Unit 2 Linear and Angular Measurement

Syllabus
Definition of metrology

Linear measuring instruments: Vernier, micrometer and interval measurement- Slip gauges and classification. Interferometer, optical flats and limit gauges Comparators: Mechanical, pneumatic and electrical types, applications. Angular measurements: -Sine bar, optical bevel protractor ,Taper measurements

Definition

Metrology is the name given to the science of pure measurement.

Engineering Metrology is restricted to measurements of length & angle

Linear and Angular Measurement

The Linear Measurement includes measurements of length, diameters, heights and thickness

The Angular measurement includes the measurement of angles or tapers

Measurements

Measurement systems are mainly used in industries for quality control.

Often widely using measurements are

Linear Measurement Angular measurement

Dimensions
A very common measurement is that of dimensions, i.e., length, width, height of an object Dimensions of the measuring instruments are classified as follows

Low resolution devices (up to 0.25mm) Medium resolution devices (up to 0.0025mm) High resolution devices (less than microns)

Low resolution devices

Steel rule Steel rule with assistance of

Calipers Dividers & Surface gauges

Thickness gauges

Medium resolution devices

Micrometer Micrometer with assistance of

Telescoping Extendable ball gauges

Vernier calipers Dial indicators Microscope

High resolution devices

Gauge blocks Gauge block with assistance of

Mechanical comparator Electronic comparator Pneumatic comparator Optical flats

Linear Measuring Instruments

Vernier caliper Micrometer Slip gauge or gauge blocks Optical flats Interferometer Comparators

Vernier caliper

Components of vernier calipers are

Main scale Vernier scale Fixed jaw Movable jaw

Types of vernier calipers

Type A vernier caliper Type B vernier caliper Type C vernier caliper

Type A Vernier Caliper

Type B Vernier Caliper

Type C Vernier Caliper

VERNIER CALIPER

Vernier calipers are available in size of 150

mm, 225 mm, 900 mm and 1200 mm.

The selection of the size depends on the

measurements to be taken.

Vernier calipers are precision instruments,

and extreme care should be taken while

handing them.

Vernier caliper
VERIER CALIPER WITH 0.02MM LEAST COUNT IS GENERLY USED IM 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 (MSD) 1. Vernier scale division (VSD) Least count is 1mm 49\50 =1\50 mm THE DIFFERENCE BETWEEN 1.MSD and 1. VSD=0.02MM =49\50 mm =1 mm

Example
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

Vernier Depth Gauge

A vernier depth is very commonly used precision instrument for measuring depth of holes recesses, slot and step. Its construction and method of reading are similar to those of a vernier caliper.

VERNIER DEPTH GAUGE

Base Graduated beam Clamping screw Fine adjustment mechanism Vernier scale

VERNIER HEIGHT GAUGE

The main parts of a vernier height gauge and their function are given. 1.base 2. beam 3.vernier slide 4. fine setting device 5. vernier plate 6. locking screws 7. scriber

MICRO METER

A micro meter is a precision instrument used to measure a job, generally within an accuracy of 0.01mm.Micrometer used to take the outside measurements are know as outside micrometer.

PARTS OF MICROMETER

Frame Anvil and spindle Screwed spindle Graduated sleeve or barrel Ratchet or friction stop Spindle clamp

Interval measurements

Slip gauges Interferometer Optical flats and limit gauges Comparators

SLIP GAUGE
Slip gauges are rectangular blocks of steel having a cross-section of about 30 by 10 mm Normal set

Range 1.001 to 1.009 1.01 to 1.09 1.1 to 1.9 1 to 9 Step 0.001 0.01 0.1 1 Pieces 9 9 9 9

10 to 90

10
Total

9
45

Special Set
Range 1.001 to 1.009 1.01 to 1.49 1.5 to 9.5 10 to 90 Step 0.001 0.01 0.5 10 Total Pieces 9 49 19 9 86

Classification

AA slip gauges A slip gauges and B slip gauges

AA slip gauges
Master slip gauges Accurate to plus or minus two microns per meter

A slip gauges
Reference purpose Type A is guaranteed accurate up to plus or minus four microns per meter

B slip gauges
Working slip gauges Type 'B' for plus or minus eight microns per meter

Classes

Grade 2 Grade 1 Grade 0 Grade 00 Calibration grade

Grade 2

This is the workshop grade Typical machine cutters width. uses tools, and include setting up

positioning

milling

checking

mechanical

Grade 1

Used for more precise work, -tool room.

Typical uses include setting up

Sine bars and sine tables Checking gap gauges and Setting dial test indicators to zero

Grade 0

This is more commonly known as the Inspection grade

Inspection Department only who have access to this grade of slips

Grade 00

This grade would be kept in the Standard Room and would be kept for work of the highest precision only.

Determination of any errors present in the workshop or Grade 2 slips.

Calibration grade

Calibration grade are used for calibration of slip gauges, other measuring instruments

Interferometer

Principle
Interferometers are optical instruments used for measuring flatness Determining minute differences in length by direct reference to the wavelength of light.

Principle of interferometer

Fringes

Fringes

Fringes

A
Here the error is indicated by the amount by which the fringes are out of parallelism with those on the base plate

B
If the work piece is concave or convex, fringe pattern will be as shown in Figure (b).

C
The surface is flat with slight rounding off at the corner

Optical flats

Optical flats can be used to measure the flatness

An optical reference flat of known quality

A monochromatic light box

Solvent and cleaning material

Typical setup of optical flat

Working

Fringe Pattern

Air wedges Flatness error of zero Cylinder with flatness error of two fringes Contact method Convex Cylinder Concave Cylinder Convex Sphere Concave Sphere Convex Spheroid Concave Spheroid Saddle Highly Irregular

Air wedge

Flatness error of zero (a)

(a) (b) Cylinder with flatness error of two fringes (b)

Contact method

Convex Cylinder

Concave Cylinder

Saddle

Highly Irregular

Application

Front and rear surface mirrors gauge blocks Bearings Seals and Anvils

Limit gauges

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Gauges
Basic dimension: exact size of part from which all limiting variations made Limits: maximum and minimum dimensions Tolerance: permissible variation of part

unilateral: one direction only Bilateral: both plus and minus (two directions)

Allowance: intentional difference in dimensions of mating parts

50

Fixed Gauges

Used for inspection purposes

Provide quick means of checking specific dimension

Easy to use and accurately finished to required tolerance

Generally finished to ten times the tolerance designed to control

51

Cylindrical Plug Gauges

Go

Dimensions usually stamped on handle at each end. "go" end longer than "no-go" for easy identification Many made with carbide tips to increase gauge life

52

Cylindrical Plug Gauges

53

Cylindrical Plug gauge

54

Plain Ring Gauges

Used to check outside diameter of pieces Ground and lapped internally to desired size

Size stamped on side of gauge

Outside diameter knurled and "no-go" end identified by annular groove on knurled surface Precautions and procedures similar to

55

Plain Ring gauges

56

Taper Plug Gauges

Used to check size of hole and taper accuracy Made with standard or special tapers Some have "go" and "no-go" rings scribed

gauge fits into hole between two rings means within required tolerance

57

Taper Plug and Ring Gauges

58

Thread Plug Gauges

Used for checking internal threads of the "go" and "no-go" variety Based on same principle as cylindrical plug gauges "go" end (longer end)

Should be turned in flush to bottom of hole

"no-go" end
Should just start into hole and become snug before third thread enters
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Thread Plug Gauges

60

Thread Ring Gauges

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Snap Gauges
One of most common types of comparative measuring instruments Faster to use than micrometers Limited in their application Used to check diameters within certain limits by comparing part size to preset dimension of snap gauge

62

Snap Gauges
Have C-shaped frame with adjustable gauging anvils or rolls set to "go" and "no-go" limits of the part Several styles

63

FEELER GAUGE

A feeler gauge (also known as a thickness gauge) is an accurately manufactured strip of metal that is used to determine the gap or clearance between two components.

FEELER GAUGE

A feeler gauge can be used to check the following:

Piston ring gap Piston ring side clearance Connecting rod side clearance

Feeler gauges are most commonly made of high-quality carbon steel, and are machined to a very smooth surface finish. Other blade materials are available, including stainless steel, brass, and plastic. Metal blades have better wear resistance and will maintain their accuracy after many uses

Radius Gauge

A radius gauge is a tool used to measure the radius of an object.

67

Thread Pitch Gauge

It used to quickly determine the pitch of various threads by matching the teeth on the leaves with teeth on the work.

68

Comparators

Mechanical comparators Electrical comparators Optical comparators Pneumatic comparators

Mechanical comparators

It is a precision instrument employed to

compare the dimension of a given

component with a working standard

It

does

not

measure

the

actual

dimension but indicates how much it

differs from the basic dimension

Electrical comparators

Electrical& Electronic Comparators

R1 R2

R3

R4

Coils Arm Battery

Coils

Iron Armature

Measuring Plunger

These comparators depend on the principle of balancing the Wheatstone bridge, (R1/R2) = (R3/R4) applicable for only to direct current obtained from a battery

Optical comparator

Pneumatic comparators
In Pneumatic comparators air is used as a means of magnification and hence they use principle of air jet. A chamber is fitted with control orifice C and a gauging orifice G through which air flows from a supply at a constant pressure P1. If the size of the control orifice C remains constant, any variation in size of G will cause alteration of pressure P2 in the chamber.

Air @ constant Pr P1

C (Control orifice) Chamber

To pressure gauge Pressure P2

G (Gauging orifice)

Workpiece

Principle of Pneumatic comparator

Systems of Pneumatic comparators

Based on the physical phenomenon, Pneumatic comparators are classified as; (a) Flow or velocity type (b) Back pressure type Flow types operate by sensing & indicating the momentary rate of flow. Compressed air after filtering & pressure regulation flows through a glass tube with a small metal float. The air then passes through a plastic tube to the gauge head with two diametrically

Pneumatic comparators (contd)

Plastic tube Scale Float Filter Pr regulator

Bore to be measured

Air supply Gauging head

Flow or Velocity type Comparator

Back pressure type Pneumatic Comparators

Oc Constant pressure source P1 P2 Om To atmosphere

Principle of back pressure type Pneumatic comparator Scale Bourdon tube Work piece

Regulator Filter Air supply

Back Pressure Circuit

Measuring head

Solex Pneumatic gauge

Air filter Air Control orifice

Scale Excess air bubbling at top Dip tube

Plug with measuring jaws

Water tank Manometer workpiece

Solex Pneumatic gauge

ANGULAR MEASUREMENT

Sine bar, optical bevel protractor ,Taper measurements

Sine bars

A sine bar is a tool used to measure angles in metalworking. It consists of a hardened, precision ground body with two precision ground cylinders fixed at each end, the rollers are positioned at a precise distance and the top of the bar is parallel to the center line of the rollers. The dimension between the two rollers is chosen to be a whole number (for ease of later calculations)

Sine bars

Autocollimator

Compiled by

D.Vasanth Kumar Assistant Professor Department of Mechanical Engineering Jansons Institute of Technology