Chapter 2 Measurement and Inspection Tools
SLIDES PREPARED BY Eng. Ahmed Al-Maqbali
PRESENTER
COLLEGE / CENTRE COLLEGE OF ENGINEERING
PROGRAM Mechanical Engineering
SEMESTER Spring 2025-26
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1. Why Do We Study Measurement ?
• Engineering is based on accuracy
• A small error (0.1 mm) can cause
misfit, vibration, leakage
• Correct measurement = less waste,
better quality, safer work
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[Link] vs Inspection (Number vs Decision)
• Measurement = gives a number
Example: Shaft diameter measured = 24.98 mm
• Inspection = gives a decision (Pass/Fail)
We compare the measured value with the tolerance
• Specification example: 25.00 ± 0.05 mm
• Acceptable range: 24.95 to 25.05 mm
• Decision examples:
• 24.98 mm → PASS (within range)
• 25.07 mm → FAIL (too large)
• 24.93 mm → FAIL (too small)
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3. Common Measurement Errors in the Workshop
• Parallax Error: Reading the scale from an angled
view instead of eye-level → incorrect reading.
• Excessive Measuring Force: Squeezing a caliper
or over-tightening a micrometer changes the
reading and may slightly deform the part.
• Dirty Surfaces / Burrs: Chips, oil, dust, or burrs
prevent proper contact between the tool and the
workpiece.
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3. Common Measurement Errors in the Workshop
• Misalignment (Tilting): Holding the tool
at an angle (not straight/perpendicular)
leads to incorrect measurements.
• Temperature Effects: Hot parts expand
→ measurements may be higher than
the true dimension.
• Wrong Tool Selection: Using a ruler
when a caliper or micrometer is required
for higher accuracy.
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4 . Precision Measuring Instruments
4.1 Vernier Caliper
4.2 Micrometer
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4.1 Vernier Caliper
• A precision measuring instrument used to measure linear dimensions accurately.
• Typical accuracy: 0.02 mm
• Suitable for general workshop measurements
• More accurate than a steel rule
❖ Application of Vernier Caliper :
Measuring external dimensions (shaft diameter)
Measuring external
Measuring internal dimensions (hole diameter) dimensions
Measuring depth of holes and grooves
Measuring depth
Measuring internal
dimensions
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4.1.1 Main Parts of Vernier Caliper
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4.1.2 Digital Caliper
▪ A battery-operated precision measuring instrument that displays readings directly on an LCD screen, allowing accurate
linear measurements without manual calculation and with metric/imperial unit selection.
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4.1.3 Principle of Reading a Vernier Scale
Vernier instruments are classified as precision instruments because they can detect very small dimensional variations.
Vernier Caliper Reading Formula
Total Reading = MSR + (VC × LC)
Main Scale (MSR) : Main Scale Reading ( cm or mm )
Vernier Scale (VS) : Vernier Coinciding Division ( mm )
Least Count ( LC ) : east count is the smallest measurable value (is clearly marked on the vernier scale ) (mm)
Note:
❑ If the least count (LC) is not specified on the vernier scale, it is
usually taken as 0.1 mm.
❑ Always check whether the main scale is graduated in millimeters
(mm) or centimeters (cm) before taking the reading.
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4.1.3 Principle of Reading a Vernier Scale
Total Reading = MSR + (VC × LC) = 1.3 cm + ( 0.3 x 0.1 ) = 1.33 cm or 13.3 mm
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4.1.3Principle of Reading a Vernier Scale
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4.2 Micrometer
• A micrometer is a high-precision measuring instrument used to measure very small linear dimensions accurately.
• Measuring external diameter of shafts
• Measuring thickness of sheets and components
• Typical accuracy: 0.01 mm
• More accurate than vernier caliper
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4.2.1 Digital Micrometer
• A digital micrometer is a high-precision electronic measuring instrument that displays measurements
directly on a digital screen.
• Direct digital reading (no manual calculation).
• Zero setting at any position.
• Can switch between metric and imperial units.
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4.2.2 Principle of Reading a Micrometer
Thimble Reading
• Main Scale (Sleeve) Reading
Read the value shown on the main scale (sleeve).
Include the visible 0.5 mm mark if present.
• Thimble Reading
Read the value on the thimble scale that aligns Main Scale
with the reference line.
Each division usually equals 0.01 mm.
Total Reading = Main Scale Reading(M.S.R) + Thimble Reading (TR)
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4.2.2 Principle of Reading a Micrometer
Main Scale Reading = 7 Thimble Reading = 0.38
M.S.R + TR = 7+ 0.38 = 7.38
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4.2.2 Principle of Reading a Micrometer
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