Basic Metrology Practices

2000 Taylor Hobson

Principles of Measurement
The Principle of linear measurement is essentially a comparison
of the piece under test with a known standard.
Two systems are generally used:
- Metric System
- Imperial or English System
Working standards are calibrated against master standards.
The calibration or testing of measuring tools and instruments
usually requires special equipment.
Ensure instruments are maintained in a serviceable condition:
- Keep instruments clean, avoid misuse.
- Return instruments to cases when not in use.
- Keep the inside of the cases clean.
- Do not attempt to dismantle an instrument.
Rules, Calipers & Squares
Steel Rule
Only one possible
reading at edge of
ruler

By using a steel rule properly, parallax errors are avoided.

These are apparent differences in dimensions caused by
changing the point of observation.
Rules, Calipers & Squares
Outside Calipers
Outside Outside Spring
Caliper Caliper

Calipers are used for measuring or comparing distances and

sizes.
Outside measuring calipers legs are curved and turn inwards.
Rules, Calipers & Squares
Inside Calipers
Inside Spring
Caliper

Inside measuring calipers legs are straight and turn outwards.

Rules, Calipers & Squares
Engineers Square
Engineers
Square

Engineers squares are used for checking Squareness and

Flatness of components.
They are also used for marking out (in conjunction with a
scriber).
Gauges
Feeler Gauges
Feeler
Gauges

Feeler Gauges are manufactured from accurately rolled shims

and are used to measure gap sizes from 0.05mm up to about
1.25mm (0.002 to 0.050 inches). The numbers are marked on
the gauge to give the thickness and thus the gap width.

NB: Feeler gauges should be wiped with a clean cloth before and after use. If
grease or dirt is trapped, a false reading may be given.
Gauges
Radius Gauges

Radius
Gauges

Radius gauges are usually made of tool steel and cut with an
inside and outside radius of a stated size. The gauges are
grouped with other sizes to make a set.
An accurately machined component can be easily compared
with the profile of a radius gauge.
Gauges
Pitch Gauges

A screw pitch gauge has a set of teeth which are of a known
thread form. The gauge is used to determine the pitch of a
thread on a bolt or screw of any diameter.
NB: Both Pitch gauges and thread, should be clean and free of burrs. It is
useful to hold the screw up to a light to see small gaps. Use the full length of the
gauge for greater accuracy.
Gauges
Screw pitches
Metric Screw Thread:

Where:
p = pitch of the thread
d = depth of the thread
r = radius at the top and
bottom of the threads

Other screw thread types include:

UNF - Unified Fine
UNC - Unified Coarse
BA - British Association
BS Whitworth (BSF, BSP & Conduit) - British Standard
Gauges
Ring Gauges

A Ring Gauge is a precision-sized gauge used for size control of

external diameters/bars.
It can be fitted over a bar end and moved along the length to
test for roundness and accuracy of diameter.
Gauges
Plug Gauges

A Plug Gauge is an precision-sized gauge which is used for size

control of internal diameters/holes.
Go No-Go gauges are double ended. If the Go end is sized to
20mm, the No-Go end is slightly bigger, i.e. 20.020mm. If the
Go end fits in the machined hole and the No-Go end doesnt
then the hole is the an acceptable size.
The tolerance on the gauges can vary and each gauge is usually
specific to a particular job.
 Now its Your Turn!

Try the Exercises in Section 1 of the Worksheet.

Micrometers
Slotted to adjust
play in threads
Thimble Cap
Measuring Faces Thimble
Micrometer Sleeve
Screw Fixed nut Ratchet
Anvil
Spindle Stop

Barrel Thimble
Locking
Ring

Frame

The Micrometer is an instrument for measuring and comparing

thickness.
Micrometers
Using a Micrometer
Ratchet Stop

Hold the frame in your hand, gripping with the 2nd, 3rd & 4th
fingers
Rotate the thimble with the ratchet stop if fitted. Ensure
uniform pressure is applied, so a consistent reading is achieved.
Micrometers
Using a Micrometer
Ratchet Stop

If a ratchet stop is not fitted, take care when turning the

thimble.
Do not apply to much pressure, as this can damage the
measuring faces and cause excessive wear of the screw threads.
Micrometers
Using a Micrometer

When measuring round objects, roll the object over the anvils to
ensure a reading is taken at the largest diameter.
Micrometers
Using a Micrometer

When checking square objects, the micrometer should be

adjusted until there is no angular movement.
Take measurements in two or three places to check parallelism
of material.
Micrometers
The Metric Micrometer
1mm Thimble 50 divisions
(1 division =1/100mm)

Barrel

1/2mm

The pitch of the screw in a metric micrometer is mm. 1 rev of

the thimble = mm.
The beveled edge of the thimble is divided into 50. Each
graduation = 1/50th of mm (1/100mm or 0.01mm).
Micrometers
Reading the Metric Micrometer
Thimble
Barrel Reading (3)

Reading (2)
Reading (1)

Read the number of whole mm divisions visible on the barrel.

Read the number of mm divisions visible on the barrel.
Read the line on the thimble which coincides with the axis line.
Micrometers
Reading the Metric Micrometer
Thimble
Barrel Reading (3)
= 0.22mm

Reading (2)
Reading (1) = 0.50mm
= 10mm

Whole mm divisions visible 10 = 10.00mm

mm divisions visible. 1 = 0.50mm
Line on the thimble 22 = 0.22mm
Total Reading.. = 10.72mm
Micrometers
The Imperial Micrometer
Thimble 25 divisions
Barrel 1 division =1/1000
(0.001)

0.025
0.100

The pitch of the screw in an imperial micrometer is 0.025. 1

rev of the thimble = 0.025.
The beveled edge of the thimble is divided into 25. Each
graduation = 1/25th of 0.025 (0.001).
Micrometers
Reading the Imperial Micrometer
Thimble
Barrel Reading (3)

Reading (2)
Reading (1)

Read the number of long vertical divisions visible on the barrel.

Read the number of smaller divisions visible on the barrel.
Read the line on the thimble which coincides with the axis line.
Micrometers
Reading the Imperial Micrometer
Thimble
Barrel Reading (3)
= 0.006

Reading (2)
= 0.025
Reading (1)
= 0.200

Larger divisions visible 2 = 0.200

Smaller divisions visible. 1 = 0.025
Line on the thimble.. 6 = 0.006
Total Reading. = 0.231
Micrometer Depth Gauges

Thimble

Barrel

Head

The Micrometer Depth Gauge is used for measuring depths of

shoulders and holes.
Micrometer Depth Gauges
Using the Micrometer Depth Gauge

Screw back the spindle to clear the bottom of the hole and place
Micrometer head over the hole.
Adjust the thimble until the head touches the bottom of the hole.
Read off the hole depth.
Micrometer Depth Gauges
Reading the Micrometer Depth Gauge

Read the number of whole mm divisions on the barrel.

Read the number of mm divisions on the barrel.
Read the line on the thimble which coincides with the axis line.
NB: Remember the scale is reversed from an ordinary micrometer.
Micrometer Depth Gauges
Reading the Micrometer Depth Gauge

Whole mm divisions . 9 = 9.00mm

mm divisions .. 1 = 0.50mm
Line on the thimble 29 = 0.29mm
Total Reading.. = 9.79mm
 Now its Your Turn!

Try the Exercises in Section 2 of the Worksheet.

Vernier Calipers
Clamping
Top Vernier Scale Block
(Imperial)
Clamping Screws

Beam
Scale
Fine Adjustment
Screw Wheel
Bottom Vernier
Scale (Metric)
Movable Jaw
(Integral
with Vernier)

Nibs

Beam Jaw

The Vernier Caliper is an instrument for measuring sizes of

components.
Vernier Calipers
Using Vernier Calipers

With the clamping screws released, hold the calipers in one

hand, the thumb rested on the fine adjustment screw wheel.
Move the jaw forward with the thumb, until contact is made
with the component.
Vernier Calipers
Using Vernier Calipers

Lock the jaws with the other hand and adjust the jaws to just
grip the work piece with the fine adjusting screw.
Remove the caliper and read off the dimension.
Vernier Calipers
The Metric Vernier Caliper

10mm

0.5mm
Beam Bottom Scale

0.48mm Bottom Vernier Scale

The Beam Bottom Scale is 10mm divided into 10 (1mm). Each

1mm is divided into 2 (0.5mm).
On the Bottom Vernier Scale, 12mm divided into 25.
(12/25 =0.48mm) - Each division is 0.48mm.
Difference is 0.5 - 0.48 = 0.02mm.
Vernier Calipers
Reading the Metric Vernier Caliper

Beam Bottom Scale

Reading (1)

Bottom Vernier Scale Reading (2)

Read the scale to the left of the 0 on the bottom Vernier.

Read the mark where the Vernier Scale is Exactly the same as
the Beam Bottom Scale.
Vernier Calipers
Reading the Metric Vernier Caliper

Beam Bottom Scale

Reading (1)
30.5mm
Bottom Vernier Scale Reading (2)
14

Bottom Vernier Scale reading. = 30.50mm

Mark where scales are aligned... 14 (x 0.02) = 0.28mm
Total Reading = 30.78mm
Vernier Calipers
The Imperial Vernier Caliper

0.024 inch
Top Vernier Scale

0.025 inch Beam Top Scale

1 inch

The Beam Top Scale is 1 inch, divided into 10. Each of the 10 is
divided into 4 (0.025 inch).
On the Top Vernier Scale, 6/10 is divided into 25.
(1/25 of 6/10 = 0.024 inch)- Each division is 0.024 inch.
Difference is 0.025 - 0.024 = 0.001 inch.
Vernier Calipers
Reading the Imperial Vernier Caliper

Top Vernier Scale

Beam Top
Reading (1) Scale
Reading (2)

Read the scale to the left of the 0 on the Top Vernier.

Read the mark where the Vernier Scale is Exactly the same as
the Beam Top Scale.
Vernier Calipers
Reading the Imperial Vernier Caliper

Top Vernier Scale

Beam Top
Reading (1) Scale
Reading (2)
3.225 inch 16

Top Vernier Scale reading = 3.225 inch

Mark where scales are aligned... 16 (x 0.001) = 0.016 inch
Total Reading = 3.241 inch
Vernier Calipers
Using Digital Calipers

Digital Calipers are operated in the same way as Vernier

Calipers.
Just read off the digital display (can be switched between Metric
and Imperial).
Vernier Height Gauge

Metric Scale

Imperial
The Vernier Height Gauge is Scale

mostly used to measure

Fine
surface heights and for Adjustment
Fine
Adjustment
making precise markings on Screw Clamp

components. Finger
Clamp Clamping
Screw
The gauge has a sharp finger
attached which can be used Finger
for both purposes.
Base
Vernier Height Gauge
Using the Vernier Height Gauge

The Height Gauge can be used to measure the height of a

component.
In this case, the height of the component is the same as the
Vernier Gauge reading.
Vernier Height Gauge
Using the Vernier Height Gauge

The Height Gauge can be used to measure the Underside of a

component.
In this case, the height of the component is the Vernier Gauge
reading plus the height of the Finger (7.95mm).
Vernier Protractor

Blade Clamp Screw

Blade

Main Scale

Vernier Scale

Dial
Clamp

The Vernier Protractor is used for precisely measuring angles on

components.
Vernier Calipers
Using a Vernier Protractor

Most protractors are graduated 0 to 90 degrees reading in two

directions.
The Blade can be slid round to any position and clamped. One
side is flat to allow it to lie flat on a workpiece.
Vernier Protractors
The Vernier Protractor

12 Vernier
Divisions

The 12 divisions on the Vernier equal 23 degrees on the main

scale.
Each of the 12 divisions is 11/12th of a degree, 1 Vernier div is
1/12th degree = 5 mins
Vernier Protractor
Reading the Vernier Protractor
Reading (1)

Reading (2)

Read the number of whole Degrees visible on the main scale.

Read the number of mins where the Vernier Scale is Exactly the
same as the main scale.
Vernier Protractor
Reading the Vernier Protractor
Reading (1)
52

Reading (2)
40
Reading Left to Right

Whole degrees visible... = 52

Mark where scales are aligned.. = 40
Total Reading... = 52 degs 40 mins
Vernier Protractor
Reading the Vernier Protractor
Reading (1)
127

Reading (2)
20
Reading Right to Left

Whole degrees visible = 127

Mark where scales are aligned.. = 20
Total Reading... = 127 degs 20 mins
 Now its Your Turn!

Try the Exercises in Section 3 of the Worksheet.

Slip Blocks

Slip blocks are used as standards for precision length

measurement in the Engineering Industry.
Slip Blocks
Four Grades of Accuracy
Workshop Grade Least Expensive
Inspection Grade
Calibration Grade
Reference Grade Most Expensive
Care of Block Gauges

When not used, Slips should be kept in their Case.

Avoid Excessive Handling - Dont touch lapped faces.
Wipe slips clean before and after they are used.
Use soft linen or cambric cloth to clean slips.
Slip Blocks
Wringing Slips

Select the blocks needed to make up the pack and clean them.
Start with the biggest pair and twist them at 90 under slight
pressure.
Slip Blocks
Wringing Slips

For slips less than 1.27mm (.05 inch) wring by sliding together.
To prevent scratches on slips, protector blocks can be used on
the ends on stacks (2mm) which are cheaper to replace.
Slip Blocks
Calibration Charts

Blocks are calibrated by comparing them to master gauges

The deviation of each slip is recorded and included in the block
set stating the error.
For High accuracy the calibration chart is essential.
Slip Blocks
The Effect of Cumulative Errors

Error due to deviation from true size.

Errors due to grease or dirt between ringing faces.
Errors due to expansion caused by exposing gauges to strong
light or excessive handling.
Choosing a Measuring instrument
Basic Rules
Choose instrument in keeping with the tolerance and
dimensions to be measured.
Use an instrument that gives a direct reading wherever
possible.
Dont use damaged or worn instruments.
Instrument resolution is not always the accuracy to which it
can be used.
Inbuilt accuracy's often exceed resolution.

NB: The larger the size being measured, the more difficult it will be to attain a
high standard of accuracy.
Choosing a Measuring instrument
Instrument Type of Value of smallest Suggested
Or Measurement Measurement Range Graduation Reliability
(Resolution)
Steel Rule Direct 150 600mm .5mm .5mm
6 - 24 in .02in .02in
Depth Gauge Direct 150mm .5mm .5mm
6in .02in .02in
Calipers Transfer 150mm none .5mm
6in .02in
Vernier Calipers Direct 600mm .01mm .05mm
24in .001in .002in
Vernier Depth Gauge Direct 300mm .01mm .05mm
12in .001in .002in
Vernier Height Gauge Direct 600mm .01mm .05mm
24in .001in .002in
Micrometers Direct 0-25mm .01mm .01mm
0-1in .001in .001in
Direct 25-50mm .01mm .01mm
1-2in .001in .001in
Inside Micrometers Direct 2.5-130mm .01mm .01mm
0.1-5.2in .001in .001in
Depth Micrometers Direct 0-300mm .01mm .01mm
0-12in .001in .001in
Slip Gauges End Standard Up to 100mm .001mm .0005mm
Up to 4in .0001in .00001in
Checking Surface Texture
Roughness average index

The Roughness average (Ra) index is an accepted method of

measuring surface finish.
The table shows a series of surface textures which can be
produced by various manufacturing processes.
Checking Surface Texture
Using Comparison Plates

Comparison plates are a range of blocks machined to various

calibrated surface textures, each texture measured in microns
(m) and micro-inches (in).
Checking Surface Texture
Visually ...

Clean work piece and appropriate comparison plate.

Compare the workpiece and plate from many different angles.
The workpiece finish should be at least as good as, if not better.
Checking Surface Texture
... or by Touch

Draw your fingernail lightly over the comparison plate.

Repeat the operation on the workpiece and note any differences.
The workpiece finish should be usually better than the plate.
Checking Surface Texture
With an Instrument

Controls and
Display

Pickup
Lead

Pickup

Traverse Unit
and Electronics
Pickup
Mount
Stylus
Checking Surface Texture
With an Instrument

Measurement
Pickup
Length

Surface to be Stylus
measured

The Pickup is pulled across the surface for a pre set distance.
A diamond tip stylus measures the roughness of the surface.
The result in Ra (Roughness average) is shown on the display.
Checking Surface Texture
With an Instrument

A typical Ra result taken on a Surtronic instrument is shown.

Checking Surface Texture
What is Ra?

Mathematically, Ra is the arithmetic average value of the

profile departure from the mean line, within a sampling
length.

A method of visualising how Ra is derived is as follows:

Graph A: A mean line X-X is fitted to the measurement data.

Checking Surface Texture
What is Ra?
Graph B: The portions of the profile within the sampling length
l and below the mean line are then inverted and placed above
the line.

Graph C: Ra is the mean height of the profile above the original

mean line.

Ra
Checking Surface Texture
Ra has its Limitations

Ra

Ra

Ra

Ra

All the above profiles have different form, but the Ra value is
the same. Other parameters are used to calculate these
differences.
 Now its Your Turn!

Try the Exercises in Section 4 of the Worksheet.

Any Questions?
Basic Metrology Practices
2000 Taylor Hobson