper is used to measure

outside diameter.

plug gage

A type of "Go" or "NoGo" gage used to

admit or refuse the
inside dimension of an
object.

They are mounted at the ends of an aluminum

handle. "Go" in one end and "No-Go" on the
opposite end.

There are three types:

- plain cylindrical
- cylindrical taper
- thread plug gage

ring gage

Available in different sizes

There are three types:

A type of "Go" or "NoGo" gage used to

admit or refuse the
outside dimension
being checked.

- plain ring gages

- taper ring gages
- thread ring gages
Ring gages are used as sets.

The 60 degree
comparator
screw
micrometer is usually
thread
called a screw thread
micrometer comparator
micrometer or pitch
micrometer.

sine bar

The pitch diameter, the most important

Measuring the pitch diameter of a screw measurement of a screw thread.
thread.

Sine bar is used for

checking angles,
typically used with
gage blocks.

The sine bar is a precision bar that has been

hardened and then ground and lapped to very
precise dimensions. It is also used for
machine setups.
Precise angles are measured using the

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sine bar.

Various types of snap gages:

Snap gage gages
snap gage diameters, lengths,and
thickness.

- adjustable snap gage

- adjustable roll snap gage
- dial indicator snap gage
The adjustable limit snap gage is used to
check outside diameter.

square

A square has two

straight edges that
form a right angle.

A machinist uses several types of squares for

a variety of jobs. A square is used for
inspecting squarness and laying out work.

A master precision square

surface
gage

Surface gage is a
scribing tool that
draws lines parallel to
a surface. When
combined with test
indicator, flatness,
parallelism and
heights may be
inspected.

Surface gages are designed for a variety of

uses. The main uses are for scribing lines,
transferring measurements and for probing
surfaces in inspection work.

The surface gage

universal
bevel
protractor

Universal bevel
protractor is used to
lay out, measure, or
check angles.
The bevel protractor can measure angles
to five minutes of a degree.

Vernier
caliper

Vernier caliper is a
precision measuring
tool capable to read
within .001 inch. Used
for inside, outside and
depth measurements.

Engineering metrology

A Vernier caliper consists of a beam with a

fixed measuring jaw, a sliding jaw witht he
Vernier scale, and a mechanism for making
fine adjustments.

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The Vernier caliper

Vernier gear-tooth
Vernier
caliper measures gear
gear-tooth
teeth using two
caliper
Vernier scales.
Designed to measure the thickness of
gear teeth.

It is rugged and
reliable tool that gives
precise and
Vernier
dependable
height gage measurements over
long vertical ranges. It
is also used for
precision layout.
The Vernier height gage

References:
http://www.tpub.com/content/construction/14256/css/14256_43.htm
http://www.phy.uct.ac.za/courses/c1lab/vernier1.html
http://en.wikipedia.org/wiki/Gauge_blocks
http://itdc.lbcc.edu/oer/machineTool/precisionTools/precisionToolsALT/precisionT
ools.htm

Engineering metrology

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