Metrology Lab Exercise2

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Wollo University

Institution of Technology
Department Of Mechanical Engineering

Instructor ; Muluken Mesfin (MSc)

KIOT
Contents to be discussed
Introduction to metrology
Measuring instruments
LINEAR MEASURMENT
STEELRULES
VERNIER CALIPER
VERNIER HEIGHT GAGU
MICROMETERS
 OUTSIDE
INSIDE
V.MICROMETER
CHAPTER ONE
What is metrology?
 Metrology is a word derived from two Greek words;
Metro: Measurement
Logy: science
Therefore, it can be defined as a science of measurement.

Measurement has became a natural part of our everyday life.


Example, water, electricity. temperature, .etc.
LINEAR MEASURMENT
Linear metrology
is defined as a science of linear measurement, for the
determination of the distance between two points in a straight
line.
The instruments used in linear metrology are generally classified
into two types
1. Non-precision measuring instruments e.g. Steel rule
2. Precision measuring instruments, e.g. Vernier calipers,
micrometers
Conti.

STEEL RULE (SCALE)


It is the simplest and most commonly used linear measuring
instrument.
It measures an unknown length by comparing it with the one
previously calibrated.
Steel rules are marked with a graduated scale whose smallest
intervals are one millimeter.
To increase its versatility in measurement, certain scales are
marked with 0.5 millimeters in one portion. some steel rules
carry graduation in centimeters on one side and inches on the
other side.
Conti.
Don’t use end as reference point, except with “knee”..
If no “knee”, use 1 inch mark as reference.
Hooked rule
Calipers
Calipers are used to transfer measurements.
Has no scale - cannot be used by itself.
Three types of calipers
 Outside
 Inside
 Hermaphrodite
Conti.
Several styles
 spring joint
 firm joint
Do not use when accuracy < .015 in is needed.
Conti.
Dividers

Dividers are very useful for laying out several equal distances or transferring a
distance measurement when other measuring devices cannot be used.
Vernier calipers
Vernier calipers are precision tools used to make accurate
measurements to within 0.001 in. or 0.02mm depending on
whether they are inch or metric vernier calipers.

Vernier calipers are available in inch and metric graduations;


however, some types have both inch and metric graduations on
the same caliper.
Parts of the vernier caliper
Conti.
Inside
jaw
Locking nut

Main scale Tail


Vernier
scale Roller

Outside
jaw
Conti.
Conti.

 The vernier caliper, regardless of the standard of measurement


used, consists of an L-shaped frame and a movable jaw.

 The L-shaped frame consists of a bar, which shows the main


scale graduations, and the fixed jaw. The movable jaw, which
slides along the bar, contains the vernier scale.

 Adjustments for size are made by means of an adjusting nut.


Readings may be locked into place by means of clamp screws.
Application

Measuring Internal Diameter

Measuring Depth of a Hole

Measuring External Diameter


Conti.
Conti.
Conti.
How to read a vernier scale
Procedure to use
1. Remove all burrs from work piece
2. Clean surface to be measure
3. Check the vernier and main scale must coincide at 0.
4. Open jaws enough to pass over work piece
5. Close jaws against work ( IF you are measuring something
with a round cross section, make sure that the axis of the object
is perpendicular to the caliper. This is necessary to ensure that
you are measuring the full diameter and not merely a chord)
and lock right-hand clamp screw.
6.Turn adjusting screw until jaws just touch work surface
7. Lock clamp screw on movable jaw
8. Read measurement
Metric vernier caliper

 The main scale is graduated in millimeters and every main division is


numbered. Each numbered division has a value of 10mm;
for example, #1 represents 10mm, #2 represents 20mm.
There are 50 graduations on the sliding or vernier scale, with every fifth
one numbered.
These 50 graduations occupy the same space as 49 graduations on the
main scale (49mm.).Therefore,
1 vernier division= 49/50
= 0.98mm
The difference between 1 main scale division and 1 vernier scale division
is
1 - 0.98 = 0.02mm
or
least count = smallest div.on the main scale/total no.of div.on vernier
scale
LC=1/50
= 0.02mm
Conti.
To read
1.First, read the graduation on the main scale just before the
vernier scale starts (that is called main scale reading (MSR))
2.Next, read the graduation on the vernier scale where two
graduation lines on main and vernier scales perfectly match
(that is called vernier scale reading(VSR)) and multiple VSR
by least count(LC).
3.The total reading
= MSR + VSR*LC
Example
MSR =19mm
VSR= 32
LC=1/50=0.02

total reading =19mm + 32*0.02mm


=19.64mm
Exercise
Vernier height gauge
 This is one of the most useful and versatile instruments used in
linear metrology for measuring ,inspecting and transferring the
height dimension over plane, step and curved surfaces.(to measure
or mark off vertical height and locating center distance.)
 It follows the principle of vernier caliper and also follows the same
procedure for linear measurement.
 It is equipped with a wear-resistant special base block in which a
graduated bar is held in the vertical position.
 The vernier height gauge as shown in figure below, consists of a
vertical graduated beam or column on which the main scale is
engraved.
 The vernier scale can move up and down over the beam.
Conti.
 The bracket carries the vernier scale which slides vertically to
match the main scale. The bracket also carries a rectangular
clamp used for clamping a scriber blade.
 The whole arrangement is designed and assembled in such a
way that when the tip of the scriber blade rests on the surface
plate, the zero of the main scale and vernier coincides.
 The scriber tip is used to scribe horizontal lines for preset
height dimensions. The entire height gauge can be transferred
on the surface plate by sliding its base.
 The height gauges can be also be provided with dial gauges
instead of a vernier, which makes reading of bracket movement
by dial gauges easy and exact.
Conti.

Clamping screw

clamp
Or
scriber
Conti.

Standard Height gauge Dial Height Gauge


Digital Height Gauge
Vernier depth gauge
Vernier depth gauge is used to measure depth of holes, distance
from a plane surface to a projection and recess.
1) It consists of main scale, vernier scale, jaws, and lock nut fine
adjustment screw like vernier caliper as shown in fig.
2) In vernier depth gauge, graduated scale can slide through the
base and vernier scale remains fixed.
3) The vernier scale is fixed to the main body of the depth gauge
and is read in the same way as vernier caliper.
4) The main scale provides the datum surface from which the
measurements are taken.
5) To make accurate measurements, the reference surface must be
flat and free from swarf and burrs
Conti.

clamping screw

base
Main scale

beam

Vernier scale
Conti.

Standard Depth Gauge Dial Depth Gauge Digital Depth Gauge


Micrometer

 Next to calipers, micrometers are the most frequently used hand


measuring instruments in linear metrology.
 Micrometers have greater accuracy than vernier calipers are used in
most of the engineering precision work involving interchangeability
of component parts.
 Micrometers having accuracy of 0.01mm are generally available but
micrometers with an accuracy of 0.001mm are also available.
 Micrometers are used to measure small or fine measurements of
length,width,thickness and diameter of a job.
 Micrometers are classified into the following types:
1. Inside micrometers
2. Outside micrometers
3. Depth –gauge micrometers
Parts of micrometers
Conti.

Fig. Cutaway view of a standard outside


micrometer with a ratched stop.
Conti.
U-shaped or C-shaped frame
which holds all parts of the micrometers together.
the gap of the frame decides the maximum diameter or length of the job to be
measured.
Carbide tipped measuring faces-anvils and spindle
the micrometer has a fixed anvils and it is located at 3.5mm from the left –hand
side of the frame. The diameter of the anvil is the same as that of the spindle
with exact alignment of their axes.
Spindle is the movable measuring face with the anvil on the front side and it is
engaged with the nut.
The spindle should run freely and smoothly throughout its length of travel.
There should not be any backlash (lost motion of the spindle when the direction
of rotation of the thimble is changed) between the screw and nut and at the
time of full reading, full engagement of the nut and screw must be possible.
Conti.
Locking Device
to lock in exact position.
this enables correct reading without altering the distance between the two
measuring faces, thus retaining the spindle in perfect alignment.
Sleeve (barrel)
A sleeve has a fixed engraved graduation marks (main scale) on it.
Thimble
It is a tubular cover, fastened and integrated with a screwed spindle. When
the thimble is rotated, the spindle moves in a forward or reverse axial
direction, depending upon the direction of rotation.
Ratched
A ratched is provided at the end of the thimble. It controls the pressure applied
on the work piece for accurate measurement and thereby avoids the
excessive pressure being applied to the micrometer.
Principle of micrometer
A micrometer is based on the principle of screw and nut. When a
screw is turned through one revolution, the nut advances by one
pitch distance ,i.e., one rotation of the screw corresponds to a
linear movement (lead) of the distance equal to the pitch of the
thread.
Pitch
which the distance from one point on one thread to the
corresponding point on the next thread.
Lead
Which is the distance a screw thread advances axially in one
complete revolution or turn.
Conti.
Inch micrometer
 Since there are 40 threads per inch on the micrometer, the pitch is
1/40 (0.025in). therefore one complete revolution of the spindle
will either increase or decrease the distance between the
measuring faces by 1/40 (0.025in).
 The 1 in. distance marked on the micrometer sleeve is divided into
40 equal divisions, each of which equals 1/40 (0.025in.).
 If the micrometer is closed until the measuring faces just touch,
the zero line on the thimble should line up with index line on the
sleeve.
 If the thimble is revolved counterclockwise one complete
revolution, one line will appear on the sleeve. Each line on the
sleeve indicates 0.025in. Thus, if three were showing on the sleeve
,the micrometer would have opened 3*0.025, or 0.075in.
Conti.
 Every fourth line on the sleeve is longer than the other and is numbered to
permit easy reading. Each numbered line indicates a distance of 0.1in. for
example ,#4 showing on the sleeve indicates a distance between the measuring
faces of 4*0.1 or 0.4in.
 Thimble has 25 equal division about its circumference. Since one turn moves
the thimble 0.025in.,one division would represent 1/25 of 0.025in or 0.001in.
Therefore each line on the thimble represents 0.001in.
To read a standard inch micrometer
1. Note the last number showing on the sleeve. Multiply that number by 0.1.
2. Note the number of the small lines visible to the right of the last number
shown. Multiply that number by 0.025.
3. Note the number of divisions on the thimble from zero to the line that
coincides with the index line on the sleeve. Multiply that number by 0.001.
4. Add the 3 products to get the total reading.
Example.
Read the following measurement
Example.

Note last number showing on sleeve and


multiply by 0.1

2 x 0.1

=0.200
Conti.

Note number of small lines visible to right and multiply


by 0.025

3 x 0.025

=0.075
Conti.

Note number of divisions on thimble from zero to line that


coincides with index line on sleeve and multiply by 0.001

13 x 0 .001

=0.013
Conti.
Add three products to get total reading

0.200
0.075
0.013
=0.288 in.
Exercise
Vernier micrometer
The inch vernier micrometer has, in addition to the graduations
found on a standard micrometer, a vernier scale on the sleeve.
This vernier scale consists of a 10 division that run parallel to
and above the index line. These 10 divisions on the sleeve
occupy the same distance as 9 division on the thimble. One
division on the vernier scale,therefore,represents 1/10*0.009,or
0.0009in.
Since one graduation on thimble represents 0.001 or 0.001in.,the
difference between one thimble division and one vernier scale
division represents 0.0010-0.0009,or 0.0001.Therefore,each
division on the vernier scale has a value of 0.0001in.
Conti.

To read a vernier Micrometer


1.Read the vernier micrometer as you would a standard
micrometer.
2.Note the line on the vernier scale that coincides with a line on
the thimble. This line will indicate the number of ten-
thousandths that must be added to the above reading in step 1.
Conti.

Friction thimble

Fig. an inch vernier micrometer caliper with a friction


thimble
Example.
Conti.
#2 is shown on the sleeve 2 *0.1 = 0.200
1 line is visible past the number 1 * 0.025 =0.025
The #11 line on the thimble is just
past the index line 11 * 0.001=0.011
#3 line on the vernier scale
coincides on with a line on thimble 3*0.0001=0.0003
total reading =0.2363in.
Metric micrometer
Metric micrometer is similar to the inch micrometer with two exceptions: the
pitch of the spindle screw and the graduations on the sleeve and thimble.
The pitch of the screw is 0.5mm; therefore ,a complete revolution of the
thimble increases or decreases the distance between the measuring faces
0.5mm.
Above the index line on the sleeve, the graduations are in millimeters with
every fifth line numbered. Below the index line, each millimeter is
subdivided into two equal parts of 0.5mm,which corresponds to the pitch of
the thread. It is apparent,therefore,that two turns of the thimble will be
required to move the spindle 1mm.
The circumference of the thimble is divided into 50 equal divisions, with every
fifth line numbered. Since one revolution of the thimble advances the
spindle 0.5mm, each graduation on the thimble equals
1/50*0.5mm=0.01mm.
Conti.

To read a metric micrometer


1. Note the number of the last main division showing above the
line to the of the thimble. Multiply that number by 1mm.
2. If there is a half-millimeter line showing below the index line
,between the whole millimeter and the thimble, then add
0.5mm.
3. Multiply the number of the line on the thimble that coincides
with the index line times 0.01mm
4. Add these products.
Example.

17 lines above the index line 17*1=17


1 line below the index line 1*0.5=0.5
11 lines on the thimble 11*0.01=0.11
total reading 17.61mm
Exercise
Metric vernier micrometer
The metric vernier micrometer, in addition to the graduation found
on the standard micrometer, has five vernier divisions on the
barrel, each representing 0.002mm.in the vernier micrometer
reading illustrated in the fig.below,each major division ( below
the index line ) has a value of 1mm. Each minor division ( above
the index line) has a value of 0.5mm.Therefore are 50 divisions
around the thimble, each having a value of 0.01mm.
To read metric vernier micrometer
1. Read the micrometer as you would a standard metric micrometer.
2. Note the line on the vernier scale that coincides with a line on the
thimble. This line will indicate the number of two-thousandths of
a millimeter that must be added to the reading from step 1.
Example

Major divisions (below the index line) 10*1=10


Minor divisions (above the index line) 0*0.5=0
Thimble divisions 16*0.01=0.16
The second vernier division
Coincides with a thimble line 2 *0.002=0.004
total reading =10.164mm
exercise
Micrometer Adjustments:
Proper care and use of a micrometer is necessary to preserve its
accuracy and keep adjustments to a minimum. Minor
adjustments to micrometers can easily be made; however,it is
extremely important that all parts of the micrometer be kept
free from dust and foreign matter during any adjustment.
To remove play in the micrometer threads
1. Back off the thimble, as shown in the figure below.
2. Insert the C-spanner into the slot or hole of the adjusting nut.
3. Turn the adjusting nut clockwise until play between the threads
has been eliminated
Note: After the micrometer has been adjusted, the spindle should
advance freely while the ratchet stop or friction thimble being
turned.
Conti.

Fig. Removing the play in micrometer spindle screw threads


Testing the accuracy of micrometers
The accuracy of a micrometer should be tested periodically to ensure that the
work produced in the size required. Always make sure that both measuring
faces are clean before checking a micrometer for accuracy.
To test a 1in. Or 25-mm micrometer, first clean the measuring faces. Then turn
the thimble using the friction thimble or retched stop until the measuring
faces contact each other. If the zero line on the thimble coincides with the
center (index) line on the sleeve, the micrometer is accurate. Micrometer
can also be checked for accuracy by measuring a gage block or other known
standard.
Conti.
To Adjust the accuracy of a micrometer
should the accuracy of a micrometer require adjustment, follow this
procedure:
1. Clean the measuring faces and inspect them for damage
2. Close the measuring faces carefully by turning the ratchet stop or
friction thimble.
3. Insert the C-spanner into the hole or slot provided in the sleeve.
4.Carefully turn the sleeve until the index line on the sleeve
coincides with the zero line on the thimble.
5.Recheck the accuracy of the micrometer by opening the
micrometer and the closing the measuring faces by turning the
ratched stop or friction thimble.
Conti.

Fig. Resetting the accuracy of a micrometer


Micrometer Depth Gage
 Used for measuring depth of blind holes, slots, recesses, and
projections
 Consists of flat base attached to micrometer sleeve
 Extension rod of required length fits through sleeve and
protrudes through base
 Held in position by threaded cap on top of thimble
Micrometer extension rods are available in various lengths,
providing a range of up to 9 in. or 225mm for metric tools .
The micrometer screw has a range of 0.5 or 1in.,or up to 25mm
for metric tools.
Depth micrometers are available with both round or flat rods,
which are not interchangeable with other depth micrometers.
The accuracy of these micrometers is controlled by a nut on the
end of each extension rod, which can be adjusted if necessary.
Conti.
To Measure with a Micrometer Depth Gage
1. Remove burrs from edge of hole and the face of the work piece.
2. Clean work surface and base of the micrometer
3. Hold micrometer base firmly against the surface of the work
4. Rotate the thimble lightly with the tip of one finger in clockwise
direction until bottom of extension rod touches bottom of hole or
recess.
5. Recheck the micrometer setting a few times to make sure that not
too much pressure was applied in the setting.
6. Carefully note the reading

NOTE: the numbers on the thimble and the sleeve are the
reverse of those on a standard micrometer.
Conti.

Fig. Micrometer depth gauge


Conti.
Inside micrometer
 Used for internal measurements larger than 1.500 in. or 40 mm.
 Set consists of
 Micrometer head with range of .500 or 1 in.
 Several extension rods of different lengths
 Set cover range 1.5000 to over 100 in.
 Large sets have hollow rods for strength
 Read same manner as standard micrometer
Conti.
Conti.
Inside micrometer caliper

Inside micrometer calipers


 Designed for measuring holes, slots and grooves
0.200 to 2.000 in or 5-50 mm
 Nibs of jaws hardened and ground to small radius
 Permit accurate measurement

 Locking nut used to lock at desired size


 Based on same principle as standard micrometer
 Special-purpose tools not used in mass production
Conti.

Standard Inside Micrometers caliper Digital Inside Micrometers


Special-Purpose Micrometers
Although the design of most micrometers is fairly standard, certain
refinements may be added to the basic design, If desired, items such as the
lock ring, ratchet, friction thimble, carbide measuring faces, and anvils
extensions increase the accuracy and the range of these instruments. Some
of the more common types of micrometers used in the machine tool
industries are as shown below.

Direct-reading micrometer
Additional digital readout
built into frame

• Large-frame micrometer
– Made for measuring large
outside diameters up to 60 in.
– Interchangeable anvils give
range of 6 in.
Conti.
• Mul-T-Anvil
micrometer

Flat
Round anvil
anvil
The round (rod) anvil is used to measure the wall thickness of tubing
and cylinders and for measuring from a hole to an edge.

The flat anvil is used to measure the distance from the inside of slots
and grooves to an edge.
Conti.
Screw Thread Micrometers

The micrometer reading indicates the


pitch diameters of the thread, which is
Equal to outside diameter less depth
of one thread.
this micrometer has a pointed spindle
and a double –V swivel anvil, which
are shaped to contact the pitch
diameter of the thread being measured
.
Conti.
Intrimik
Use for measuring inside diameter
 Consists of head with three contact points spaced 120º apart attached to
micrometer
 Contact points forced out
to contact inside of hole
 Self-centering
 Provides direct reading
 Range: 0.275 to 12.000 in
 Accuracy: 0.0001 - 0.0005 in
Conti.

Transfer-Type Instruments

Size of object taken with instrument not


capable of giving direct reading
Small hole gages for small measures Sets
of four
Range: 0.125 - 0.500 in.
To Use Small Hole Gage
Require extreme care in setting
Measure hole with rule
Select proper small hole gage
Clean hole and gage
Adjust gage slightly smaller than hole
and insert
Adjust gage till touching sides of hole
or slot
Swing handle back and forth ("feel")
and adjust knurled end
Remove gage, check size with outside
Conti.
Telescope Gages(transfer-type instrument)
 Used to obtain size of holes, slots, and recesses from 0.3125 to 6.000 in.
(8 to 152 mm)
 T-shaped: pair of telescoping
tubes connected to handle
 Knurled knob on handle end
locks plungers into position
Conti.
To Measure Using a Telescope Gage
 Measure hole size and select gage
 Clean gage and hole
 Depress plungers until smaller that hole
 Insert into hole, release plungers
 Lightly snug up knurled knob
 Hold bottom leg in position and move handle downward
through center, move top leg from side to side
 Tighten knurled knob to lock plunger position
 Recheck "feel" on gage
 Check gage size with outside micrometers
Special purpose gauge

Screw Pitch Gauges (consisting of


a metal case containing many
separate leaves. Each leaf has teeth
corresponding to a definite pitch.
By matching the teeth with the
thread on work, the correct pitch
can be read directly from the leaf)

Radius Gauges (available as individual


leaves and each leaf is marked with its
radius. They are designed to check
both convex and concave radii)
Conti.

Fig. Feeler gauge ( use for measuring distance between two mating parts
Or check the clearance between two mating parts. )

A feeler gauge is a simple tool used to measure


thicknesses. It is mostly used in engineering to measuring
the clearance between two parts..
Conti.

Tap and Drill Gauges (consisting


of a flat rectangular steel plate with
holes accurately drilled and
identified according to their size)

Level (used for setting up and testing


machinery)
SQUARES
• Used for laying out, checking, and setting up work.
• Beam and blade form a right angle.

• Good quality squares are hardened.


1. Solid and Adjustable Squares.
Not accurate enough for precision work or inspection.
Combination set
 Checking inside and outside squareness.
 Drawing lines parallel to edges of work piece.
 Measuring depth.
 Finding centers of round work pieces.
 Checking 450 angles.

Fig. Combination set


Conti.
Using Solid Steel Squares

 Remove all burrs from work surface. Wipe clean.


 Wipe square clean.
 Face source of light.
 Hold work with one hand. Grasp square with other.
 Place inside of square against finished surface.

blade to surface of work.


All light should be excluded.
Conti.

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