MS&M M4 PRAVEEN KP Lr: in ME

MEASURING GAUGES & GAUGES

COMPARATORS
 Gauges are tools which are used for

 Precision instruments possess high checking the size, shape and relative

degree of accuracy and are able to positions of various parts.

measure parts within accuracy of 0.01 CLASSIFICATION OF GAUGE

mm or more. Ex.Vernier caliper,
According to the shape and purpose for
Micrometer, etc.
which each is used.
 Non precision instruments
measurement are limited to the 1. Plug gauges
measurement of parts with reference
2. Ring gauges
to the visible line graduation on the
instrument used Graduated steel rule, 3. Snap gauges

calipers, dividers, etc. 4. Thread gauges

 Linear measurement-They include the
5. Form gauges
measurement of lengths, diameters,
heights and thicknesses. Instruments (a) Screw pitch gauges
under this category are, Steel rule,
(b) Radius and fillet gauges
Calipers, Dividers, Micrometers,
6. Thickness gauges
Vernier Calipers, Slip gauges, Height
gauges, etc., Comparators, Measuring (a) Slip gauges
machines, etc.
(b) Feeler gauges
 Angular measurement-Various angular
measuring instruments are Protractor, (c) Standard wire gauges

Adjustable bevel, Combination set, 7. Indicating gauges

Bevel protractors, Angle gauges, Sine
1. Plug gauges
bar, Clinometers, etc.
 Plug gauges are used for checking holes
of different sizes and shapes.

1
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

 Plug gauges for straight cylindrical 3. Snap gauges

holes, tapered, threaded, splined holes
 Snap gauges are used for checking
square and are available.
plain external dimensions. They are
 These gauges may be either single
may be solid and progressive, or
ended or double ended. Double ended
adjustable or double ended.
plain gauge have Go' and 'No Go
 Most gauges provided with 'Go' and No
members opposite ends, whereas
Go features in a single jaw. Shafts are
progressive gauge have both gauging
mainly checked by snap gauges.
sections combined on one end.

2. Ring gauges

4. Thread pitch gauge

 Ring gauges are used for checking

external diameters.
 They are used in pairs, "Go' and No Go'.
 A thread gauge, also known as a screw
They are commonly used for
gauge or pitch gauge, is used to
inspection/ checking of the shafts.
measure the pitch or lead of a screw
thread.

2
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

 Thread pitch gauges are used as a COMPARATORS

reference tool in determining the pitch
 The comparator is an instrument used
of a thread that is on a screw or in a
for comparing the dimensions of a
tapped hole.
component with a standard of length.
5. Feeler gauges: (Thickness gauges)  The purpose of a comparator is to
detect and display the small difference
 A feeler gauge consists of blades a
between the unknown linear
number of hardened and tempered
dimension and length of standard.
steel of various thicknesses mounted in
steel case. USES OF COMPARATORS
 This gauge is useful to machinists, tool
1) To inspect newly purchased gauges.
repair makers’ men in gauging or
2) To check the components at a very fast
machine narrow slots, to check
clearance, gap between mating set rate, especially in mass production.

tappet parts, and check to to the 3) As laboratory standards from which

bearing clearance, of individual leaves working or inspection gauges are set and
etc. correlated.

4) In selective assembly of parts; for

grading and grouping of parts with respect
to tolerance.

5) As working gauges, to prevent the work

spoilage and to maintain required
tolerance at all stages of manufacture.

CLASSIFICATION OF COMPARATORS

1) Mechanical comparators.

2) Electrical comparators.

3) Optical comparators

3
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

4) Pneumatic comparators.  The linear displacement of plunger

moves the rack and that rotates
MECHANICAL COMPARATORS
smaller gear (pinion) and larger gear
 The mechanical comparators utilize wheel. This moves the pointer above
mechanical method of magnifying the the dial.
movement of contact plunger.

(1) Dial Gauge indicator

(2) Reed type comparator.

(3) Sigma comparator etc.

DIAL GAUGE INDICATOR

 It is an instrument used for measuring

linear dimensions by a pointer moving
on a graduated dial through the action
of a plunger.
 lt measures to an accuracy of 0. 01mm.
REED TYPE MECHANICAL COMPARATOR
 The main applications of a dial gauge
Components:
are:
 To compare the dimensions of a work  Reeds (Two horizontal, Two vertical)
piece against a known standard like slip  Blocks( Fixed Block, Floating Block)
gauges.  Plunger(Spindle)
 To check the flatness and parallelism of  Pointer
flat surface.  Scale
 To check concentricity of holes and
Working
shafts. etc.
 The plunger (spindle) is made to come  Out of four reeds, two placed vertically
in contact with the top of the work (D) and two placed horizontally
piece and is moved along the length. connected between the two blocks (A
and B).

4
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

 ‘A’ block is fixed block, whereas ‘B’  Knife Edge (Attached at the notch in
block is floating Block. the plunger to capture the movement
 Out of the two vertical reeds Left of plunger)
vertical reed is fixed and the right  Moving Block (Bears the Knife Edge.
vertical is movable and which is moving block is the part of the Cross
connected to the block ‘B’. Strip)
 The Floating block connects to the  Cross strip hinge (Four flat steel springs
plunger. arranged at right angles to each other
 As the plunger moves upside, then the and having a pivot at its center so-
floating blocks (B) moves upside as called cross strip)
well, and the vertical Reed on the right  Y-shaped arm (A metal forked arm,
side will move upside gradually and the connects the cross strip to driving
pointer starts deflecting on the scale. drum)
 Driving Drum ( connects the pointer to
the Y shaped arm)
 Slit diaphragm ( Holds the
plunger/Spindle in place)
 a pointer
 a Scale

Construction and working of Sigma

comparator

1. The Plunger will hold the contact with

SIGMA COMPARATOR the work piece, and it is positioned in
place with the help of slit diaphragms.
Components in Sigma comparator
2. The plunger will have a notch at its
 The Plunger (The main part which will
center as shown in the figure.
have the direct contact with the
workpiece and having a notch at its 3. A knife Edge is attached to the plunger
center) to magnify the linear movement of the

5
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

plunger. And which is connected to the  This lever causes the mirror to tilt at an
Cross strip with the help of moving the angle.
block.  The light from the light source is made
to incident onto the mirror by passing
4. The Y-shaped metallic arm is connected
through the condensing lens, then
to the cross strip to Driving drum. This arm
passing through the projector lens.
rotated and makes the drum to rotate and
 As the light rays incident on the tilted
hence the pointer will move on the scale.
mirror surface, the mirror
Advantages
reflects these rays on the inner surface
1. If any shock loads forced on the plunger of the graduated scale.
those will not affect the inside equipment,  Which can be viewed through the
due to the knife edge will be dis-engage eyepiece
after some extent of movement.
Advantages:
2. Constant measuring pressure can be
 High amplification is possible.
achieved by using the magnetic plunger in
 The scale can be made to move past
sigma comparator.
the datum and hence a high range of
Disadvantages reading is possible with no parallax
error.
1. Due to more number of moving parts,
 Less moving parts and hence greater
there will be wear in moving parts.
accuracy.
2. Less sensible due to friction in moving
 Suitable for measuring geometric
part
properties which require high

OPTICAL COMPARATORS magnification.

 As the plunger slides over the uneven Limitations:

surface, the plunger moves in a vertical

 An external power source is needed.
axis, this movement is greatly
 The lenses may make the instrument
magnified by a lever that is pivoted.
costlier.

6
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

 Suitable to use in a dark surrounding  This air is moves to the manometer and
only. pushes downwards liquid in the
 Continuous operation may put a strain manometer.
on the eyes, as the reading is viewed  The variation in the manometer
through the eyepiece. pressure is then used to find the
dimensions of a component.
Application:

 Largely used in electronic

instrumentation industries and
research institutes.

Advantages

1. It is cheaper, simple to operate and the

cost is low.

2. It is free from mechanical hysteresis and

wear.
SOLEX PNEUMATIC COMPARATOR
3. The magnification can be obtained as
 It works on the principle of pressure
high as 10,000 X.
difference generated by the air flow.
 Air is supplied at constant pressure 4. The gauging member is not in direct
through the orifice and the air escapes contact with the work.
in the form of jets through a restricted
5. Indicating and measuring is done at two
space which exerts a back pressure.
different places.
 The excess air is passed to the water
6. Tapers and ovality can be easily
tank through dip tube.
detected.

7
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

Disadvantages  This current flows in the diagonal

connection causes a deflection of the
1. They are very sensitive to temperature
pointer of the meter
and humidity changes.

2. The accuracy may be influenced by the

surface roughness of the component being
checked.

3. Different gauging heads are needed for

different jobs.

4. Auxiliary equipment’s such as air filters,

pressure gauges and regulators are
needed.

ELECTRICAL COMPARATORS

 It consist of measuring head, display

head, inductive coils, stylus, amplifier
and control unit and a display unit
(meter). The stylus is fixed to a spindle
on which a soft iron plate is mounted,
between two identical inductive coils.
 The two inductive coils which are
connected in the Wheatstone bridge
circuit can be electrically balanced
when the iron plate on the stylus, is in
the middie position.
 The displacement of the stylus results
in upsetting the balance of the circuit
and ingenerating a current.

8
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

SURFACE TEXTURE pattern of the roughness. It is measured in

millimeters.
 Surface finish, also known as surface
4. Roughness Width Cut Off: Roughness
texture or surface topography, is the
width cut off is the greatest spacing of
nature of a surface as defined by the
respective surface irregularities to be
three characteristics of lay, surface
included in the measurement of the
roughness, and waviness.
average roughness height. It should
 It comprises the small, local deviations
always be greater than the roughness
of a surface from the perfectly flat ideal
width in order to obtain the total
(a true plane)
roughness height rating.
5. Lay: Lay represents the direction of
predominant surface pattern
produced and it reflects the machining
operation used to produce it.
6. Waviness Height:
Waviness height is the peak to valley
1. Roughness: Roughness consists of
distance of the surface profile, measured
surface irregularities which result from the
in millimeters.
various machining process. These
irregularities combine to form surface
texture.
2. Roughness Height: It is the height of
the irregularities with respect to a
reference line. It is measured in
millimeters or microns or micro inches. It
is also known as the height of unevenness.
3. Roughness Width: The roughness width
is the distance parallel to the nominal
surface between successive peaks or
ridges which constitute the predominate

9
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

LINEAR AND ANGULAR MEASUREMENT

SLIP GAUGES (GAUGE BLOCKS)

 They are used as standards for

precision length measurement.
 They are available in sets and consist of
a number of hardened blocks made of
high grade alloy steel.
 A particular size can be built up by
wringing individual slip gauges VERNIER BEVEL PROTRACTOR
together. (UNIVERSAL BEVEL PROTRACTOR)

 It is a precision instrument used for

measuring angles precisely to an
accuracy of 5 minutes.
 It is used to measure acute angles (i.e.
less than 90°), obtuse angles (more
than 90) and for setting work holding
VERNIER DEPTH GAUGE devices at required inclination -on

 A Vernier depth gauge is used for machine tools, work tables,etc.

measuring depth of holes, recesses,  Main scale is graduated in degrees in

slots and steps. four steps 0 to 90° and 900 to 00, 00 to

 The Vernier scale is fixed to the main 900 and 00 to3600.

body of the depth gauge. CLINOMETER

 The main scale can be slided through
 Also known as an inclinometer, the
the body, the end of which provides
essential function of the device is to
the datum
determine accurate measurements as
 Surface from which the measurements
they relate to sloping, height and
are taken.
distance.

10
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

 The main functional element of a SINE BAR

clinometer is the sensitive vial
mounted on a rotatable disc, which
carries a graduated ring with its
horizontal axis supported in the
housing of the instrument.
 The bubble of the vial is in its centre
position, when the clinometer is placed
on a horizontal surface and the scale of
the rotatable disc is at zero position.
 If the clinometer is placed on an incline  A sine bar is a device used to measure
surface, the bubble deviates from the angles in metals.
centre.
 It can be brought to the centre by  It consists of a hardened ground body

rotating the disc. with two precision ground cylinders

 The rotation of the disc can be read on attached at the ends.

the scale.
 The distance between the centres of
 It represents the deviation of the
the cylinders is accurately controlled,
surface over which the clinometer is
the top of the bar is parallel to a line
placed from the horizontal plane.
through the centres of the two rollers.

 For checking the angle of small size

components, a sine bar is set up
approximate (Nominal) angle on a
surface plate by suitable combination
of slip gauges.

 The component being checked is

placed over the surface of a sine bar.

11
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

 A dial gauge is mounted upon a  During the working ,light coming from
suitable stand such as universal surface the light source and this light rays splits
gauge. by target graticule.
 The optical square deflects this light
 It is moved over the component
rays by 90 degree and go to reflector
throughout its length. If there is a
through collimating lens, if reflector is
variation in parallelism of the upper
perpendicular, the light rays are
surface of the component and the
reflected and move to same path and it
surface plate, it is indicated by the
is visible in eye piece at point O.
deflection of pointer.
 If the reflector is reflected at small
angle, then reflected light will
 Now, we tried to adjust the slip gauges
depleated by twice angle of tilt and will
height so that the dial indicator reads
be brought into focus to pont O’ , which
zero position.
displace by “x” distance from its orginal
position and distance x can be
measured with micrometer

AUTOCOLLIMATOR

 It is an optical instrument used to

measure small angular difference and
also used to align optical components
and mechanical deflection.
 It consist of light source used to
generate light rays, reflector act as a
work piece, micrometer microscope is Application of Autocollimator
used to see the point of incident rays.  Checking flatness of machine tool beds
 Optical square used to change the and slide ways.
direction of light rays by 90 degree.  Measuring very small angle with high
precision.
 Verifying parallelism
12
[email protected]
MS&M M4 PRAVEEN KP Lr: in ME

 Checking the column’s squareness in

relation to the base.
 Examining the flatness of bed plates
and table tops.
 Checking for small linear shifts.
Advantage
 Very high accuracy.
 Ability to measure wide range angle.
 Easy to set up and operate.
 Calibration at the level of international
standards.
 Result can be seen directly on the
screen.
Disadvantage
 Regular maintenance is required
 Measurements require much time.
 For the detector to trace the sample, it
has to be cut and processed.
ANGLE GAUGES

 It is similar to slip gauges and it is used

for measuring angle
 It is generally made of high grade alloy
steel

13
[email protected]