ENGG.

METROLOGY for MECHATRONICS

(GTI/MCT/07/01)

1.0) Engg. Measurements

By
SREERAJ
 OBJECT OF MEASUREMENT
MEASUREMENT :
Help to timely detect inaccurately
machined parts and to avoid rejects and
defects.
HOW TO MEASURE?
1)MEASURING INSTRUMENT :
Any device that may be used
to obtain a dimensional or surface
measurement.
2)GAUGES
Intended for quickly checking
 STANDARDS OF
MEASUREMENT
1) International standard Metre.
In 1960 11th general conference
on weights and measures adopted the
International System of Units(SI).
2) Imperial Standard Yard.

LINE AND END STANDARDS

In line standard unit of length is
defined as the distance between the
centres of engraved lines as in a steel rule.
rule
In the end standards it is the distance
between the end faces of the standard as
CLASSIFICATION OF MEASURING
INSTRUMENTS
PRECISION INSTRUMENTS
Eg : Micrometre,Vernier caliper
ACCURA etc.
CY NON-PRECISION
INSTRUMENTS
Eg : Graduated rule,Scale etc.
DIRECT READING : Used to determine
the actual dimension and size.

MODE IN DIRECT or TRANSFER TYPE : It

transfer the measurement from the
work to a direct measuring instrument
and a comparison is made.
LINE MEASURING
DEVICES
TYPE
END MEASURING
DEVICES
Most measuring instruments have specific and
limited uses, although some can be used for more
than one purpose. Some are measuring linear
dimensions , some are for angular or geometric
dimensions and some are devoted for measuring
surface finish. Some are for reference purposes as
standards of comparison.
 PRINCIPAL MEASURING INSTRUMENTS

1.LINEAR 2.ANGULAR
3.TAPER
A.NON PRECISION A.NON PRECISION
(a) Steel Rule (a) Protractors
(b) Calipers (b) Adj.Bevel
(c) Dividers (c) Engineers Square
(d) Telescopic Gauge (d) Combination set
(e) Depth Gauge
B.PRECISION 4.SURFACE
B.PRECISION (a) Bevel Protractors
(a) Micrometers (a) Straight edge
(b) Dividing Head
(b) Vernier Calipers (b) Surface Table
(c) Sine bar
(c) Height Gauges (c) Surface Gauge
(d) Angle Gauges
(d) Slip Gauges (d) Optical Flat
(e) Spirit Levels
(f) Clinometers (e) Profilometer
C.COMPARATORS (g) Autocollimators (f) Use of Laser

D.MEASURING
MACHINES
 LINEAR MEASUREMENT – NON PRECISION
Includes
the measurement of
length,diameter,height,thicknessetc.Basic principle
of linear measurement is that of comparison with
standard dimensions on suitably engraved
instrument or device.
STEEL RULE

It is one of the most useful tool in the shop for taking

linear dimensions of blanks and articles to an
accuracy of from 1.0 to 0.5 mm. This hardened steel
strip rules are available in different lengths
150,300,500 and 1000mm.Usually marked in both
CALIPER
S
A caliper is used to transfer and compare a
dimension from one object to another or from a part to a
scale or micrometer where the measurement cannot be
made directly. There are 4 types mainly.

OUTSIDE
CALIPER It is a two
legged steel instrument with
its legs bent inwards. It is
used for measuring or
comparing thickness,
diameters, and other outside
dimensions. A steel rule must
be used in conjunction with
them if a direct reading is
desired. The size of a caliper is
INSIDE CALIPER

An inside
caliper is exactly
similar to an outside
caliper in
appearance with its
legs bent outward.
This is used for
comparing or
measuring hole
diameters, distances
between shoulders
or other parallel
SPRING CALIPER
For finer work the
use of spring caliper
both outside and
inside advocated. A
loop spring on top of
the joint between the
two legs applies
force tending to
separate the legs at
the bottom. An
adjusting nut and
screw keep the legs
in position. When a
spring caliper is
applied to an object ,
it must make sure
HERMAPHRODITE CALIPER

This is sometimes
called odd-leg
caliper. It has one
pointed leg like a
divider and one
bent leg as shown
in fig. The caliper
is extremely
useful for scribing
lines parallel to
the edge of the
work and for
TRANSFER
CALIPER
This is
convenient for
measuring recessed
work where ordinary
calipers cannot be
with drawn. The nut is
first locked and the
caliper opened or
closed against the
work. The nut is then
loosened and the leg
swung clear of the
obstruction leaving
DIVIDER
S
A divider is
similar in construction
to a caliper except that
both legs are straight
with sharp hardened
points at the end. This
is used for transferring
dimensions , scribing
circles, and doing
general lay out works.
A large circle or an arc
having a large radius
may be made with a
TELESCOPIC
GAUGE This is used for measuring the
inside size of slots or holes.
The gauge consist of a handle
and two plungers, one
telescopic in to the other and
both under spring tension.
The plungers can be locked in
position by turning a knurled
screw at the end of the
handle. The measurement is
made by first compressing
plungers and locked in
position and after inserting to
the slot it is allowed to
DEPTH GAUGE

This is used for

measuring the depth of
blind holes, slots,
grooves, the height of
shoulders in holes etc.
this is essentially a
narrow steel rule to
which a sliding head is
clamped at right angles
to the rule. The head
forms a convenient
marker in places where
 LINEAR MEASUREMENT -
PRECISION
VERNIER
CALIPER

Primarily intended for measuring both

inside and outside diameters of shaft,
thickness of parts etc. to an accuracy of
INTERNAL LOCKING NUT A vernier
JAW scale is the name
MAIN SCALE given to any scale
making use of the
difference
between two
scales which are
nearly, but not
quite alike,
for obtaining
VERNIER SCALE
small
FIXED JAW differences.

MOVABLE JAW
VERNIER SCALE

49 MM
MAIN SCALE
READING : On the main scale,1cm is divided
in to 10 parts, each being 1mm. The vernier
scale has 50 divisions. Every 5th division is
numbered. The length of 50 divisions on the
vernier is equal to the length of 49 divisions
(49mm) in the main scale.
Therefore, each vernier division = 49/50
= 0.98mm
Difference b/w one division on
the main scale and Toone
readdivision
the vernier first note
on
thethe vernier is equal
centimetres, to
millimeters, that the1-0.98
zero of
=the
0.02mm
vernier has moved from the zero of the
main scale. Then count the number of
divisions on the vernier scale from zero line to
Example :

1) 2 MAIN DIVISIONS
2) 1 SUB DIVISION 3) COINCIDING LINE 15TH

1)2 Main Divisions = 2x10mm =

20mm
2)1 Sub-Division = 1x1mm =
1mm
Assignment
1

1)Main divisions 3 = = 3 x10mm =

2)Sub divisions 30mm
5 = = 5 x 1mm =
3)Vernier divisions 37
5mm= = 37 x 0.02 =
0.74mm
Total =
ASSIGNMENT
2:

READING : 9.16mm
ASSIGNMENT
3:

READING :
17.16mm
 ENGLISH VERNIER
CALIPER.
An English vernier has an accuracy of 0.001 in.

On the main scale, 1 Inch is divided in to

10 equal parts and each 1/10th is divided in to
4 giving ¼ of 1/10th = 1/40 in = 0.025 in. The
vernier scale has 25 divisions, which are
numbered from 0 to 25. every 5th division is
numbered. The length of 25 division on the
vernier is equal to the 24 divisions on the main
scale. 24 divisions being equal to 24x0.025=
0.6 in.

One division on the vernier equals 1/25

MICROMETER
This instrument, invented by William
Gascoigne in the 17th century, is often used to
measure diameters of wires and spheres ,
thickness of parts, parallelism of faces etc. To
improve accuracy (as with all measurements)
we would take several readings and find their
average. Thus we could not only ensure
accuracy but, by taking readings at different
positions along the length, we could test for a
consistent diameter along a piece of work.

There are different kinds of micrometers

available.
a) EXTERNAL
b) INTERNAL or INSIDE
 EXTERNAL MICROMETER.
It is primarily used
to measure external
dimensions like
diameters,
thickness. Usually
these will be having
The essential
a least parts of micrometer are,
count or
accuracy of
1)FRAME This is made of steel, cast steel,
: 0.01
malleable
mm. cast iron or light alloy.
2)HARDENED ANVIL : Usually made of a
hardened steel and the face will be given with
a highly accurate lapped surface. The anvil
shall protrude from the frame for a distance of
at least 3mm for the easiness of measure as
3) SCREWED SPINDLE : Extremely hard and
stable one-piece spindle (the heart of our
accuracy). This spindle does the actual
measuring and possesses thread of 0.5mm
pitch.
4) GRADUATED SLEEVE or BARREL : It has
datum or fiducial line and fixed graduations.
5) THIMBLE : This is tubular cover fastened
with the spindle and moves with the spindle.
The beveled edge of the thimble is divided in
to 50 equal parts, every fifth being numbered.
6) RATCHET or FRICTION STOP : This is a
small extension to the thimble. The ratchet
slips when the pressure on the screw exceeds
a certain amount. This produces uniform
EXTERNAL MICROMETER -
PARTS
 READING
Before: using the micrometer it is important to
ensure that the faces of the anvil and spindle
are clean and to check that the instrument
reads zero when they are closed.
The thimble is on a screw thread of pitch
0.5mm, so that the gap between anvil and
spindle will change by 0.5mm when the
thimble is moved through one revolution. The
graduations on the sleeve are each of 0.5mm
to reflect this.
The thimble has a scale of 50 equal divisions,
each division is 0.01mm (each individual
thimble mark is therefore 1/50th of 0.5mm =
0.01mm).
Each revolution of the ratchet moves the
spindle face 0.5mm towards the anvil face.
The object to be measured is placed
between the anvil face and the spindle face.
The ratchet is turned clockwise until the
object is ‘trapped’ between these two
surfaces and the ratchet makes a ‘clicking’
noise. This means that the ratchet cannot be
tightened any more and the measurement
can be read.
Example 1:
1. Read the scale on the sleeve. The example
clearly shows12 mm divisions.
2. Still reading the scale on the sleeve, a
further ½ mm (0.5) measurement can be seen
on the bottom half of the scale. The
measurement now reads 12.5mm.
3. Finally, the thimble scale shows 16 full
divisions (these are hundredths of a mm).
The final measurement is 12.5mm + 0.16mm
= 12.66
Example 1 :

Sleeve reads full mm =

12.00
Sleeve reads 0.5 mm =
0.50
Thimble reads =
Example 2 :

Sleeve reads full mm = 16.00

Sleeve reads 0.5 mm = 0.00
Thimble reads = 0.36
Total measurement =
Example 3:

Sleeve reads full mm =

Sleeve reads 0.5 mm =
Thimble reads =
Total measurement =
Example 4 :

Sleeve reads full mm =

Sleeve reads 0.5 mm =
Thimble reads =
Total measurement =
 Example 5 :

Sleeve reads full mm =

Sleeve reads 0.5 mm =
Thimble reads =
Total measurement =
 ERROR ON MICROMETER

Micrometer Correction :
A micrometer is
said to be having an error when the the zero
on the thimble and the zero line on the index
line is not collinear while it is in the closed
condition.
When the zero on
the thimble is below the index line, then the
zero error must be deducted from the reading
and vice versa.
Example :
When the micrometer is closed
let the reading on the thimble be 47. Let the
micro meter reading of the object be
15.58mm. Find the actual reading.

Zero error = ( 50-47=3 ;

3x0.01=0.03)
Since the zero of the thimble is above the
index line zero error is negative.
Therefore zero error is -0.03. which implies it
should be added with the micrometer
reading. Thus the actual reading is 15.58 +
0.03 = 15.61mm.
DEPTH MICROMETER.

It is an
instrument used to
measure the depth of
pockets to an accuracy
of 0.01mm. Depth
micrometer can only be
used in places where
there is a satisfactory
seating for the
instrument head, and
the bottom of the hole
being measured is
parallel with the
 The principle of measurement is
similar to that of an external micrometer.
Each one is supplied with three
interchangeable spindles and thus has the
measuring ranges 0 to 25mm, 25-50mm, 50-
INSIDE MICROMETER
75mm, 75-100mm.
This is intended for the
measurement of internal features like bore
dia, pocket sizes etc. In principle, it is
similar to an external micrometer and is
used for measuring holes with a dia over
50mm.
Instrument consist of a measuring
unit, extension rod with or with out spacing
collar, and a handle. The first range can be
vary from 50 to 63mm. Further
INSIDE MICROMETER
MEASURING WITH AN INTERNAL MICROMETER
SLIP GAUGES

Slip gauges or precision

gauges blocks, as they are sometimes called,
are used for precise measurement of parts
and for verifying measuring tools such as
micrometer, comparators, and various limit
gauges. Slip gauges often called johannsen
gauges after their originator, are rectangular
blocks made of alloy steel having a cross-
section of about 32mm by 9mm which, before
being finished to size, are hardened and
finished to a high degree of accuracy. They
are also carefully matured so that they are
independent of any variation in shape or size.
SLIP GAUGES or GAUGE BLOCKS
SLIP GAUGE BOX
 Slip gauges are made in five grades
of accuracy: Grade 1,Grade II, Grade 0, Grade
00 and calibration grade. The grade most
commonly used in the production of
components, tools, and gauges is Grade 1, for
rough work Grade II and for checking other
gauges and standards Grades 00 and
calibration grade.

Slip gauges are supplied in sets,

the sizes of which varies from a set of about
112 pieces down to one containing 32 pieces.
The grade and size of set desirable depend on
the class of work for which they are required
 During the use the slip gauges are
“wrung” together to form the required
dimension taking extreme care in handling.
The cleanliness of the surface of the slip
gauges and a standard temperature of 20°C
during measurement is essential for accurate
and reliable inspection. A number of slip
gauge holders also
WRINGING will be :sold
EFFECT together
Since the with
eachmeasuring
box. faces of gauges are
lapped and made to a high degree
of surface finish, when rub with each
other these will cling together. This
is so called wringing effect of slip
gauges.
 QUESTIONS- ASSIGNMENT

1)What is a measuring instrument?

2)What is a gauge?
3)Explain different standards of measurement.
4)Differentiate line standard and end standard with
eg.
5)Brief- Classification of measuring instrument.
6)With a neat sketch explain briefly
A) steel rule
B) Calipers
i) out side ii) Inside iii) Spring iv) Hermaphrodite
v) Transfer vi) Dividers
7) Explain about telescopic gauges- construction &
applications.
QUESTIONS- ASSIGNMENT (Cont.)
8)Write a short note on depth gauge.
9)What is a “ Vernier scale ”?
10) Explain about vernier caliper& its parts.
11) With a neat sketch explain about
micrometer & its parts.
12) What is meant by error on micrometer?
How to consider it while measuring?
13) With a sketch explain about Depth,
Internal micrometers.
14) Give a small note on slip gauges & its
applications.
15) What are the cares to be taken while
dealing with slip gauges?