EFFECTIVE USE OF

GAUGES AND MEASURING INSTRUMENTS

MEASUREMENT
KNOWING / INSPECTING ACTUAL VALUE OF CHARACTERISTIC

TYPES OF INSPECTION ( sona )

METROLOGY METALLURGY TESTING

 Principles of Measurement

The Principle of linear measurement is essentially a

comparison of the piece under test with a known standard.
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.
CONDITIONS FOR INSPECTION
* MEASURING INSTRUMENT & JOB

* BASED UPON CHARACTERISTIC AND TOLERANCE SELECT

MEASURING INSTRMENT / GAUGE AND ITS LEAST COUNT.

* CONTACT AREA OF GAUGE AND JOB SHOULD BE CLEAN

* REFERENCE MUST BE TRUE / FULLY ALIGNED

LEAST COUNT

* SMALLEST UNIT ON SCALE OF MEASURING INSTRUMENT

* LEAST COUNT OF THE MEASURING INSTRUMENT

SHOULD BE 1/10TH OF THE TOLERANCE.
Surface
A surface is a boundary that separates an object from another object
or substance.

Dimension
Dimensions are the macroscopic sizes of a part, e.g. diameter or length.

Tolerance
A tolerance is an allowable range for a dimension to take, a specified
interval of dimensions where the part will still function acceptably

Roughness

Roughness includes the finest irregularities of a surface. Roughness

generally results from a particular production process or material condition.
 0.1 A

CHARACTERISTIC
CHARACTERISTIC TOLERANCE REFERENCE

* STRAIGHTNESS / FLAGHTNESS

* CYLINDERICITY

* CIRCULARITY

* ACCURACY OF SURFACE PROFILE

* PARALLELISM

* PERPENDICULARITY

* ANGULARITY

* CONCENTRICITY

* SYMMETRY
SURFACE ERRORS

* FORM ERROR

* WAVINESS

* ROUGHNESS
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.
Vernier Protractor

Blade Clamp
Screw

Blade

Main
Scale

Vernier
Scale
Dial
Clamp

The Vernier Protractor is used for precisely measuring angles on components.

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.
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 - Don’t 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.
 UNITS SYMBOLS

NO BINDING FOR SPECIFIC TYPE OF FINISHING

OPERATION .

Rz Ra CHIP FORMING OPERATION .

NO CHIP FORMING OPERATION .

BETTER THE SURFACE CONDITION BETTER THE INSPECTION ACCURACY

PRINCIPAL OFSURFACE FINISH TESTER
* ROLE OF SURFACE FINISH / TEXTURE

* BETTER THE SURFACE CONDITION / TEXTURE , ACCURATE THE

INSPECTION RESULTS

* BETTER THE SURFACE CONDITION / TEXTURE , BETTER THE

REPEATIBILITY / REPRODUCABILITY OF INSPECTION RESULTS
INSPECTION RESULTS

* BETTER THE SURFACE CONDITION / TEXTURE , BETTER THE LIFE

OF THE PARTS PRODUCED . ( COMPONENTS )

* IN ALL THE MEASURING INSTRUMENTS SURFACE CONDITION /

TEXTURE IS CONTROLED TO A VERY CLOSE DEGREE OF ACCURACY
HENCE NEEDS TO BE HANDLED VARY CAREFELLY.
AIR GAUGE

Slit Jetted average diameter

Long Air Plug deep bores
Single Jetted runout/concentricity
Square Air Plug groove/slots
Taper Air Plug/Ring taper bore/angle
PRINCIPLE OF AIR GAUGE
DIAL

DIAPHARAM

AIR OUT
AIR IN

WHY AIR GAUGE

* EASY TO INSPECT ( NO SKILL REQUIRED )

* ECONOMICAL

* VERSATILE (DIA , TAPER , OVALITY )

HOW TO SET AN AIR GAUGE

RANGE SETTING

OPEN BOTH THE ADJUSTERS FULLY

CHECK THE GAUGE WITH SETTING

MASTERS FOR RANGE

* IF RANGE IS LESS TIGHT THE RIGHT ADJUSTER

* IF RANGE IS MORE TIGHT THE LEFT ADJUSTER

* FOR SETTING ZERO PRESS OR LIFT THE DIAL

DO,S

* CLEAN THE JOB AND GAUGE BEFORE USE

* CHECK THE AIR SUPPLY AND FILTER REGULARLY

DONT,S

* DO NOT FORCE THE O/S PIECE INTO THE GAUGE

* TO NOT ROTATE THE SETTING MASTER / JOB TOO FAST

* DO NOT HIT THE HARDENED PIECE TO GAUGE

* AVOIDE SPEEDY INSPECTION OF LENGTHY PARTS

MICROMETERS
SPINDLE SLEEVE Slotted to adjust
RATCHET play in threads
Measuring Thimble
ANVIL Thimbl
Faces Micrometer Cap
e
Anvil Screw Fixed Ratche
Spindl Sleeve
nut t Stop
e

CLAMP THIMBLE

Barrel Thimbl
Locking e
FRAME Ring

Frame

( MICROMETER WITH LEAST COUNT 0.001 )

HOW TO READ
SLEEVE READING : 6
CORRECT WAY OF HOLDING
THIMBLE READING : 0.37

VERNIER SCALE READING : 0.003

RESULT 6.373
TIPS FOR ACCURATE MEASUREMENTS

* READ THE SCALE DIRECTLY FROM FRONT ( PARALLEX ERROR )

* USE RATCHET WHILE MEASURING FOR CONSISTENT RESULTS

* CHECK ZERO BEFORE USE

* AVOIDE SPEEDY INSPECTION OF LENGTHY PARTS

* CLEAN THE SPINDLE FACES BEFORE USE

DONT,S

* DO NOT DROP

*DO NOT SPIN THE MICROMETER VIOLENTLY

 DIALS

PLUNGER DIALS PUPPY DIALS

REVOLUTION
BAZEL CLAMP
COUNTER
BAZEL

POINTER

STEM/PLUNGE
WORK PIECR

ROTATION
MEASURING PIN

DIAL INDICATOR 0 ~ 10 MM LEAST COUNT (0.01)

REV COUNT VALUE

DIAL SCALE READING

RESULT = REV COUNT VALUE + DIAL SCALE READING

DIAL BORE GAUGE
INDICATOR
SETTING OF BORE GAUGE

DIAL CLAMP

GRIP

STEM

ANVIL GUIDE PLATE

LARGE REFERENCE SMALL
DIAMETER DIAMETER
HOW TO READ
INDICATOR

CLOCK WISE ROTATION OF THE POINTER FROM

ZERO INDICATE THAT THE MEASURED DIMENSION DIAL CLAMP

IS SMALLER THAN THE REFERENCE

ANTIC LOCK WISE ROTATION OF THE POINTER FROM ZERO GRIP

INDICATE THAT THE MEASURED DIMENSION IS MORE THAN THE

REFERENCE .

ANVIL
BORE SIZE TO MEASURE 42.3 ~ 42.8 MM GUIDE PLATE

SELECT BORE GAUGE 30 ~ 60 MM

DIAL INDICATOR 0.01 LEAST COUNT

ANVIL NOMINAL SIZE 40 MM

WASHER SIZE 2.0 MM + 0.5 MM

TIPS FOR ACCURATE MEASUREMENTS

* SELECT THE CONTACT TIP BEST SUITED FOR APPLICATION

* SET THE ZERO WITH MASTER RINGAUGE / GUAGE BLOCKS

DONT,S
* DO NOT DROP

* WHILE MOUNTING THE DIAL ON STEM CLAMP IT FIRMLY

DO NOT OVER TIGHTEN IT
VERNIER CALIPER
INSIDE JAWS SLIDER
CLAMP
MAIN SCALE

DEPTH BAR

DIAL

EXTERNAL JAWS

HOW TO READ

MAIN SCALE READING 70

DIAL READING 0.35

RESULT 70.35
TIPS FOR ACCURATE MEASUREMENTS

* READ THE SCALE DIRECTLY FROM FRONT ( PARALLEX ERROR )

* HOLD THE JOB CLOSE TO JAW SURFACE

* FOR INSIDE MEASUREMENT KEEP INSTRUMENT PARALLEL TO

JOB AXIS AND AS DEEP AS POSSIBLE

DONT,S

* DO NOT DROP

* DO NOT USE AS COMPASS

* DO NOT USE ON ROTATING SURFACES

HEIGHT GAUGE

TIPS FOR ACCURATE MEASUREMENTS

* CLAMP THE SCRIBER / DIAL BY INSERTING GUIDE RACK

IT TO FULL LENGTH. LOCK/CLAMP

* TAKE CARE WHILE SETTING ZERO

SCRIBER READING

* MOVE IT SMOOTHLY

DONT,S
BASE
* PLACE THE INSTRUMENT AT THE SAFE CORNER

* NO DAMAGE TO SCRIBER TIP

* THERE SHOULD BE NO PLAY BETWEEN SLIDES

OTHER GAUGES
COMPARATOR GAUGE SNAP GAUGE
COMPARATOR GAUGE

COMPARATOR GAUGE

THREAD PLUG GAUGE

THANK YOU