ME001L - Lesson 2

Measuring and
Marking Out Work
(Part 1)
Prepared By

Ricardo S. Balog
RME. MEng’g
Engineering and Architecture
 Intended Learning Outcomes
Towards the end of the lesson, students are expected to:

● Understand the concept of linear, angular measurements;

● Identify and select measuring and marking out tools, instruments for
specific applications;

● Know how to make linear, angular measurements;

● Demonstrate correct use and care of measuring tools, instruments;

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 Measuring and Marking Out Work
2.1 Linear Measurement
2.1.1. Importance, concept of linear measurement
Measuring can be considered to be the most important process in engineering. Without the ability to measure
accurately, we will not be able to:
● Mark out (layout) components for fabrication;
● Set up machines correctly to produce components to the required size and shape;
● Check components while in the process of making them to ensure that they finally end up the correct size and
shape;
● Inspect finished components to ensure that they have been correctly manufactured; which is particularly important
for large fabrications that have to be assembled on site.

Note: Metal fabrication and welding engineers seldom have to work to the fine limits and close tolerance of size that mechanical
engineers require: except when the components are to fitted (say with bolts) with other components when assembling
structures.
• The measure of length, is the measure of the shortest distance in a straight line between two points, lines or faces; regardless
of what you call this distance (width, thickness, breadth, depth, height and diameter), it is still a measurement of length.

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 Measuring and Marking Out Work
2.1.2. Systems of length measurement
There are two systems for the measurement of length:
● End system of measurement- refers to the measurement of
distance between two faces of a component;
● Line system of measurement - refers to the measurement
of the distance between two lines or marks on a surface.

Note: No matter what system is used, measurement of length

is the comparison of the size of a component or a feature of a
component and a known standard of length. For example, in a
workshop this may be a steel rule or a micrometer caliper,
which are directly related to fundamental international
standards of length.

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 Measuring and Marking Out Work
2.2 Basic measuring and marking out tools
2.2.1. Steel rule
● Frequently used in workshops and on site for measuring components of limited accuracy quickly.
The quickness and ease with which it can be used, coupled with its low cost, makes it a popular
and widely used measuring device. Metric rules may be obtained in various lengths from 150 mm
to 1000 mm (1 meter). Imperial rules may be obtained in various lengths from 6 inch to 36 inch (1
yard). It is convenient to use a rule engraved with both systems, the inch system on the front and
the metric system on the reverse side, the back.
● Steel rules may be “rigid” or “flexible” depending upon their thickness and the ‘ temper ’ of the
steel used in their manufacture. When choosing a steel rule the following points should be looked
for:
 Made from hardened and tempered, corrosion resistant spring steel;
 Engine divided: that is, the graduations should be precision engraved into the surface of the metal;
 Ground on the edges so that it can be used as a straight edge when scribing lines or checking a surface
for flatness;
 Ground on one end so that this end can be used as the zero datum when taking measurements from a
shoulder;
 Satin chrome finished so as to reduce glare and make the rule easier to read, also to prevent corrosion.

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 Measuring and Marking Out Work
2.2.1. Steel rule (continued)

• Note: No matter how accurately a rule is made, all measurements

made with a rule are of limited accuracy. This is because of the
difficulty of sighting the graduations in line with the feature being
measured
• When using a rule to make direct measurements, the accuracy of
measurement depends upon the visual alignment of a mark or
surface on the work with the corresponding graduation on the rule.
This may appear relatively simple but, in practice, errors can very
easily occur. These errors can be minimized by using a thin rule
and keeping your eyes directly above and at 90° to the mark on
the work. If you look at the work and the rule from an angle, you
will get a false reading. This is known as a parallax error.

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 Measuring and Marking Out Work

2.2.2. Steel tape

● Uses for measuring distances greater than 1
meter in length. Woven or fabric tapes are
unsuitable for engineering as they tend to
stretch and always have to be used with a
spring balance to apply a prescribed tension.
● Flexible steel tapes are available in sizes
ranging from the handy pocket size
(approximately 5 meters in length) up to and
exceeding 30 meters.

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 Measuring and Marking Out Work

2.2.3. Calipers: Construction and use

Calipers are used in conjunction with a rule to transfer the distance across or between the
faces of a component in such a way as to reduce sighting errors; i.e, to convert from end
measurement to line measurement. Firm-joint calipers are usually used in larger sizes and
spring-joint calipers are used for fine work. The accurate use of calipers depends upon
practice, experience, and a highly developed sense of feel. When using calipers, the following
rules should be observed:
● Hold the caliper gently and near the joint;
● Hold the caliper square (at right-angles) to the work; no force should be used to “spring”
the caliper over the work. Contact should only just be felt;
● The caliper should be handled and laid down gently to avoid disturbing the setting;
● Lathe work should be stationary when taking measurements. This is essential for safety and
accuracy .

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2.2.3. Calipers: Construction and use

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2.2.3. Calipers: Construction and use

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2.2.4 Micrometer Caliper: Construction, principle of operation, and use

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2.2.4 Micrometer Caliper: Construction, principle of operation,
and use
● Principle of Operation - depends upon the principle that the
distance a nut moves along a screw is proportional to the
number of revolutions made by the nut and the lead of the
screw thread. Thereby, controlling the number of complete
revolutions as well as the fractional revolution made by the
nut, the distance it moves along the screw can be accurately
controlled. In a micrometer caliper, the screw thread is rotated
by the thimble which has a scale that indicates the partial
revolutions. The barrel of the instrument has a scale which
indicates the ‘whole’ revolutions. In a standard metric
micrometer caliper the screw has a lead of 0.5 millimeter and
the thimble and barrel are graduated as in the figure shown at
the right.

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2.2.4 Micrometer Caliper: Construction,
principle of operation, and use
● Micrometer reading (0.01mm) - is given by:
1. Take largest visible ‘ whole ’ millimeter
graduation visible on the barrel,
2. Add the next “half” millimeter graduation,
if this is visible,
3. Add the thimble division coincident with
the datum line.

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 Measuring and Marking Out Work
2.2.4 Micrometer Caliper: Construction, principle of
operation, and use
Micrometer Caliper, (0.001 inch)
● Scales
The figure at the right shows the scales for a micrometer
graduated in “inch” units. The micrometer screw has 40 T.P.I.
(threads per inch); hence, the lead of the screw is 1/40 inch
(0.025 inch). The barrel graduations are 1/10 inch sub-divided
into 4. Therefore, each subdivision is 1/40 inch (0.025 inch) and
represents one revolution of the thimble. The thimble carries 25
graduations, so one thimble graduation equals a movement of
0.025 inch/25 equals 0.001 inch.

Reading - An inch micrometer reading is given by:

1.The largest visible 1/10 inch (0.1 inch) division, plus
2.The largest visible 1/40 inch (0.025 inch) division, plus
3.The thimble division coincident with the datum line.

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2.2.4 Micrometer Caliper: Construction, principle of
operation, and use
Micrometers: Care and proper use of
Micrometers will soon lose its initial accuracy when not taken
care of and used properly . To maintain this accuracy you
should observe the following precautions:

● Wipe the work and the anvils of the micrometer clean

before making a measurement;
● Do not use excessive force when making a measurement;
two “clicks” of the ratchet is sufficient
● Do not leave the anvil faces in contact when not in use;
● When machining, stop the machine before making a
measurement. Attempting to make a measurement with
the machine working can ruin the instrument and also lead
to a serious accident. This rule applies to all measuring
instruments and all machines

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2.2.5 Vernier Caliper: Principle of operation
• The vernier calipers works on the principle of “difference between two scales”; that is, the difference between the
reading on the main scale and vernier scale.
• The main scale (divisions) is marked in standard increments of measurement like in a rule.
• The vernier scale that slides along the main scale is marked with divisions of smaller increments; that is, the number
of divisions in the vernier is one (1) division less than the number of divisions on the main scale such that:
Vernier scale division = (No. main scale divisions -1) divided by the No. of divisions on vernier.
Least Count = 1 main scale div. - vernier scale div.
Note: Least count is the minimum reading on the vernier or is equivalent to the value of each division on the vernier
scale.

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2.2.5 Vernier Caliper: Construction and use
• Precise external and internal measurements of length, diameter, objects as well as depth,
height of steps in a workpiece.

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2.2.5 Vernier Caliper: Construction and use
Procedure: Reading a Vernier Caliper
1. Take the reading on main scale (value of the
graduation on the main scale that immediately past
the zero graduation on the vernier.
2. Take note of the “nth” graduation on the vernier that
coincides with any graduation on the main scale.
Multiply this nth graduation by the “least count” to give
the vernier scale reading.
3. Take the sum of the main scale and vernier scale
readings.

Care: As for all measuring instruments, vernier calipers must

be kept clean before and after use. They should always be
kept in the case provided. This not only protects the
instruments from damage, it also supports the beam and
prevents it from being distorted. Never use the measuring
jaws for scribing!

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2.2.5 Vernier Caliper: Construction and use
Exercises: Reading a Vernier Caliper

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2.4. Angular Measurement
• Angles are measured in degrees and fractions of a degree. One degree of arc is 1/360 of a complete circle. One
degree of arc can be subdivided into minutes and seconds (not to be confused with minutes and seconds of time):
● 60 seconds (“) of arc = 1 minute (‘) of arc
● 60 minutes (‘) of arc = 1 degree (°) of arc
2.4.1. Use of Try Squares for Checking Perpendicularity of Edges
• A try-square is not a measuring tool; it does measure an angle. It only indicates whether the edges being checked are
perpendicular or not.

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2.4. Angular Measurement

2.4.2. Use of plain bevel protractor to measure angles other than right angles
• Shown in the figure below is a simple bevel protractor for measuring angles of any magnitude from 0 to 180 deg.Such
protractor has limited accuracy of plus or minus 0.5 deg.

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 2.3. Basic Measuring and Marking Out Tools
2.4. Angular Measurement

2.4.3 Use of vernier bevel protractor to measure Angles other than right
angles
• Where greater accuracy is required the vernier protractor should be used.
The scales of a vernier protractor are shown in in the figure below.The main
scale is divided into degrees of an arc, and the vernier scale has 12
divisions each side of zero. These vernier scale divisions are marked 0 to 60
minutes of arc, so that each division is 1/12 of 60 which equals 5 minutes of
arc. The reading for a vernier protractor is given by the sum of:
●The largest ‘ whole ’ degree on the main scale as indicated by the
vernier zero mark;
●The reading of the vernier scale division in line with a main scale
division.For example, the reading for the scales shown in the figure at the
right will be:
➢Whole ’degrees; 17° 00’
➢Vernier 25 mark in line with main scale 00 25’
➢Total angle 17° 25’

Measuring and Marking Out Work