Precision Measuring Tools

TABLE OF CONTENTS

INTRODUCTION
THE NEED FOR ACCURACY IN MEASURING
CARE OF MEASURING TOOLS
TYPES OF MEASUREMENTS
Linear Measurement
Round Work Measurement
Polar Measurement
LECTURE PROPER
Straight Edges/ Hook Rulers/ Meter Stick
How to Read Ruler Graduations
Metric
English
Conversions
Metric To English
English to Metric
Practical measurement Work shop
CALIPERS
Classification Of Calipers As To Use
Inside Calipers
Outside Calipers
Types Of Calipers As To Construction
Measuring With A Caliper
Setting And Reading With A Caliper
Practical Measurement Work Shop
MICROMETERS
Classification of Micrometers
Inside Micrometers
Outside Micrometers
Depth Micrometers
Principle of the Micrometer
How To Hold Micrometers
How To Read The Graduations Of The Micrometers
Practical Measurement Work shop
VERNIER CALIPER
Uses Of The Vernier Caliper
How To Read Graduations Of The Vernier Caliper
Practical Measurement Work Shop

Universal Bevel Protractor With A Vernier

Uses Of Universal Bevel Protractor
Parts of the Universal Bevel Protractor
How To Read Graduations Of The Universal Bevel Protractor
Practical Measurement Work Shop
Gage Blocks/ Filler Gages
Uses Of Gage Blocks/ Filler Gages
How To Measure With Gage Blocks/ Filler Gages
Practical Measurement Work Shop
DIAL INDICATORS
Uses Of Dial Indicators
How To Read Graduations Of The Dial Indicator
Practical Measurement Work Shop

Chapter 1
Introduction
The Need for Accuracy in Measuring.
Personnel in machine works should begin at once to understand
accuracy in its relative terms. He should appreciate from the start the value of
the various measuring tools in obtaining the degree of accuracy the given
operations demands. There is no more reason why we should not use a
micrometer the moment we return to our work places.
Care of Measuring Tools.
It goes without saying that precision measuring tools should be handled
with the greatest care. Good tools are made of hardened steel and will stand a
lifetime of one without breakage, but the accuracy of even the finest tool can
be quickly impaired by careless or abusive treatment. In working with
measuring tolls, be careful to avoid accidental scratches or nicks that will
obscure graduations or distort surfaces. Rust is the enemy of all finely finished
surfaces. Tools should be wiped clean of fingerprints after using and kept in
separate boxes or cases. A light dressing of oil applied with a soft, lint-free
cloth will protect tools in storage.
Types of Measurement
Linear Measurement

Linear measurements on flat surfaces are perhaps the most common

measurements made in general practice in the machine shop. The tools varies
with the sizes of the dimension, the nature of the work, and the degree of
accuracy required. It may range from a steel tape, rule, divider or trammel to a
micrometer or vernier caliper. The measurement may be made direct as with
steel rule or slide caliper. Many related tools such as straight edges, steel
squares, and protractors are used in conjunction with linear measuring tools to
determine flatness, squareness and angularity.
Round Work Measurement

For round work, measurements are usually made by contact, using tolls
with contact point or surfaces such as spring calipers, micrometers, and
vernier calipers. Contact measurements are made in two ways: (1) by presetting the tool to the required dimensions, using a steel rule, micrometer, or
other tool as a gage, and then comparing the set dimensions with the actual
size of the work: and (2) the reverse of this method, first setting the contact
points to the surfaces of the work and then using a steel rule, vernier caliper
to read the size. The first method is generally preferred where repeated test
must be made, such as in machining a piece of a given size, or when
checking the same dimension on a number of identical parts. The second

method is preferred for determining the actual size of the piece of an accurate
measure of variation from a required standard.
Polar Measurement

Measurement in degrees is widely used in engineering and the physical

sciences, particularly astronomy, navigation, and surveying. The usual means
of locating a star or a point on the surface of the earth is by its angular
distance in degrees, minutes, and seconds from certain fixed points or lines.
Positions on the surface of the earth are measured in degrees of latitude north
and south of the equator and degrees of longitude east and west of the prime
meridian, which is usually taken arbitrarily as the meridian that passes through
Greenwich, England.
Degree, in trigonometry, arc equalling 1/360 of the circumference of a
circle, or the central angle subtended by such an arc. The degree is the
common unit of measurement for angles and for arcs of a circle. It is divided
into 60 minutes, each equal to 1/21,600 of the circumference of a circle; each
minute is divided into 60 seconds, each equal to 1/1,296,000 of the
circumference of a circle. Degrees are usually indicated by the symbol ,
minutes by , and seconds by , as in 411809, 41 degrees 18 minutes 9
seconds.

Chapter 2
Lecture Proper:

Straight edges/ Hook Rulers/ Meter Stick/ Steel Squares

Among the most useful tools in the shop are the steel rulers. Although
these are actually rules or rulers, most machinists call them scales. They are
made in a variety of kinds such as springs tempered, flexible, narrow, and
hooked, and in lengths from 1 to 48 in. The most popular the spring tempered
6 in. rule.
How to Read Ruler Graduations
Metric

Most steel rules are graduated. That is marked by fine lines upon each
edge of both sides, and often at the ends, in different subdivisions of a meter.
The different graduations are classified by number. For the graduation many
shopsmen prefer meter, centimeter, and millimeter.
English

Most steel rules are graduated. That is marked by fine lines upon each
edge of both sides, and often at the ends, in different subdivisions of an inch.
The different graduations are classified by number. For the graduation many
shopsmen prefer, have 64th, 32nd , 16th, and 8th.
Conversions
English

1 MILE
1 YARD
1 FOOT

5280 FEET
3
FEET
12 INCHES

Metric

1 KILOMETER
1 METER
1 CENTIMETER

1000
100
1000
10

METER
CENTIMETER
MILLIMETER
MILLIMETER

Metric to English
Metric- English

1 KILOMETER

0.6214 MILE
1093 YARDS

3280.8 FEET
1.0936 YARDS
3.281
FEET
39.37 INCHES
0.3937 INCHES
0.03937 INCHES

1 METER

1 CENT-METER
1 MILLI-METER

English to Metric
English- Metric

1 MILE

1 YARD

1 FOOT
1 INCH

Practical Measurement Work Shop

1.6093 KILO-METER
1609 METER
160900 CENTI-METER
1609000 MILLI-METER
.09146 METER
9.146 CENTIMETER
91.46 MILLI-METER
30.48 CENTI-METER
304.8 MILLI-METER
2.54 CENTIMETER
25.4 MILLI-METER

Calipers
A caliper is a tool used measuring diameters. It is always used with a
steel scale and at times with a micrometer. The caliper itself can not be
directly as a steel scale and therefore, when a measurement is taken with a
caliper, the opening is measured on the steel scale or micrometer.

Classification of Calipers as to Use:

Inside Calipers

Calipers that have measuring end of the legs curving outwardly and are
used to measure inside dimension such as the diameter of a hole.
Outside Calipers

Calipers that have measuring ends of the legs curving inwardly so that
no part of the legs except the ends ever contact the part being measured.

Types of Calipers as to Construction

Spring Joint

Firm Joint calipers

Are similar in construction to the spring type except that the legs are
held in a set position by means of a friction joint. Firm joint calipers are
particularly convenient in making large measurements.

Transfer Calipers
Are calipers used for making measurement of recesses or diameters,
which are larger than the opening through which the caliper is inserted. They
are provided with an auxiliary arm against which the one leg bears, thereby
allowing collapsing of the leg for removal from the hole while preserving the
measurement.

Hermaphrodite Calipers
Caliper that have one inside or outside leg and one leg terminating in a
divider point. They are used for such layout work as scribing a line parallel to
a shoulder edge, and may be either of the spring or form joint type.
Measuring with a Caliper
Accurate use of calipers requires considerable practice and the
development of a sense of touch. To get a delicate sense of touch of a caliper
on the work, it should be held lightly and not with a grab-grip. If the caliper
will just barely hang on the work without falling off, the pressure is about right.
It is possible to force calipers over or into work by using too much pressure,
and thus introduce an error in reading.
When measuring with outside calipers, the axis of the calipers should
be held perpendicular to the axis of the work. With inside calipers, the axes of
work and calipers should coincide. It is particularly important with inside
calipers that the tips of both feet bear on the work, not one foot and the side
of the opposite leg.
Never caliper the work while it is moving or revolving; it is not
accurate and the caliper may get caught and be broken.
Calipers are not efficient for accurate measurements, but they are
efficient for measuring stock, roughing cuts, lengths, and any dimensions that

need not be extremely accurate. The caliper may be used if necessary for
every close measurement, but it is easier, quicker, and surer to use a
micrometer.
Setting and Reading with a Caliper
To set an outside caliper hold the rule in the left hand with the end
against the little finger in such a position that the light falls directly on the
scale. Hold the caliper in the right hand, in such a position that it may be
adjusted by the adjusting nut between the thumb and finger. Place the end of
one leg of the caliper against the end of the scale and against the finger so
that it will not slip around, and then adjust the other leg to the desired
graduation on the rule. Hold the caliper true and looking squarely at the end to
be set to the line, adjust the caliper until the end seems to split the line.
A firm joint caliper is held in about the same way but must be adjusted
by tapping lightly against some solid object.
To read an outside caliper it is held substantially as above except that
as it is not to be adjusted, the adjusting screw should not be touched.
Calipers are not efficient for accurate measurements, but they are
efficient for measuring stock, roughing cuts, lengths and any other dimensions
that need not be extremely accurate. The caliper may be used if necessary for
very close measurements, but it is easier and quicker and surer to use a
micrometer and a gage.

Practical Measurement Work Shop

Micrometers
Micrometer is probably the most commonly used precision device in the
industry for obtaining measurements of the order 0.001 to 0.0001 inch its
measuring accuracy is based on an accurate screw and a fixed nut. The
micrometer is composed of a U- shaped frame, the ends of one leg of which
carries a fixed anvil, the other leg carrying a tubular member or barrel. The
micrometer nut is fixed in the barrel and is slotted and provided with a tapered
thread and nut at its outer end to allow adjustment for wear. The measuring
spindle and screw are integral, being supported on the nut at the threaded
end and in an accurately fitted hole in the frame of the spindle end. To the
outer end of the spindle is fastened a shell or thimble, which extends over the
turns around the barrel. The measurement is made between the faces of the
anvil and spindle.

Micrometers are made in a variety of sizes ranging from in. to about

48 in., however, the one most commonly used is the 1 in. size for
measurements from 0.001 to 1.000 in. they are made also in a variety of
styles such as outside micrometers, thread micrometers, and depth
micrometers.
Classification of Micrometers
They are made also in a variety of styles such as outside micrometers,
inside micrometers, thread micrometers, and depth micrometers.
Inside Micrometers

Inside micrometers are used for measuring the diameters of holes and
other inside dimensions larger than 1 inch and up 0 several feet, inside
micrometers are provided that measure from anvils placed at the end of the
thimble and barrel. By means of interchangeable measuring rods a wide range
of measurement multiple of 1 inch so that measurement are possible from
minimum to maximum size by 0.001 inch intervals.
Outside Micrometers

Outside micrometers are used for measuring the diameters and other
outside dimensions. For measuring diameters outside dimensions larger than
1 inch and up 0 several feet, inside micrometers are provided that measure
from anvils placed at the end of the thimble and barrel. By means of
interchangeable measuring rods a wide range of measurement multiple of 1
inch so that measurement are possible from minimum to maximum size by
0.001 inch intervals.

Depth Micrometers

It is used for measuring depth of holes and slots or the distance from
surface to the other. It is similar in general construction to the rule depth gage
and vernier depth gage except that a micrometer head is used for measuring.
A base whose lower surface is at right angles to the micrometer axis is
fastened to the micrometer barrel and is used as reference point. A measuring
rod is encased in the hollow screw and is clamped by means of a chuck at the
end of a thimble at one of several scribed graduations of the rod. The distance
between the graduations is equal to the micrometer screw movement so that
a range of measurements from zero to several inches by intervals of 1.001
inch is possible by clamping the rod progressively at the separate scribed
graduations. Each graduation on the rod is a V groove into which fingers in
the chuck fit for accurately locating the rod.

Other types of micrometers depth gages are made with several

interchangeable measuring rods of different lengths in contrast to a single rod
with spaced grooves.
Principle of the Micrometer
The basis of the tool is an accurate screw, which can be revolved, in a
fixed nut to vary the opening between the two measuring faces, at the end of
the screw spindle and the other on the anvil. The graduations on the barrel
and thimble indicate precisely the position of the screw spindle and the
amount of opening between the measuring faces. The thimble rotates with the
screw spindle and travels along the barrel. The graduations on the beveled
edge of the thimble accurately subdivide each revolution of the screw so that
readings may be taken in units, usually of 0.001 in. or 0.01 in.
How to Hold Micrometers
Figure x-xx indicates clearly the proper way to hold the micrometer in
order to accurately measure a piece held in the hand. Note carefully the
position of the fingers; the micrometer is held by the little finger or the third
finger, whichever is less awkward, against the palm of the hand, which allows
the spindle to be operated in either direction with the thumb and index finger.
The correct way to hold a micrometer when measuring work not held in the
hand, is shown in figure 3-38.
When making a measurement be sure the micrometer is held square
across the diameter. Turn the spindle down to the work, but not down too
hard. It is easy to spring a micrometer 0.001 or 0.002 inch and this not only
gives a false measurement but also injures the micrometer.
It seems easy for some people occasionally to read a micrometer 0.025
over or under; such a mistake is inexcusable. It is even more careless to add
25 and 5 and call it 35, or 75 and 5 and read it 85. Be careful when using a
micrometer to hold it properly, to adjust it carefully, and to read it accurately.
The ratchet stop. In the use of the micrometer, the measuring pressure
is dependent on the operators sense of feel. Errors of 0.0001 to 0.0003 inch
may be introduced in a measurement as a result of this factor. In order to
overcome this source of error, a device known as a ratchet stop is provided
for use with the micrometer. Attached to the end of the thimble, it serves as a
constant-torque turning means. The outer knurled member, when turned,
exerts a turning force on the thimble through ratchet teeth under spring
pressure. When the spindle and anvil contact the part to be measured and the
correct pressure has been reached, the ratchet teeth will slip, preventing
further pressure from being applied. Ratchet stops are set to give a measuring
pressure of approximately 25 lb per square in. of spindle face area.
How to Read the Graduations of the Micrometers
The instructions that follow on hoe to read a micrometer caliper apply
to a micrometer that reads thousandths of an inch only. How to read a

micrometer graduated in ten- thousandths of an inch. There are ten

longitudinal spaces laid out on the sleeve. This set of spaces is the vernier
scale by means of which a reading as fine as 0.0001 inch can be made.
Figure 3-46 is an enlarged view of the barrel showing the vernier scale.
The vernier scale is used in reading a micrometer whenever the
longitudinal line on the spindle does not coincide, that is, is not in alignment
with the line on the thimble.
A vernier scale, consisting of 10 spaces running parallel to the
longitudinal lines on the sleeve, covers exactly nine of the spaces on the
beveled edge of the thimble. These lines are numbered from 0 to 0 (meaning
from 0 to 10).
Since the 10 spaces or divisions of the vernier equal to the overall
space of nine divisions of the thimble, then one division on the vernier equals
1/10 of 9/10,000 inch (0.0009 inch).
Graduations on the thimble, then one division on the vernier equals
1/1000 or 10/10,000 inch. The difference between one division on the thimble
and one division on the barrel is therefore (10/10,000) - (9/10,000) or 1/10,000
or 0.0001 in.
The zero lines of the vernier and the thimble coincide when the reading
is exact in thousandths and the difference between lines on the thimble and
the lines on the vernier at 1, 2,3 etc. equals 0.0001 in. 0.0002 in. etc. thus as
the 1, 2, 3, etc., vernier lines coincide with any thimble line, the thimble has
moved past the exact setting 1, 2, 3, etc., ten thousandths of an inch.
Practical Measurement Work Shop

Vernier Caliper
The vernier caliper is a measuring tool much used in machine shops,
especially in tool and die making departments where fine exact work is done.
The vernier caliper is wrench like and has a scale that allows direct reading of
the adjusted width between the jaws of the wrench. The vernier caliper is
similar in principle to the caliper rule described before except that the vernier
scale is added for making precision measurements. IN addition, much greater
refinements are made in the quality of the device with respect to the accuracy
of the graduations, the squareness and parallelism of the jaw, and the fit of
the movable jaw on the bar. The width of graduations on vernier devices are
smaller than those on rules, being of the order of .003 or .004 in. it will be
evident that in order to use the vernier caliper to the observed accuracy some
degree of skill and judgment is necessary.
Uses of the Vernier Caliper
The vernier caliper is used for making inside as well as outside
measurements. The ends of the jaws are provided with nibs that are ground
on the outside to a radius less than the smallest inside diameter which may be
measured.
How to Read Graduations of the Vernier Caliper
The vernier consists of a fixed scale and a vernier scale, which is
movable in relation to the former. The vernier scale makes possible the

accurate reading of a measurement to a fractional part of the smallest division

on the fixed scale and therefore converts a scale into a precision device.
Although a vernier scale can theoretically be designed to indicate to very small
fractions of length, it is limited practically to about 0.001 in. when applied to
simple scales.

Practical Measurement Work Shop

Universal Bevel Protractor with a Vernier

Uses of Universal Bevel Protractor
A Universal Bevel Protractor is a measuring tool used to measure
angles. With the help of a vernier, it will measure angles accurately.
Parts of the Universal Bevel Protractor
How to Read Graduations of the Universal Bevel Protractor
Figure x-xx show part of a vernier protractor. The upper scale is the
one showing degrees, each tenth degree being numbered. The lower scale is
the vernier, each line being equal to degree or 5 minutes. Each space on
the vernier is 5 minutes shorter than two spaces on the scale.
When the zero on the vernier exactly coincides with the graduation on
the scale, the reading is in the exact degrees. When the graduation marked 0
on the vernier does not exactly coincide with any graduation on the scale, the
graduation on the vernier that does coincide with any graduation on the scale
indicates the number of twelfths of a degree to be added to the whole degree
reading.

Practical Measurement Workshop

Gage Blocks/ Filler Gages

Uses of Gage Blocks/ Filler Gages
A set of gage blocks usually used in machine shops where extreme
accuracy is desired. They are rectangular blocks of steel very carefully
hardened and finished. Their surfaces are so fine and parallel that when
rubbed together in the proper manner they will stick together.
Each block is very accurate to within a few millionth of an inch. They
are very often referred to as precision or gage blocks. Whenever accuracy is
desired to four decimal places in any length or height dimension, these blocks
are used. For example, if a machinist has a dimension of 2.467 in. that he has
to use in setting up a job and that dimensions has to be very accurate, he
makes a combination of various size blocks whose total will equal 2.467 in.
Precision blocks have other uses like checking the accuracy of
measuring tools such as micrometers and vernier calipers. It is good practice
on the part of machinists to have their measuring instruments checked
occasionally for accuracy.
How to Measure with Gage Blocks/ Filler Gages
To build up any dimension using gage blocks, the first consideration is
to use a few blocks as possible. The second point to be remembered is
always to work from right to left of the decimal point when making the
combination. In other words, eliminate the last figure in the dimension sought
firs. A typical set of 81 blocks divided into the following:
1 block - 0. 050 in
10 blocks - 0.100 in. to 0.1009 in. by 0.0001 in. steps

50 blocks - 0.101 in. to 0.150 in. by 0. 001 in steps

16 blocks - 1. 200 in. to 0. 950 in. steps
4 blocks - 1. 000 in. to 4. 000 in. by 1 in. steps

Example: Set up the 1. 3247 in. dimension

Step 1
Step 2

Step 3

Step 4
Step 5

Write the dimension on paper

Eliminate the last figure to the right of the
decimal point by selecting a block with a 7
in. the fourth place. In this case, use the
0.1007 block. This amount still to be
accounted for. The size of the block is
written in the last column on the right for
addition to prove our problem
Result
Eliminate the last figure to the right other
than zero
Result
Eliminate the last figure again
Result
Eliminate the 1.000
Result

1.3247
0.1007

check
0.1007

1. 2240
0. 112

0. 112

1.1300
0.13
1.000
1.000
0.000

0.130
1.000
1.3427

Practical Measurement Work Shop

Dial Indicators
Dial indicator is an instrument in which the movement of a spring
loaded measuring spindle is magnified by means of a rack and train of gears
which actuate a pointer on a graduated dial. Typically scale graduations are
0.001, 0.0005, and 0.0001 in. for various types and sizes while the
magnification varies from about 50 to one to 1250 to one. The rim of the dial
or bezel is rotatable so that for a certain setting the zero on the scale may be
brought opposite the position of the pointer for convenient reading. Although
the dial indicator is a direct measuring type of device, it is commonly used as
a measurement from a standard figure.
Uses of Dial Indicators
dial indicator has many common uses. It may be used as a means of
checking run out or out of roundness of a piece rotated between centers or to
check the trueness of the rotating part of a machine either by a clamp or by
means of a heavy base to which it is attached. In a similar manner it may be
used to set or check the parallelism of one surface with respect to another.
When mounted to a base and upright commonly known as test set, it may be
used on a surface plate to test the size straightness, and parallelism of parts.
Built- in dial indicators are frequently used in such devices as calipers, snap
gages, bore gages, thickness gages, height gages, and bench comparators
for determining variations in size from a master or standard.
How to Read Graduations of the Dial Indicators

Practical Measurement work Shop