Design of Linear
Measurement Instruments
❑Themeasuringaccuracyoflinegraduatedinstrumentsdepends
ontheoriginalaccuracyoflinegraduations.Excessivethickness
orpoordefinitionofgraduatedlinesaffecttheaccuracyof
readingscapturedfromtheinstrument.
❑Anyinstrumentincorporatingascaleisasuspectunlessitis
providedcompensationagainstwear.
❑Attachmentscanenhancetheversatilityofinstruments.
However,everyattachmentusedalongwithaninstrument,
unlessproperlydeployed,maycontributetoaccumulatederror.
Wearandtearofattachmentscanalsocontributetoerrors.
10
Design of Linear
Measurement Instruments
❑Instrumentssuchascalipersdependonthefeeloftheuserfortheir
precision.Goodqualityoftheinstrumentpromotesreliability,but
ultimatelyskilloftheuserensuresaccuracy.
❑Theprincipleofalignmentstatesthatthelineofmeasurementand
thelineofdimensionbeingmeasuredshouldbecoincident.This
principleisfundamentaltogooddesignandensuresaccuracyand
reliabilityofmeasurement.
❑Dialversionsofinstrumentsaddconvenienceinreading.
Electronicversionsprovidedigitalreadoutswhichareeveneasier
toread.
11
Design of Linear
Measurement Instruments
❑Oneimportantelementofreliabilityofaninstrumentisits
readability.
❑Ifcostisnotanissue,digitalinstrumentsmaybepreferred.The
chiefadvantageofelectronicmethodistheeaseof‘signal
processing’.Thereadingsmaybeexpresseddirectlyintherequired
formwithoutadditionalarithmetic.Thereadingscanbestoredona
memorydeviceforfurtheruseandanalysis.
❑Whenever,contactbetweentheinstrumentandsurfaceofthejob
beingmeasuredisinevitable,contactforceshouldbeoptimumto
avoiddistortion.Thedesignercannotleavethefateofthe
instrumentontheskilloftheuseralone.
12
Linear and Angular Measurement
13
Measuringtoolsandinstruments
Direct (contact) measurement
(e.g. micrometer or caliper)
Indirect(non-contact)measurement
(advancedmethodssuchasoptical,
ultrasonic,laser,etc.)
▪Calipers
▪Gauges and Gauge Blocks
▪Sine Bar
▪Special-purpose tools
▪Rules
▪VernierCalipers
▪VernierGauges
▪Micrometers
▪Protractors
▪DialIndicators
Graduated
(either linear or angular
graduations incorporated into
measuring system of the tool)
Non-graduated
(gauges or adjustable
tools which compare
the measurements)
Surface Plate
14
Surface Plate
15
Surface Plate
16
V‐ Blocks
17
V-Block:
❑Checkingroundnessofcylindrical
workpiece
❑Marking centers accurately
❑90°angle
❑Types:
i.Depending on accuracy
▪Grade A
▪Grade B
ii.Depending on design
▪One vee
▪Two vee
V‐ Blocks
18
V‐ Blocks
19
Linear and Angular Measurement
20
GraduatedLinearMeasurement-Rules
Linear and Angular Measurement
21
GraduatedLinearMeasurement-Rules
Linear and Angular Measurement
22
GraduatedLinearMeasurement-Rules
Linear and Angular Measurement
23
GraduatedLinearMeasurement-Rules
Linear and Angular Measurement
24
GraduatedLinearMeasurement-Rules
Imperialsteelrulewithvariouslengths
havinggraduationsoneachside
Samerulewithrelativelylarger
graduations
Metricsteelrulewithvariouslengths
havinggraduationsoneachside
How to read a rule:
A = 12 mm (12
th
graduation)
B = 22 mm (22
nd
graduation)
C=31.5mm(between
D=40.5mm(between
31st
40th
and 32nd)
and 41st)
resolution?
Linear and Angular Measurement
25
GraduatedLinearMeasurement-Scaled Instruments
Linear and Angular Measurement
26
GraduatedLinearMeasurement-Depth Gauge
Linear and Angular Measurement
27
GraduatedLinearMeasurement-Combination Set
Linear and Angular Measurement
28
GraduatedLinearMeasurement-Combination Set
Linear and Angular Measurement
29
GraduatedLinearMeasurement-Vernier Instruments
Linear and Angular Measurement
30
GraduatedLinearMeasurement-Vernier Instruments
❑Twoscales:Main&
Vernier
❑Slightdifferencein
divisionsisused
enhance the
accuracy
❑Threeelements:
Beam,FixedJaw&
SlidingJaw
❑Errors in
measurements
❑DigitalCaliper
Linear and Angular Measurement
31
GraduatedLinearMeasurement-Vernier Instruments
Linear and Angular Measurement
32
GraduatedLinearMeasurement-Vernier Instruments
Components of vernier calipers are
❑Main scale
❑Vernier scale
❑Fixed jaw
❑Movable jaw
Types of vernier calipers
1)Type A vernier caliper
2)Type B vernier caliper
3)Type C vernier caliper
Linear and Angular Measurement
33
GraduatedLinearMeasurement-Vernier Caliper
Linear and Angular Measurement
34
GraduatedLinearMeasurement-Vernier Caliper
Guidelines for the use of Vernier Caliper
Linear and Angular Measurement
35
GraduatedLinearMeasurement-Vernier Caliper
Guidelines for the use of Vernier Caliper
Linear and Angular Measurement
36
GraduatedLinearMeasurement-Vernier Caliper
Linear and Angular Measurement
37
GraduatedLinearMeasurement-Vernier Caliper
Linear and Angular Measurement
38
GraduatedLinearMeasurement-Vernier Caliper
❑Verniercalipersareavailableinsizeof150mm,225mm,900mmand1200mm.
❑Theselectionofthesizedependsonthemeasurementstobetaken.
❑Verniercalipersareprecisioninstruments,andextremecareshouldbetaken
whilehandingthem.
Verrier caliper with 0.02 mm Least Count is generally used in work shop.
In this Vernier caliper main scale division (49mm) are divided in to 50 equal part in the Vernier scale.
i.e. 1 main scale division =1 mm (MSD)
1. Vernier scale division =49\50 mm
(VSD)
Least count is : 1mm –49\50 =1\50 mm
The difference between 1 MSD and 1 VSD = 0.02mm
Linear and Angular Measurement
39
GraduatedLinearMeasurement-Vernier Caliper
Main scale reading =35mm
The vernier division coinciding with the main scale is the 20th division.
Value=20 multiplied by 0.02=0.40mm.
Total reading is 35mm+0.40= 35.40mm
35.40 mm
Example
Linear and Angular Measurement
40
GraduatedLinearMeasurement-Vernier Caliper
Dial Caliper
Linear and Angular Measurement
41
GraduatedLinearMeasurement-Vernier Caliper
Electronic Digital Caliper
Linear and Angular Measurement
42
GraduatedLinearMeasurement-Vernier Caliper
Electronic Digital Caliper
Linear and Angular Measurement
43
GraduatedLinearMeasurement-Vernier Depth Gauge
Linear and Angular Measurement
44
GraduatedLinearMeasurement-Vernier Height Gauge
❑KindofVernierCaliper
❑Haveaccessoriesto
makesuitablefor
heightmeasurement
Linear and Angular Measurement
45
GraduatedLinearMeasurement-Micrometer Instruments
Linear and Angular Measurement
46
GraduatedLinearMeasurement-Micrometer Instruments
Conformity to ABBE’s Law
Linear and Angular Measurement
47
GraduatedLinearMeasurement-Micrometer Instruments
Conformity to ABBE’s Law
Linear and Angular Measurement
48
GraduatedLinearMeasurement-Micrometer Instruments
Parts of Micrometer
▪Frame
▪Anvil and spindle
▪Screwed spindle
▪Graduated sleeve or barrel
▪Ratchet or friction stop
▪Spindle clamp
Linear and Angular Measurement
49
GraduatedLinearMeasurement-Micrometer Instruments
Linear and Angular Measurement
50
GraduatedLinearMeasurement-Micrometer Instruments
V-anvilMicrometer(measuringodd
flutedtaps,millingcutters,reamers,
andcheckingoutofroundness)Dial-indicatingMicrometer
Direct-reading
Micrometer
ScrewThreadMicrometer(measuring
pitchdiameterofscrewthreads)
Linear and Angular Measurement
51
GraduatedLinearMeasurement-Micrometer Instruments
Outside Micrometers
Linear and Angular Measurement
52
GraduatedLinearMeasurement-Micrometer Instruments
Outside Micrometers
Linear and Angular Measurement
53
GraduatedLinearMeasurement-Micrometer Instruments
Outside Micrometers
Linear and Angular Measurement
54
GraduatedLinearMeasurement-Micrometer Instruments
Types of Micrometers
Linear and Angular Measurement
55
GraduatedLinearMeasurement-Micrometer Instruments
Types of Micrometers
Linear and Angular Measurement
56
GraduatedLinearMeasurement-Micrometer Instruments
Types of Micrometers
MetricMicrometer
SLEEVE (BARREL) READING
Metric Vernier
Micrometer
THIMBLEREADINGVERNIERREADING
Linear and Angular Measurement
57
GraduatedLinearMeasurement-Micrometer Instruments
Vernier Micrometer
Linear and Angular Measurement
58
GraduatedLinearMeasurement-Micrometer Instruments
Vernier Micrometer
Linear and Angular Measurement
59
GraduatedLinearMeasurement-Micrometer Instruments
Linear and Angular Measurement
60
GraduatedLinearMeasurement-Micrometer Instruments
Linear and Angular Measurement
61
GraduatedLinearMeasurement-Micrometer Instruments
Inside Micrometer Caliper
Linear and Angular Measurement
62
GraduatedLinearMeasurement-Micrometer Instruments
Inside Micrometer Caliper
StandardInsideMicrometers DigitalInsideMicrometers
Linear and Angular Measurement
63
GraduatedLinearMeasurement-Micrometer Instruments
Inside Micrometer Caliper
Linear and Angular Measurement
64
GraduatedLinearMeasurement-Micrometer Instruments
Linear and Angular Measurement
65
GraduatedLinearMeasurement-Micrometer Instruments
Linear and Angular Measurement
66
GraduatedLinearMeasurement-Pin Gauge
Linear and Angular Measurement
67
GraduatedLinearMeasurement-Pivotal Stylus & Autocollimator
Linear and Angular Measurement
68
GraduatedLinearMeasurement-Pivotal Stylus & Autocollimator
Measuring the diameter of small bore by Pivoted Stylus
Linear and Angular Measurement
69
Non-GraduatedLinearMeasurement-Calipers
Calipers:
➢Consists of two legs
➢Accessory to scale
➢Reducesightingerrors
andincreaseaccuracy
➢Two types:
ii.Firm Joint type
✓Outside
✓Inside
ii.Spring type
✓Outside
✓Inside
✓Transfer
✓Hermaphrodite
Linear and Angular Measurement
70
Non-GraduatedLinearMeasurement-Calipers
➢Standard calipers have a fine adjustment screw and a quick-adjusting spring nut.
➢Accuracy obtained with these tools depends mostly on the inherent skill of users.
➢The measurements are carefully transferred to a graduated measuring tool.
Caliper for inside
measurement
Caliper for outside
measurement
Caliper used
as a divider
Linear and Angular Measurement
71
Non-GraduatedLinearMeasurement-Calipers
❑Therearemanyjobswhosedimensionscannotbemeasured
accuratelywithasteelrulealone.Atypicalcaseinpointisajob
withcircularcross‐section.
❑Anattempttotakemeasurementusingasteelrulealonewillleadto
error,sincethesteelrulecannotbepositioneddiametricallyacross
thejobwiththerequireddegreeofaccuracy.
❑Calipersaretheoriginaltransferinstrumenttotransfersuch
measurementsontoarule.Theycaneasilycapturethediameterof
ajob,whichcanbemanuallyidentifiedasthemaximumdistance
betweenthelegsofthecaliperthatcanjustslideoverthediameter
ofthejob.
❑Eventhoughcalipersarehardlyusedinproductioninspection,they
arewidelyusedintoolroomandrelatedwork.
Linear and Angular Measurement
72
Non-GraduatedLinearMeasurement-Calipers
❑Calipersdophysicallyduplicatetheseparationbetweenthereference
pointandmeasuredpointofanydimensionwithintheirrange.Theydo
thejoboftransferringadimensiononly,butnotmeasuringinstruments
ontheirown.
❑Calipersareavailableinvarioustypesandsizes.Twomajortypesarethe
firmjointcaliperandthespringcaliper.
❑Firmjoint,asthenameitselfsuggests,canholdthepositionoftwolegs
openedouttoaparticulardegreeunlessmovedbycertainforce.Thisis
possiblebecauseofhigherfrictioninthejointformedbetweenthetwo
legsofthecaliper.Alocknutisneededtolockthecaliperinaparticular
position.
❑Ontheotherhand,aspringcalipercanholdaparticularpositionthanksto
thespringpressureactingagainstanadjustingnut.Thispermitsvery
carefulcontrolandnolockisneeded..
Linear and Angular Measurement
73
Non-GraduatedLinearMeasurement-Calipers
Linear and Angular Measurement
75
Non-GraduatedLinearMeasurement-SpecialPurposeGauges
ScrewPitchGauges(consistingofametalcasecontainingmanyseparate
leaves.Eachleafhasteethcorrespondingtoadefinitepitch.Bymatchingthe
teethwiththethreadonwork,thecorrectpitchcanbereaddirectlyfromthe
leaf)
TapandDrillGauges(consistingofaflatrectangular
steelplatewithholesaccuratelydrilledandidentified
accordingtotheirsize)
Radius Gauges (available as individual leaves and each
leaf is marked with its radius. They are designed to check
both convex and concave radii)
Linear and Angular Measurement
76
Non-GraduatedLinearMeasurement-Slip Gauge
Linear and Angular Measurement
77
Non-GraduatedLinearMeasurement-Rectangular Gauge Blocks
Slip Gauge Box
Slipgaugesarerectangular
blocksofsteelhavingacross-
sectionofabout30by10mm
Normalset
Range Step Pieces
1.001 to
1.009
0.001 9
1.01 to 1.09 0.01 9
1.1 to 1.9 0.1 9
1 to 9 1 9
10 to 90 10 9
Total 45
Linear and Angular Measurement
78
Non-GraduatedLinearMeasurement-Rectangular Gauge Blocks
Slip Gauge Box-Special Set
Range Step Pieces
1.001 to 1.009 0.001 9
1.01 to 1.49 0.01 49
1.5 to 9.5 0.5 19
10 to 90 10 9
Total 86
Classification
▪AA slip gauges
▪A slip gauges and
▪B slip gauges
1.AA slip gauges
Master slip gauges
Accurate to plus or minus two microns per meter
2.A slip gauges
Reference purpose
Type A is guaranteed accurate up to plus or minus four microns per
meter
3.B slip gauges
Working slip gauges
Type 'B' for plus or minus eight microns per meter
Linear and Angular Measurement
79
AngularMeasurement
Linear and Angular Measurement
80
AngularMeasurement–Sine Bars
Linear and Angular Measurement
81
AngularMeasurement–Sine Bars
Linear and Angular Measurement
82
AngularMeasurement–Sine Bars
Linear and Angular Measurement
83
AngularMeasurement–Sine Bars
Linear and Angular Measurement
84
AngularMeasurement–Sine Bars
Linear and Angular Measurement
85
AngularMeasurement–Sine Bars
Linear and Angular Measurement
86
AngularMeasurement–Sine Bars
Linear and Angular Measurement
87
AngularMeasurement–Sine Bars
Linear and Angular Measurement
89
AngularMeasurement–Rollers
Linear and Angular Measurement
90
AngularMeasurement–Rollers
Linear and Angular Measurement
91
AngularMeasurement–Rollers
Linear and Angular Measurement
92
AngularMeasurement–Rollers
Linear and Angular Measurement
93
AngularMeasurement–Sprit Level
Linear and Angular Measurement
94
AngularMeasurement–Sprit Level
❑Characteristicelementofalevel
❑Sensitivity:expressedastheangleoftiltinsecondsfor
whichbubblewillmovebyonedivisiononthetube
❑Sensitivity=Angleinseconds/1divisionoftube
❑Constantofspritlevel:changeintilt,expressedin
mm/m
❑Accuracyoflevel:baseshouldbeflatwithinprescribed
limits
❑Errors:duetoerrorinthevial,curvaturebeingnon-
uniform,scalepositionedincorrectlyandtemperature
variations
Linear and Angular Measurement
95
AngularMeasurement–Angles Gauges
Linear and Angular Measurement
96
AngularMeasurement–Angles Gauges
Linear and Angular Measurement
97
AngularMeasurement–Protractor
Linear and Angular Measurement
98
AngularMeasurement–UniversalBevelProtractor
Linear and Angular Measurement
99
AngularMeasurement–UniversalBevelProtractor
Linear and Angular Measurement
100
AngularMeasurement–UniversalBevelProtractor
Linear and Angular Measurement
101
AngularMeasurement–UniversalBevelProtractor
Linear and Angular Measurement
102
AngularMeasurement–UniversalBevelProtractor
Linear and Angular Measurement
103
AngularMeasurement–UniversalBevelProtractor
Linear and Angular Measurement
104
AngularMeasurement–OpticalBevelProtractor
Linear and Angular Measurement
105
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
106
AngularMeasurement–OpticalInstruments
Autocollimator
❑Infinitytelescopeandcollimatorcombinedinto
one
❑Anopticalinstrumentusedforsmallangular
differences
❑Providesverysensitiveandaccurateapproach
Application
▪Measurementofstraightnessandflatness
▪Preciseangularindexing
▪Assessmentofsquareness
▪Parallelismofcomponents
Linear and Angular Measurement
107
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
108
AngularMeasurement–OpticalInstruments
Autocollimator
Linear and Angular Measurement
109
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
110
AngularMeasurement–OpticalInstruments
Autocollimator
Linear and Angular Measurement
111
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
112
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
113
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
114
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
115
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
116
AngularMeasurement–OpticalInstruments
Linear and Angular Measurement
117
Comparators
1)Mechanical comparators
2)Electrical comparators
3)Optical comparators
4)Pneumatic comparators
Linear and Angular Measurement
118
Comparators –Mechanical comparators
❑Itisaprecisioninstrumentemployedtocomparethedimensionofagiven
componentwithaworkingstandard
❑Itdoesnotmeasuretheactualdimensionbutindicateshowmuchitdiffersfrom
thebasicdimension
Linear and Angular Measurement
119
Comparators –
Mechanical comparators
Linear and Angular Measurement
120
Comparators –Electrical comparators
Linear and Angular Measurement
121
Comparators –
Electrical comparators
❑Thesecomparatorsdependonthe
principleofbalancingthe
Wheatstonebridge,(R
1/R
2)=
(R
3/R
4)applicableforonlyto
directcurrentobtainedfroma
battery.
Linear and Angular Measurement
122
Comparators –Electronic Comparators
Linear and Angular Measurement
123
Comparators –Electronic Comparators
Linear and Angular Measurement
124
Comparators –Optical Comparators
Linear and Angular Measurement
125
Comparators –Optical Comparators
Linear and Angular Measurement
126
Comparators –Pneumatic Comparators
❑InPneumaticcomparatorsairisusedasameansof
magnificationandhencetheyuseprincipleofairjet.
❑AchamberisfittedwithcontrolorificeCanda
gaugingorificeGthroughwhichairflowsfroma
supplyataconstantpressureP
1.
❑IfthesizeofthecontrolorificeCremainsconstant,
anyvariationinsizeofGwillcausealterationof
pressureP
2inthechamber.
❑Thisvariationismeasuredbyasuitablepressure
gaugegraduatedtoreadinlinearunits.
Linear and Angular Measurement
127
Comparators –Pneumatic Comparators
❑Basedonthephysicalphenomenon,
pneumaticcomparatorsareclassifiedas;(a)
Floworvelocitytype(b)Backpressuretype
❑Flowtypesoperatebysensing&indicating
themomentaryrateofflow.
Systems of Pneumatic comparators
❑Compressedairafterfiltering&
pressureregulationflowsthrougha
glasstubewithasmallmetalfloat.
❑Theairthenpassesthroughaplastic
tubetothegaugeheadwithtwo
diametricallyoppositeorificesforthe
airtoescape.
Linear and Angular Measurement
128
Comparators –Pneumatic Comparators
Systems of Pneumatic comparators
Linear and Angular Measurement
129
Comparators –Pneumatic Comparators
Back pressure type Pneumatic Comparators
Linear and Angular Measurement
130
Comparators –Pneumatic Comparators
Back pressure type Pneumatic ComparatorsConstant
pressure
source
P1 P2
To atmosphere
O
c mO
Principle of back pressure type Pneumatic comparator
Back Pressure Circuit
Air supply
Filter
Regulator
Bourdon tube
Scale
Work piece
Measuring head