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Mechanical Measurement & Metrology
Course Contents
1.1 Introduction
1.2 Need Of Inspection
1.3 Objectives of Metrology
1.4 Precision And Accuracy
1.5 Errors in Measurement
1.6 General Care Of Metrological
Instrument
1.7 Standardization and
Standardizing Organization
1. Introduction Mechanical Measurement & Metrology
1.1 Introduction
 Metrology is a science of measurement. Metrology may be divided depending upon the
quantity under consideration into: metrology of length, metrology of time etc.
Depending upon the field of application it is divided into industrial metrology, medical
metrology etc.
 Engineering metrology is restricted to the measurement of length, angles and other
quantities which are expressed in linear or angular terms.
 For every kind of quantity measured, there must be a unit to measure it. This will enable
the quantity to be measured in number of that unit. Further, in order that this unit is
followed by all; there must be a universal standard and the various units for various
parameters of importance must be standardized.
 It is also necessary to see whether the result is given with sufficient correctness and
accuracy for a particular need or not. This will depend on the method of measurement,
measuring devices used etc.
 Thus, in a broader sense metrology is not limited to length and angle measurement but
also concerned with numerous problems theoretical as well as practical related with
measurement such as:
1. Units of measurement and their standards, which is concerned with the establishment,
reproduction, conservation and transfer of units of measurement and their standards.
2. Methods of measurement based on agreed units and standards.
3. Errors of measurement.
4. Measuring instruments and devices.
5. Accuracy of measuring instruments and their care.
6. Industrial inspection and its various techniques.
7. Design, manufacturing and testing of gauges of all kinds.
1.2 Need of Inspection

 Inspection means checking of all materials, products or component parts at various
stages during manufacturing. It is the act of comparing materials, products or
components with some established standard.
Page 1.2
Mechanical Measurement & Metrology 1. Introduction
 In old days the production was on a small scale, different component parts were made
and assembled by the same craftsman. If the parts did not fit properly at the time of
assembly, he used to make the necessary adjustments in either of the mating parts so
that each assembly functioned properly.
 Therefore, it was not necessary to make similar parts exactly alike or with same accuracy
as there was no need of inspection.
 Due to technological development new production techniques have been developed.
The products are being manufactured on a large scale due to low cost methods of mass
production. So, hand fit method cannot serve the purpose any more. The modern
industrial mass production system is based on interchangeable manufacture, when the
articles are to be produced on a large scale.
 In mass production the production of complete article is broken up into various
component parts. Thus the production of each component part becomes an
independent process. The different component parts are made in large quantities in
different shops. Some parts are purchased from other factories also and then assembled
together at one place. Therefore, it becomes essential that any part chosen at random
should fit properly with any other mating parts that too selected at random. This is
possible only when the dimensions of the component parts are made with close
dimensional tolerances. This is only possible when the parts are inspected at various
stages during manufacturing.
 When large number of identical parts are manufactured on the basis of
interchangeability if their dimensions are actually measured every time lot of time will
be required. Hence, to save the time gauges are used, which can tell whether the part
manufactured is within the prescribed limits or not.
Thus, the need of inspection can be summarized as:
1. To ensure that the part, material or a component conforms to the established standard.
2. To meet the interchangeability of manufacture.
3. To maintain customer relation by ensuring that no faulty product reaches the
customers.
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4. Provide the means of finding out shortcomings in manufacture. The results of inspection
are not only recorded but forwarded to the manufacturing department for taking
necessary steps, so as to produce acceptable parts and reduce scrap.
5. It also helps to purchase good quality of raw materials, tools, equipment which governs
the quality of the finished products.
6. It also helps to co-ordinate the functions of quality control, production, purchasing and
other departments of the organization.
To take decision on the defective parts i.e., to judge the possibility of making some of
these parts acceptable after minor repairs.
1.3 Objectives of Metrology

While the basic objective of a measurement is to provide the required accuracy at
minimum cost, metrology would have further objective in a modern engineering plant
with different shops like Tool Room, Machine Shop, Press Shop, Plastic Shop, Pressure
Die Casting Shop, Electroplating and Painting Shop, and Assembly Shop; as also
Research, Development and Engineering Department. In such an engineering
organization, the further objectives would be as follows:
1. Thorough evaluation of newly developed products, to ensure that components designed
is within the process and measuring instrument capabilities available in the plant.
2. To determine the process capabilities and ensure that these are better than the relevant
component tolerance.
3. To determine the measuring instrument capabilities and ensure that these are adequate
for their respective measurements.
4. To minimize the cost of inspection by effective and efficient use of available facilities and
to reduce the cost of rejects and rework through application of Statistical Quality Control
Techniques
5. Standardization of measuring methods. This is achieved by laying down inspection
methods for any product right at the time when production technology is prepared.
6. Maintenance of the accuracies of measurement. This is achieved by periodical
calibration of the metrological instruments used in the plant.
7. Arbitration and solution of problems arising on the shop floor regarding methods of
measurement.
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8. Preparation of designs for all gauges and special inspection fixtures.

Development of Material Standard
 The need for establishing standard of length was raised primarily for determining
agricultural land areas and for the erection of buildings and monuments. The earliest
standard of length was established in terms of parts of human body. The Egyptian unit
was called a cubit. It was equal to the length of the forearm (from the elbow to the tip of
the middle figure).
 Rapid advancement made in engineering during nineteenth century was due to
improved materials available and more accurate measuring techniques developed. It
was not until 1855 that first accurate standard was made in England. It was known as
imperial standard yard. This was followed by International Prototype meter made in
France in the year 1872. These two standards of lengths were made of material (metal
alloys) and hence they are called as material standards in contrast to wavelength
standard adopted as length standard later on.
Imperial Standard Yard
 The imperial standard yard is made of 1 inch square cross-section bronze bar (82%
copper, 13% tin, 5% zinc) 38 inches long. The bar has two 1/2 inch diameter X 1/2 inch
deep holes. Each hole is fitted with 1/10th inch diameter gold plug. The top surface of
these plugs lie on the neutral axis of the bronze bar.
The purpose of keeping the gold plug lines at neutral axis has the following advantages.
- Due to bending of beam the neutral axis remains unaffected
- The plug remains protected from accidental damage.
The top surface of the gold plugs is highly polished and contains three lines engraved
transversely and two lines longitudinally.
The yard is defined as the distance between two central transverse lines on the plugs
when,
1. The temperature of the bar is constant at 62°F and,
2. The bar is supported on rollers in a specified manner to prevent flexure.
Page 1.5
Figure 1.1 Imperial Standard Yards

International Standard Meter (Prototype)
 This standard was established originally by International Bureau of Weights and
Measures in the year 1875. The prototype meter is made of platinum-iridium alloy (90%
platinum and 10% iridium) having a cross-section as shown in Fig. 1.2.
 The upper surface of the web is highly polished and has two fine lines engraved over it.
It is in-oxidisable and can have a good finish required for ruling good quality of lines. The
bar is kept at 0°C and under normal atmospheric pressure. It is supported by two rollers
of at least one cm diameter symmetrically situated in the same horizontal plane. The
distance between the rollers is kept 589 mm so as to give minimum deflection. The web
section chosen gives maximum rigidity and economy of costly material. The distance
between the centers portions of two lines engraved on the polished surface of this bar
of platinum-iridium alloy is taken as one meter.
 According to this standard, the length of the meter is defined as the straight line
distance, at 0°C between the centre portions of pure platinum-iridium alloy (90%
platinum, 10% iridium) of 102 cm total length and having a web cross-section as shown
in Fig. 1.2.
Page 1.6
Figure 1.2 International Prototype Meter Cross-sections

 The metric standard when in use is supported at two points which are 58.9 cm apart as
calculated from Airy's formula, according to which the best distance between the
supporting points is given by
√
Where, L = total length of bar (assumed uniform), b = distance between points, n =
number is supports
 For prototype meter,
√
 This reference was designated as International Prototype Meter M in 1899. It is
preserved by (BIPM) at Sevres in France. The BIPM is controlled by the International
Committee of Weights and Measure.
 The imperial standard yard was found to be decreasing in length at the rate of one-
millionth of an inch for the past 50 years when compared with internal standard meter.
The prototype meter is quite stable. There-fore, yard relationship had to be defined in
terms of meter as 1 yard = 0.9144 meter, or inch = 25.4 mm.
Disadvantages of Material Standard
1. The material standards are influenced by effects of variation of environmental
conditions like temperature, pressure, humidity and ageing etc., and it thus changes in
length.
2. These standards are required to be preserved or stored under security to prevent their
damage or destruction.
3. The replica of these standards was not available for use somewhere else.
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4. These are not easily reproducible.

5. Conversion factor was to be used for changing over to metric working.
6. Considerable difficulty is experienced while comparing and verifying the sizes of gauges.
Wavelength Standard
 The major drawback with the metallic standards meter and yard is that their length
changes slightly with time. Secondly, considerable difficulty is experienced while
comparing and verifying the sizes of gauges by using material standards. This may lead
to errors of unacceptable order of magnitude. It therefore became necessary to have a
standard of length which will be accurate and invariable. Jacques Babinet a French
philosopher suggested that wavelength of monochromatic light can be used as natural
and invariable unit of length.
 In 1907 the International Angstrom (A) unit was defined in terms of wavelength of red
cadmium in dry air at 15°C (6438.4696 A = 1 wavelength of red cadmium). Seventh
General Conference of Weights and Measures approved in 1927, the definition of
standard of length relative to the meter in terms of wavelength of the red cadmium as
an alternative to International Prototype meter.
 Orange radiation of isotope krypton-86 was chosen for new definition of length in 1960,
by the Eleventh General Conference of Weights and Measures. The committee decided
to recommend that Krypton-86 was the most suitable element and that it should be
used in a hot-cathode discharge lamp maintained at a temperature of 63° Kelvin.
According to this standard meter was defined as equal to 1650763.73 wavelengths of
the red orange radiation of Krypton isotope 86 gases.
 The standard as now defined can be reproduced to an accuracy of about 1 part in 109.
The meter and yard were redefined in terms of wave length of orange Kr-86 radiation as,
1 meter = 1650763.73 wavelengths, and
1 yard = 0.9144 meter
= 0.9144 x 1650763.73 wavelengths
= 1509458.3 wavelengths.
Page 1.8
Meter as of Today
 Although Krypton-86 standard served well, technologically increasing demands more
accurate standards. It was through that a definition based on the speed of light would be
technically feasible and practically advantageous. Seventeenth General Conference of
Weights and Measure. Agreed to a fundamental change in the definition of the meter on
20th October 1983.
 Accordingly, meter is defined as the length of the path travelled by light in vacuum in
1/299792458 seconds. This can be realized in practice through the use of an iodine-
stabilized helium-neon laser.
 The reproducibility is 3 parts in 1011, which may be compared to measuring the earth's
mean circumference to an accuracy of about 1 mm. With this new definition of meter,
one standard yard will be the length of the path travelled by light travelled in 0.9144 x
1/299792458 sec. I. e., in 3 x 10-9 sec.
The advantages of wavelength standard are:
1. It is not a material standard and hence it is not influenced by effects of variation of
environmental conditions like temperature, pressure, humidity and ageing.
2. It need not be preserved or stored under security and thus there is no fear of being
destroyed as in case of meter and yard.
3. It is not subjected to destruction by wear and tear.
4. It gives a unit of length which can be produced consistently at all the times in all the
circumstances, at all the places. In other words it is easily reproducible and thus identical
standards are available with all.
5. This standard is easily available to all standardizing laboratories and industries.
6. There is no problem of transferring this standard to other standards meter and yard.
7. It can be used for making comparative measurements of very high accuracy. The error of
reproduction is only of the order of 3 parts in 1011
Subdivision of standards
The international standard yard and the international prototype meter cannot be used
for general purposes. For practical measurement there is a hierarchy of working
standards. Thus depending upon their importance of accuracy required, for the work the
standards are subdivided into four grades;
1. Primary standards 2. Secondary standards
Page 1.9
[Type text] [Type text] [Type text]
3. Territory standards 4. Working standards.

1. Primary Standards
For precise definition of the unit, there shall be one, and only one material standard, which
is to be preserved under most careful conditions. It is called as primary standard.
International yard and International meter are the examples of primary standards. Primary
standard is used only at rare intervals (say after 10 to 20 years) solely for comparison with
secondary standards. It has no direct application to a measuring problem encountered in
engineering.
2. Secondary Standards
Secondary standards are made as nearly as possible exactly similar to primary standards as
regards design, material and length. They are compared with primary standards after long
intervals and the records of deviation are noted. These standards are kept at number of
places for safe custody. They are used for occasional comparison with tertiary standards
whenever required.
3. Tertiary Standards
The primary and secondary standards are applicable only as ultimate control. Tertiary
standards are the first standard to be used for reference purposes in laboratories and
workshops. They are made as true copy of the secondary standards. They are used for
comparison at intervals with working standards.
4. Working Standards
Working standards are used more frequently in laboratories and workshops. They are
usually made of low grade of material as compared to primary, secondary and tertiary
standards, for the sake of economy. They are derived from fundamental standards. Both
line and end working standards are used. Line standards are made from H-cross-sectional
form.
Figure 1.3 Working Line Standards

Most of the precision measurement involves the distance between two surfaces and not
with the length between two lines. End standards are suitable for this purpose. For shorter
Page 1.10
lengths up to 125 mm slip gauges are used and for longer lengths end bars of circular cross-
section are used. The distance between the end faces of slip gauges or end bars is controlled
to ensure a high degree of accuracy.
Sometimes the standards are also classified as:
1. Reference standards- Used for reference purposes.
2. Calibration standards - Used for calibration of inspection and working standards.
3. Inspection standards - Used by inspectors.
4. Working standards - Used by operators, during working.
Line and End Measurements
A length may be measured as the distance between two lines or as the distance between
two parallel faces. So, the instruments for direct measurement of linear dimensions fall into
two categories.
1. Line standards. 2. End standards.
Line Standards
When the length is measured as the distance between centers of two engraved lines, it is
called line standard. Both material standards yard and meter are line standards. The most
common example of line measurements is the rule with divisions shown as lines marked on
it.
Characteristics of Line Standards
1. Scales can be accurately engraved but the engraved lines themselves possess thickness and
it is not possible to take measurements with high accuracy.
2. A scale is a quick and easy to use over a wide range.
3. The scale markings are not subjected to wear. However, the leading ends are subjected to
wear and this may lead to undersize measurements.
4. A scale does not possess a "built in" datum. Therefore it is not possible to align the scale
with the axis of measurement.
5. Scales are subjected to parallax error.
6. Also, the assistance of magnifying glass or microscope is required if sufficient accuracy is to
be achieved.
End standards
When length is expressed as the distance between two flat parallel faces, it is known as end
standard. Examples: Measurement by slip gauges, end bars, ends of micrometer anvils,
Page 1.11
vernier calipers etc. The end faces are hardened, lapped flat and parallel to a very high
degree of accuracy.
Characteristics of End Standards
1. These standards are highly accurate and used for measurement of close tolerances in
precision engineering as well as in standard laboratories, tool rooms, inspection
departments etc.
2. They require more time for measurements and measure only one dimension at a time.
3. They are subjected to wear on their measuring faces.
4. Group of slips can be "wrung" together to build up a given size; faulty wringing and careless
use may lead to inaccurate results.
5. End standards have built in datum since their measuring faces are f l at and parallel and can
be positively locked on datum surface.
6. They are not subjected to parallax effect as their use depends on feel.
Comparison between Line Standards and End Standards:
Sr.
Characteristic Line Standard End Standard
No.
1. Principle Length is expressed as the Length is expressed as
distance between two lines the distance between
two flat parallel faces
2. Accuracy Limited to ± 0.2 mm for high Highly accurate for
accuracy, scales have to be used measurement of close
in conjunction with magnifying tolerances up to ± 0.001
glass or microscope mm.
3. Ease and time Measurement is quick and easy Use of end standard
& requires skill and is time
measurement consuming.
4. Effect of wear Scale markings are not subject to These are subjected to
wear. However, significant wear wear on their measuring
may occur on leading ends. Thus surfaces.
it may be difficult to assume zero
of scale as datum.
5. Alignment Cannot be easily aligned with the Can be easily aligned
Page 1.12
axis of measurement. with the axis of
measurement.
6. Manufacture Simple to manufacture at low Manufacturing process is
and cost cost. complex and cost is high.
7. Parallax effect They ate subjected to parallax They ate not subjected
error to parallax error
8. Examples Scale (yard, meter etc.) Slip gauges, end bars, V-
caliper, micrometers etc.
The accuracy of both these standards is affected by temperature change and both are
originally calibrated at 20 ± 0.5°C. It is also necessary to take utmost case in their
manufacture to ensure that the change of shape with time, secular change is reduced to
negligible.
Classification of Standards and Traceability
 In order to maintain accuracy and interchangeability in the items manufactured by various
industries in the country, it is essential that the standards of units and measurements
followed by them must be traceable to a single source, i.e., the National Standards of the
country. Further, the National Standards must also be linked with International Standard to
maintain accuracy and interchangeability in the items manufactured by the various
countries.
 The national laboratories of well-developed countries maintain close tolerance with
International Bureau of Weights and Measures, there is assurance that the items
manufactured to identical dimensions in different countries will be compatible.
Application of precise measurement has increased to such an extent that it is not
practicable for a single national laboratory to perform directly all the calibrations and
standardizations required by a large country. It has therefore become necessary that the
process of traceability technique needs to be followed in stages, that is, National
laboratories, standardizing laboratories, etc. need to be established for country, states, and
industries but all must be traceable to a single source as shown in Fig. 1.4 below.
Page 1.13
Figure 1.4 Classifications of Standards in Order

Clearly, there is degradation of accuracy in passing from the defining standards to the
standard in use. The accuracy of a particular standard depends on a combination of the
number of times it has been compared with a standard of higher order, the recentness of
such comparisons, the care with which it was done, and the stability of the particular
standard itself
Measuring system element
A measuring system is made of five basic elements. These are:
1. Standard
2. Work piece
3. Instrument
4. Person
5. Environment.
The most basic element of measurement is a standard without which no measurement is
possible. Once the standard is chosen a measuring instrument incorporations this standard
is should be obtained. This instrument is then used to measure the job parameters, in terms
of units of standard contained in it. The measurement should be performed under standard
environment. And, lastly, there must be some person or mechanism (if automatic) to carry
out the measurement.
Methods of Measurement
Page 1.14
These are the methods of comparison used in measurement process. In precision
measurement various methods of measurement are adopted depending upon the accuracy
required and the amount of permissible error.
The methods of measurement can be classified as:
1. Direct method 6. Coincidence method
2. Indirect method 7. Deflection method
3. Absolute/Fundamental method 8. Complementary method
4. Comparative method 9. Contact method
5. Transposition method 10. Contactless method etc.
1. Direct method of measurement.
This is a simple method of measurement, in which the value of the quantity to be measured
is obtained directly without any calculations. For example, measurements by using scales,
vernier calipers, micrometers, bevel protector etc. This method is most widely used in
production. This method is not very accurate because it depends on human insensitiveness
in making judgment.
2. Indirect method of measurement.
In indirect method the value of quantity to be measured is obtained by measuring other
quantities which are functionally related to the required value. E.g. angle measurement by
sine bar, measurement of screw pitch diameter by three wire method etc.
3. Absolute or Fundamental method.
It is based on the measurement of the base quantities used to define the quantity. For
example, measuring a quantity directly in accordance with the definition of that quantity, or
measuring a quantity indirectly by direct measurement of the quantities linked with the
definition of the quantity to be measured.
4. Comparative method.
In this method the value of the quantity to be measured is compared with known value of
the same quantity or other quantity practically related to it. So, in this method only the
deviations from a master gauge are determined, e.g., dial indicators, or other comparators.
5. Transposition method.
It is a method of measurement by direct comparison in which the value of the quantity
measured is first balanced by an initial known value A of the same quantity, and then the
value of the quantity measured is put in place of this known value and is balanced again by
another known value B. If the position of the element indicating equilibrium is the same in
Page 1.15
both cases, the value of the quantity to be measured is√ . For example, determination of
a mass by means of a balance and known weights, using the Gauss double weighing
method.
6. Coincidence method.
It is a differential method of measurement, in which a very small difference between the
value of the quantity to be measured and the reference is determined by the observation of
the coincidence of certain lines or signals. For example, measurement by vernier caliper
micrometer.
7. Deflection method.
In this method the value of the quantity to be measured is directly indicated by a deflection
of a pointer on a calibrated scale.
8. Complementary method.
In this method the value of the quantity to be measured is combined with a known value of
the same quantity. The combination is so adjusted that the sum of these two values is equal
to predetermined comparison value. For example, determination of the volume of a solid by
liquid displacement.
9. Method of measurement by substitution.
It is a method of direct comparison in which the value of a quantity to be measured is
replaced by a known value of the same quantity, so selected that the effects produced in
the indicating device by these two values are the same.
10. Method of null measurement.
It is a method of differential measurement. In this method the difference between the value
of the quantity to be measured and the known value of the same quantity with which it is
compared is brought to zero.
11. Contact method.
In this method the sensor or measuring tip of the instrument actually touches the surface to
be measured. e.g., measurements by micrometer, vernier caliper, dial indicators etc. In such
cases arrangement for constant contact pressure should be provided to prevent errors due
to excessive contact pressure.
Page 1.16
12. Contactless method.
In contactless method of measurement, the there is no direct contact with the surface to be
measured. e.g., measurement by optical instruments, such as tool makers microscope,
projection comparator etc.
1.4 Precision and Accuracy

Precision
 The terms precision and accuracy are used in connection with the performance of the
instrument. Precision is the repeatability of the measuring process.
 It refers to the group of measurements for the same characteristics taken under identical
conditions. It indicates to what extent the identically performed measurements agree with
each other. If the instrument is not precise it will give different (widely varying) results for
the same dimension when measured again and again. The set of observations will scatter
about the mean. The scatter of these measurements is designated as 0, the standard
deviation. It is used as an index of precision. The less the scattering more precise is the
instrument. Thus, lower, the value of 0, the more precise is the instrument.
Accuracy
 Accuracy is the degree to which the measured value of the quality characteristic agrees with
the true value. The difference between the true value and the measured value is known as
error of measurement.
 It is practically difficult to measure exactly the true value and therefore a set of observations
is made whose mean value is taken as the true value of the quality measured.
Distinction between Precision and Accuracy
 Accuracy is very often confused with precision though much different. The distinction
between the precision and accuracy will become clear by the following example. Several
measurements are made on a component by different types of instruments (A, B and C
respectively) and the results are plotted.
 In any set of measurements, the individual measurements are scattered about the mean,
and the precision signifies how well the various measurements performed by same
instrument on the same quality characteristic agree with each other.
Page 1.17
Figure 1.5 Precision And Accuracy
 The difference between the mean of set of readings on the same quality characteristic and
the true value is called as error. Less the error more accurate is the instrument. Figure 1.5
shows that the instrument A is precise since the results of number of measurements are
close to the average value. However, there is a large difference (error) between the true
value and the average value hence it is not accurate.
 The readings taken by the instruments are scattered much from the average value and
hence it is not precise but accurate as there is a small difference between the average value
and true value. Fig. 1.5 (c) shows that the instrument is accurate as well as precise.
1.5 Errors in Measurement

 It is never possible to measure the true value of a dimension, there is always some error.
The error in measurement is the difference between the measured value and the true value
of the measured dimension.
Page 1.18
 Error in measurement =Measured value - True value. The error in measurement may be
expressed or evaluated either as an absolute error or as a relative error.
Absolute Error
 True absolute error. It is the algebraic difference between the result of measurement and
the conventional true value of the quantity measured.
 Apparent absolute error. If the series of measurement are made then the algebraic
difference between one of the results of measurement and the arithmetical mean is known
as apparent absolute error.
Relative Error
 It is the quotient of the absolute error and the value of comparison used for calculation of
that absolute error. This value of comparison may be the true value, the conventional true
value or the arithmetic mean for series of measurement.
The accuracy of measurement, and hence the error depends upon so many factors, such as:
- Calibration standard
- Work piece
- Instrument
- Person
- Environment etc. as already described.
No matter, how modern is the measuring instrument, how skillful is the operator, how accurate
the measurement process, there would always be some error. It is therefore attempted to
minimize the error. To minimize the error, usually a number of observations are made and their
average is taken as the value of that measurement.
 If these observations are made under identical conditions i.e., same observer, same
instrument and similar working conditions excepting for time, then, it is called as Single
Sample Test'.
 If however, repeated measurements of a given property using alternate test conditions,

such as different observer and/or different instrument are made, the procedure is called as
`Multi-Sample Test'. The multi-sample test avoids many controllable errors e.g., personal
error, instrument zero error etc. The multi-sample test is costlier than the single sample test
and hence the later is in wide use.
Page 1.19
 In practice good numbers of observations are made under single sample test and statistical
techniques are applied to get results which could be approximate to those obtainable from
multi-sample test.
Types of Error
During measurement several types of error may arise, these are
1. Static errors which includes
- Reading errors
- Characteristic errors
- Environmental errors.
2. Instrument loading errors.
3. Dynamic errors.
Static errors
These errors result from the physical nature of the various components of measuring
system. There are three basic sources of static errors. The static error divided by the
measurement range (difference between the upper and lower limits of measurement) gives
the measurement precision.
Reading errors
Reading errors apply exclusively to the read-out device. These do not have any direct
relationship with other types of errors within the measuring system.
Reading errors include: Parallax error, Interpolation error.
Attempts have been made to reduce or eliminate reading errors by relatively simple
techniques. For example, the use of mirror behind the readout pointer or indicator virtually
eliminates occurrence of parallax error.
Interpolation error.
It is the reading error resulting from the inexact evaluation of the position of index with
regards to two adjacent graduation marks between which the index is located. How
accurately can a scale be readthis depends upon the thickness of the graduation marks, the
spacing of the scale division and the thickness of the pointer used to give the reading
Interpolation error can be tackled by increasing; using magnifier over the scale in the
viscinity of pointer or by using a digital read out system.
Page 1.20
Characteristic Errors
It is defined as the deviation of the output of the measuring system from the theoretical
predicted performance or from nominal performance specifications.
Linearity errors, repeatability, hysteresis and resolution errors are part of characteristic
errors if the theoretical output is a straight line. Calibration error is also included in
characteristic error.
Loading Errors
Loading errors results from the change in measurand itself when it is being measured, (i.e.,
after the measuring system or instrument is connected for measurement). Instrument
loading error is the difference between the value of the measurand before and after the
measuring system is connected/contacted for measurement. For example, soft or delicate
components are subjected to deformation during measurement due to the contact pressure
of the instrument and cause a loading error. The effect of instrument loading errors is
unavoidable. Therefore, measuring system or instrument should be selected such that this
sensing element will minimize instrument loading error in a particular measurement
involved.
Environmental Errors
These errors result from the effect of surrounding such as temperature, pressure, humidity
etc. on measuring system.
External influences like magnetic or electric fields, nuclear radiations, vibrations or shocks
etc. also lead to environmental errors.
Environmental errors of each component of the measuring system make a separate
contribution to the static error. It can be reduced by controlling the atmosphere according
to the specific requirements.
Dynamic Errors
Dynamic error is the error caused by time variations in the measurand. It results from the
inability of the system to respond faithfully to a time varying measurement. It is caused by
inertia, damping, friction or other physical constraints in the sensing or readout or display
system.
For statistical study and the study of accumulation of errors, these errors can be broadly
classified into two categories
1. Systematic or controllable errors, and
2. Random errors.
Page 1.21
Systematic Errors
Systematic errors are regularly repetitive in nature. They are of constant and similar form.
They result from improper conditions or procedures that are consistent in action. Out of the
systematic errors all except the personal error varies from individual to individual depending
on the personality of observer. Other systematic errors can be controlled in magnitude as
well as in sense. If properly analyzed they can be determined and reduced. Hence, these are
also called as controllable errors.
Systematic errors include:
1. Calibration Errors. These are caused due to the variation in the calibrated scale from its
normal value. The actual length of standards such as slip gauge and engraved scales will vary
from the nominal value by a small amount. This will cause an error in measurement of
constant magnitude. Sometimes the instrument inertia and hysteresis effect do not allow
the instrument to transit the measurement accurately. Drop in voltage along the wires of an
electric meter may include an error (called single transmission error) in measurement.
2. Ambient or Atmospheric conditions (Environmental Errors). Variation in atmospheric
condition (i.e., temperature, pressure, and moisture content) at the place of measurement
from that of internationally agreed standard values (20° temp. and 760 mm of Hg pressure)
can give rise to error in the measured size of the component. Instruments are calibrated at
these standard conditions; therefore error may creep into the given result if the atmosphere
conditions are different at the place of measurement. Out of these temperatures is the
most significant factor which causes error in, measurement due to expansion or contraction
of component being measured or of the instrument used for measurement.
3. Stylus Pressure. Another common source of error is the pressure with which the work
piece is pressed while measuring. Though the pressure involved is generally small but this is
sufficient enough to cause appreciable deformation of both the stylus and the work piece.
In ideal case, the stylus should have simply touched the work piece. Besides the
deformation effect the stylus pressure can bring deflection in the work piece also.
Variations in force applied by the anvils of micrometer on the work to be measured results
in the difference in its readings. In this case error is caused by the distortion of both
micrometer frame and work-piece.
4. Avoidable Errors. These errors may occur due to parallax, non-alignment of work piece
centers, improper location of measuring instruments such as placing a thermometer in
Page 1.22
sunlight while measuring temperature. The error due to misalignment is caused when the
centre line of work piece is not normal to the centre line of the measuring instrument.
5. Random Errors. Random errors are non-consistent. They occur randomly and are
accidental in nature. Such errors are inherent in the measuring system. It is difficult to
eliminate such errors. Their specific cause, magnitudes and source cannot be determined
from the knowledge of measuring system or conditions of measurement.
The possible sources of such errors are:
1. Small variations in the position of setting standard and work piece.
2. Slight displacement of lever joints of measuring instruments.
3. Operator error in scale reading.
4. Fluctuations in the friction of measuring instrument etc.
Comparison between Systematic Errors and Random Errors
Systematic Errors Random Errors
These errors are repetitive in nature and These are non-consistent. The sources
are of constant and similar form giving rise to such errors are random.
These errors result from improper Such errors are inherent in the measuring
conditions or procedures that are system or measuring instruments.
consistent in action.
Except personal errors, all other Specific causes, magnitudes and sense of
systematic errors can be controlled in these errors cannot be determined from
magnitude and sense. the knowledge of measuring system or
condition.
If properly analyzed these can be These errors cannot be eliminated, but the
determined and reduced or eliminated. results obtained can be corrected.
These include calibration errors, variation These include errors caused due to
in contact pressure, variation in variation in position of setting standard
atmospheric conditions, parallax errors, and work-piece, errors due to
misalignment errors etc. displacement of lever joints of
instruments, errors resulting from
backlash, friction etc.
Errors likely to creep in Precision Measurements
Page 1.23
The standard temperature for measurement is 20°C and all instruments are calibrated at
this temperature. If the measurements are carried out at temperature other than the
standard temperature, an error will be introduced due to expansion or contraction of
instrument or part to be measured. But if the instrument and the work piece to be
measured are of same material, accuracy of measurement will not be affected even if the
standard temperature is not maintained. Since both will expand and contract by the same
amount.
The difference between the temperature of instrument and the work piece will also
introduce an error in the measurement, especially when the material of the work piece or
instrument has higher coefficient of expansion. To avoid such errors, instrument and the
work piece to be measured should be allowed to attain the same temperature before use
and should be handled as little as possible. For example, after wringing together several slip
gauges to form a stock for checking a gauge, they should be left with the gauge for an hour,
if possible preferably on the table of the comparator which is to be used for performing the
comparison.
To attain accurate results, high grade reference gauges should be used only in rooms where
the temperature is maintained very close to the standard temperature.
Handling of gauges changes its temperature, so they should be allowed to stabilize.
There are two situations to be considered in connection with the effect of temperature,
these are:
(a) Direct measurement. Let us consider a gauge block being measured directly by
interferometry. Here, the effect of using a non-standard temperature produces a
proportional error, E = l  (t - ts), where
- L = nominal length
-  = coefficient of expansion
- (t - ts) = deviation from standard temperature
- t = temperature during measurement
- ts = standard temperature
(b) Comparative measurement. If we consider two gauges whose expansion coefficients are
respectively α1 and α2, then the error due to nonstandard temperature will be, Error, E = l
(α1 - α2) (t - ts)
Page 1.24
As the expansion coefficients are small numbers, the error will be very small as long as both
parts are at the same temperature. Thus, in comparative measurement it is important that
all components in the measuring system are at the same temperature rather than
necessarily at the standard temperature.
Other ambient conditions may affect the result of measurement. For example, if a gauge
block is being measured by interferometry, then relative humidity, atmospheric pressure
and CO2 of the air affects the refractive index of the atmosphere. These conditions should all
be recorded during the measurement and the necessary correction made.
Internationally accepted temperature for measurement is 20°C and all instruments are
calibrated at this temperature. To maintain such controlled temperature, the laboratory
should be air-conditioned.
Effect of supports
When long measuring bars, straight edges are supported as beam, they are defected or
deformed. This elastic deformation occurs because a long bar, supported at to ends sags
under their own weight. This problem was considered by Sir G.B. Airy, who showed that the
position of the supports can be arranged to give minimum error. The amount of deflection
depends upon the positions of the supports.
Figure 1.6 Effect of support

Two conditions are considered, as shown in Fig. 1.7,
(1) A bar of length L supported, equidistant from the centre. In this case the slope at the
ends of the bar is zero. For minimum deflection, the distance between the supports should
be 0.554 times the length of the bar S = 0.544 L or S/L = 0.544
(a) Line standard and End bars (slope at ends zero)
Page 1.25
(b) Straight edges (deflection at ends equals’ deflection).

Figure 1.7 Support Positions for Different Conditions of Measurement
(2) A straight edge of length L supported, equidistant from the centre. The straight edges
are used to check the straightness and flatness of the parts. They are maker of H section.
In this case the deflection at the ends is equal to the deflection at the centre. For minimum
deflection the distance between the supports should be 0.577 times the length i.e. for any
points
Effect of alignment
Abbe's alignment principle: It states that "the axis or line of measurement should coincide
with the axis of measuring instrument or line of the measuring scale."
If while measuring the length of a work piece the measuring scale is inclined to the true line
of the dimension being measured there will be an error in the measurement.
The length recorded will be more than the true length. This error is called "Cosine error". In
many cases the angle 0 is very small and the error will be negligible.
Page 1.26
Figure 1.8 (A) And (B) Effect of Misalignment

The cosine error may also, occur while using dial gauge, if the axis of the pointer is not along
the direction of measurement of work. Also, when in indicator is fitted with a ball-end stylus
form, the arm should be so set that the direction of movement of the work is tangential to
the arc along which the ball moves, otherwise cosine error will be introduced.
The combined cosine and sine error will occur if the micrometer axis is not truly
perpendicular to the axis of the work piece (Refer Fig. 1.9). The same error occurs while
measuring the length of the end gauge in a horizontal comparator if the gauge is not
supported so that its axis is parallel to the axis of the measuring or anvils or if its ends,
though parallel to each other are not square with ends.
Page 1.27
Figure 1.9 Combined Sines and Cosine Error

Referring Fig.1.9, if D = true diameter, L =apparent length, d = micrometer anvil diameter
Then D = (L cos θ) - d sin θ = L cos θ – d sin θ
And error, = L – D = L – (L cos θ – d sin θ) = L (1- cos θ) + d sin θ
The errors of above nature are avoided by using with spherical ends.
Contact pressure
The variation in the contact pressure between the anvils of the instrument and the work
being measured produce considerable difference in reading. Though the pressure involved is
generally small, but it is sufficient enough to came appreciable deformation of both the
anvil (and stylus) and the work piece. The deformation of the work piece and the anvils of
instrument depend -upon the contact pressure and the shape of the contact surfaces. When
there is a surface contact between the instrument anvils and work piece, there is very little
deformation, but when there is a point contact the deformation is appreciable.
Figure 1.10 Effect of Contact Pressure on Measurement

Fig. 1.10 shows the error caused by combined deformation of the stylus and the work piece.
Page 1.28
To minimize this error the development of correct feel is one of the skills to be acquired by
the inspector. To avoid this effect of contact pressure the micrometer is fitted with a ratchet
mechanism to apply the correct pressure during measurement. The ratchet slips when the
applied pressure exceeds the minimum required operating pressure.
Parallax Error
A very common error that may occur in an instrument while taking the readings is parallax
error.
Parallax error occurs when:
 The line of vision is not directly in line with the measuring scale
 The scale and the pointer are separated from each other (hot in the same plane).
Refer Fig. 1.11
Let d = separation of scale and pointer
D = distance between the pointer and eye of the observer
Ѳ = angle which the line of sight makes with the normal to scale.
Figure 1.11 Parallax Errors
Now generally, Ѳ is small therefore, tan Ѳ = Ѳ and error e = dѲ.

For least error d should be minimum possible, value of Ѳ can be reduced to zero by placing
mirror behind the pointer which ensures normal reading of scale.
Dust
Page 1.29
The dust present in the atmosphere may change the reading by a fraction of micron, where
accuracy of the order of micron is desired such as while using slip gauges the effect of dust
can be prevented by
1. Incorporating electrostatic precipitators in laboratory or in the air ducts in addition to air
filters.
2. The work pieces and masters should be cleaned by clean chamois or by a soft brush.
3. Gauges should never be touched with moist fingers.
4. The contact surfaces should be sprayed with suitable filtered clean solvent.
Errors due to vibrations
Vibrations may affect the accuracy of measurement. The instrument anvil will not give
consistent and repetitive reading if it is subjected to vibration.
For eliminating or reducing effect of vibration on measurement, the following precautions
should be taken:
1. The laboratory should be located away from the sources of vibration.
2. Slipping cork, felt, rubber pads should be used under the gauge.
3. Putting a gauge on a surface plate resting in turn on a heavy plate also reduces the effect of
vibrations.
4. Precision measurement -should be carried out away from shop floor.
5. Errors due to location
The part to be measured is located on a table or a surface plate which forms the datum for
comparison with the standard. The reading taken by the comparator is thus the indication of
the displacement of the upper surface of the measured part from the datum. If the datum
surface is not flat, or if the foreign matter such as dirt, chips etc. are present between the
datum and the Work piece surface then error will be introduced in the reading taken.
Figure 1.12 Surface Displacements
Error due to poor contact
Page 1.30
Fig. 1.13 shows how the poor contact between the working gauge or instrument and the
work piece causes an error. Although, everything feels all right, yet the error is bound to
occur. To avoid this type of error the gauge with wide area of contact should not be used
while measuring irregular or curved surface and correct pressure should be applied while
making the contact.
Figure 1.13 Errors Due To Poor Contact

Error due to wear in gauges
The measuring surfaces of instrument such as the anvils of the micrometer are subjected to
wear due to repeated use. The internal instrument error such as threads of the micrometer
spindle can also lead to error in measurement.
Wear can be minimized by keeping gauge, masters and work pieces clean and away from
dust. Gauge, anvils and such other part s of the instrument which are subjected to wear
should be properly hardened. Chrome plated parts are more resistant to wear.
The lack of parallelism due to wear of anvils can be checked by optical flats; and, the-wear
on spherical contacts of the instrument by means of microscope.
1.6 General Care of Metrological Equipment

 The equipment (apparatus) used for precision measurements is designed to fine limits of
accuracy and is easily liable to be damaged by even-slight mishandling and such damage
may not be noticeable. A great deal of careful handling is, therefore, required.
 As far as possible, the highly finished surfaces should not be touched by hand because the
natural acids on the skin are likely to corrode the finished surface and also the temperature
of body may upset the dimensions of the precision instruments.
 In order to overcome this many standard metrology laboratories recommend washing of
hands thoroughly and coating them with a thin fily; of pure petroleum jelly before handling
the instruments.
 Further very precise equipment like slip gauges is allowed to be handled only by using a
piece of chamois leather or tongs made from a strip of "Perspex".
Page 1.31
 When the equipment is not in use, it should be protected from atmospheric corrosion. For
this purpose the highly finished surfaces are first wiped with a solvent to remove any finger
mark and then coated with mixture of heated petroleum jelly and petrol.
 This mixture spreads much more easily and is applied with cloth or with fingers. Brushing is
not recommended as it is liable to ti air which, with the moisture it contains, may cause
rusting.
 As the standard temperature for measurement is 20°C, for very precise measurement the
instruments and work pieces should be allowed to attain this temperature before use and
the handling should be as little as possible.
1.7 Standardization and Standardizing Organization

 For overall higher economy, efficiency and productivity in a factory and country, it is
essential that diversity be minimized and interchangeability among parts encouraged. All
this is possible with standardization. Standardization is done at various levels, viz.
International, National, association, company.
 Realizing the role of standardization in the development of industry, organizations to handle
the complexities of standardization have been evolved in each of the chief industrial
countries. In India, Bureau of Indian Standards (BIS) is responsible for evolving standards on
metrological instruments, etc.
 There are several sectional committees, each dealing with various main branches of
industry, in BIS. The detailed work of drawing up specifications is done by more specialized
technical committees who prepare a draft standard based on practice in other countries and
the needs of the country, and circulate it to relevant industries, government and service
departments, research and teaching organizations, and others likely to be interested.
 Comments are invited both from producer and user to consider all aspects; meetings help to
discuss the matters in depth and final standards issued. The technical committees also keep
on revising the existing standards from time to time.
 The Bureau of Indian Standards is the National body for standardization in India. The
functions of the Bureau are:
1. Formulation, publication and promotion of Indian Standards
2. Inspection of articles or process under Certification Scheme;
3. Establishment, maintenance and recognition of laboratories;
Page 1.32
4. Formulate, implement and coordinate activities relating to quality maintenance and
improvement in products and processes;
5. Promote harmonious development in standardization, quality systems and certification and
matters connected therewith both within the country and at international level;
6. Provide information, documentation and other services to consumers and recognized
consumer organizations on such terms and conditions as may be mutually agreed upon;
7. Give recognition to quality assurance systems in manufacturing or processing units on such
terms and conditions as mutually agreed upon;
8. Bring out handbooks, guides and other special publications; and for conformity to any other
standard if so authorized.
Thus, the main functions of the Bureau can be grouped under standards formulation,
certification marking and laboratory testing, promotional and international activities.
Bureau of Indian Standards has under the Mechanical Engineering Division Council, EDC, a
separate Engineering Metrology Sectional Committee. This Committee was set up in 1958
and its main task is to formulate standards for the various aspects of dimensional
metrological measuring instruments and accessories used in the mechanical engineering
field. A large number of Indian Standards in the field of engineering metrology have been
formulated.
 In Great Britain, British Standards Institution plays similar role to BIS.
 In Europe, the International Federation of National Standardizing Association, known as
I.S.A., coordinates the work of the continental countries. Before Second World War, U.K.
and U.S.A. did not take any part in it, but after war, the countries like. U.K., U.S.A. and Russia
have taken part in its works. In 1946, the I.S.A., was re-formed as the International
Organization for Standardization, I.S.O. In fact, for engineering matters, the foremost
standards organization at international level is I.S.O. The national standards organisations of
individual countries are the members of I.S.O. The I.S.O. recommendations are used as basis
for national and company standards. Lot of co-operative discussions in the field of
standardization has also been carried out in three countries-America, Britain and Canada
known was ABC conference. The International Electro-technical Commission (IEC) deals with
electrical engineering standards. Both ISO and IEC have published recommendations on
some aspects of engineering metrology.
 National Physical Laboratories (NPL) carry out lot of research work in various fields;
responsible for defining standards, and also issue certification marks for quality instruments.
Page 1.33
International organization of Weights and Measurements

It was established in 1975 under the “International meter convention” in Paris with the
object of maintaining uniformity of measurements throughout the world. It comprises of:
1. The General Conference of Weights and Measures
2. The International Committee of Weights and Measures.
3. The International Organization of Legal Metrology.
General Conference of Weights and Measures
Its objects are:
 To draw up and promote the decisions necessary for the propagation and perfection of an
international system of units and standards of measurement.
 To approve the results of new fundamental metrological determinations and the various
scientific resolutions in the field of metrology which are of international interest.
International Committee of Weights and Measures
This Committee is placed under the authority of the General Conference of Weights and
Measures and is responsible for promoting the decisions taken by the latter. Its objects are:
 To direct and supervise the work of the International Bureau of Weights and Measures.
 To establish co-operation among national laboratories of metrology for executing the
metrological work which the General Conference of Weights and Measures decides to
execute jointly by the member states of the organization.
 To direct such work and co-ordinate the results and to look after the conservation of the
International Standards.
Principal Global Organizations involved in Metrology
BIPM (Bureau International des PoidsetMeasures): It is created under the Meter convention
for measurement standard activities. It provides leadership in ensuring collaboration on
metrological matters and the maintenance of an efficient worldwide measurement system.
It serves as the technical focal point to guarantee the equivalence of national standards.
BIPM with its laboratories and offices at Serves act as a permanent international centre for
Metrology under the supervision of the CIPM.
ILAC (International Laboratory Accreditation Conference): It is engaged in international
laboratory accreditation and the standards writing bodies. It has demonstrated competence
in calibration and testing.
Page 1.34
IEC (International Electro technical Commission): A voluntary sector to prescribe standards.
CIPM (Committee International des Poidset Measures): Most of the activities of CIPM are
performed under the supervision of CIPM. Several (CCs) consultative committees have been
set up by the CIPM.
CGPM (Conference General des Poidset Measures).
ISO (International Organization for Standardization): A voluntary sector to specify standards.
NMI (National Metrology Institute). A national laboratory responsible for the development
and maintenance of measurement standards for the dissemination of the SI units, their
multiples and sub multiples, and capable of making accurate measurements available to all
users.
International Organization of Legal Metrology (OIML); It was established in 1955 under the
"International Convention of Legal Metrology" Paris to unify the metrological practices. Its
objects are
International organization of legal Metrology: It was established in 1955 under the
“International convention of legal metrology” Paris to unity the metrological practices. Its
objects are:
 To determine the general principles of Legal Metrology. Legal Metrology is concerned with
the statutory technical and legal requirement of units of measurements, methods of
measurements and measuring instruments with a view to assure public guarantee in respect
of the security and the appropriate accuracy of measurements.
 To study with the object of unification, statutory and regulatory problems of legal metrology
the solution of which is of international interest.
 To establish the draft of a model law and regulation on measuring instruments and their
use.
 To prepare a plan for the physical organization of a model service for the verification and
control of measuring instruments and to establish the necessary and adequate
characteristics and qualities which measuring instruments should possess in order that they
may be approved by the member states and their use recommended on international basis.
This organization comprises of the International Conference of Legal Metrology, the
International Committee of Legal Metrology and the International Bureau of Legal
Metrology.
Page 1.35
OIML has made a number of international recommendations. They have also published a
"Vocabulary of Legal Metrology-Fundamental Terms" the English translation of which is
published in India by the Directorate of Weights and Measures, Ministry of Industry.
The functions of the Directorate of Weights and Measures are:
 To ensure the conservation of national standards and to guarantee their accuracy by
comparison with international standards.
 To guarantee and impart proper accuracy to the secondary standards by comparison with
national standards.
 To carry out scientific and technical work in all fields of metrology and methods of
measurements.
 To take part in the work of other national organizations interested in metrology.
 To draw up draft laws relating to legal metrology and to promulgate the corresponding
regulations.
 To regulate and advise on, supervise and control the manufacture and repair of measuring
instruments.
 To inspect the use of instruments and the measurement operations when such use and such
operations are covered under public guarantee.
 To detect frauds in measurement or sale of goods and to book offender for trials where
necessary.
 To coordinate the activities of authorities exercising metrological supervision.
 To cooperate with all to ensure respect for the regulations of legal metrology.
 To organize training in legal metrology
 To represent the country in international activities regarding legal metrology.
National Service of Legal Metrology: The National Service of Legal Metrology has following
organizations to assist it in discharge of its duties:
 National Bureau of Legal Metrology. (It is the directing organization)
 National Institute of Legal Metrology. (It is entrusted with the performance of scientific and
research work)
 National Bureau of Verification.
There are regional bureau of verification, local bureau of verification, mobile bureau of
verification, and verification centers to assist national bureau of verification in ensuring
Page 1.36
appropriate accuracy of the standards, carrying out metrological supervision, verifying
measuring instruments.
 Verification agents (Authorized to exercise the functions of verification)
Page 1.37
2
LINEAR & ANGULAR MEASUREMENT
Course Contents
2.1 Introduction
2.2 Vernier Instruments
2.3 Reading the Vernier Scale
2.4 Types of Vernier Calipers
2.5 Vernier Height Gauge
2.6 Vernier Depth Gauge
2.7 Micrometers
2.8 Bore Gauge
2.9 Dial Indicator
2.10 Slip Gauge
2.11 Telescopic gauges
2.12 Introduction to Angular
Measurement
2.13 Bevel Protectors
2.14 Sine Principle and Sine
Bars
2.15 Angle Gauges
Page 2.1
Mechanical Measurement & Metrology 2. Linear Measurement
2.1 Introduction
- Linear measurement applies to measurement of lengths, diameters, heights, and
thickness including external and internal measurements.
- The line measuring instruments have series of accurately spaced lines marked on
them, e.g. scale. The dimension to be measured is aligned with the graduations of
the scale.
- Linear measuring instruments are designed either for line instruments, the
measurement is taken between two end surfaces as in micrometers, slip gauges etc.
- The instruments used for linear measurements can be classified as:
1. Direct measuring instruments
2. Indirect measuring instruments
- The direct measuring instruments are of two types:
1. Graduated
2. Non Graduated
- The graduated instruments include rules, vernier calipers, vernier height gauges,
vernier depth gauges, micrometers, dial indicators etc.
- The non-graduated instruments include calipers, trammels, telescopic gauges,
surface gauges, straight gauges, wire gauges, screw pitch gauges, thickness gauges,
slip gauges etc. They can also be classified as:
1. Non-precision instruments such as steel rule, calipers etc.
2. Precision measuring instruments, such as vernier instruments, micrometers, dial
gauges etc.
2.2 Vernier Instruments
Figure 2.1 Vernier Instrument
Page 2.2
2. Linear Measurement Mechanical Measurement & Metrology
- The principle of vernier is that when two scales or divisions slightly different in size are
used, the difference between them can be utilized to enhance the accuracy of
measurement.
- The vernier caliper essentially consists of two steel rules and these can slide along each
other. One of the scales, i.e., main scale is engraved on a solid L-shaped frame. On this
scale cm graduations are divided into 20 parts so that one small division equals 0.05 cm.
One end of the frame contains a fixed jaw which is shaped into a contact tip at its
extremity.
- The three elements of vernier caliper, viz, beam, fixed jaw, and sliding jaw permit
substantial improvements in the commonly used measuring techniques over direct
measurement with line graduated rules.
- The alignment of the distance boundaries with the corresponding graduations of the
rule is ensured by means of the positive contact members (the jaws of the caliper
gauges).
- The datum of the measurement can be made to coincide precisely with one of the
boundaries of the distance to be measured.
- The movable jaw achieves positive contact with the object boundary at the opposite end
of the distance to be measured. The closely observable correspondence of the reference
marks on the slide with a particular scale value significantly reduces the extent of read-
out alignment errors.
Figure 2.2 Vernier Instruments
- A sliding jaw which moves along the guiding surface provided by the main scale is
coupled to a vernier scale. The sliding jaw at its left extremity contains another
Page 2.3
measuring tip.
- When two measuring tip surfaces are in contact with each other, scale shows zero
reading. The finer adjustment of the movable jaw can be done by the adjusting screw
- First the whole movable jaw assembly is adjusted so that the two measuring tips just
touch the part to be measured. Then lock nut B is tightened. Final adjustment depending
upon the sense of correct feel is made by the adjusting screw.
- The movement of adjusting screw makes the part containing locking nut A and sliding
jaw to move, as the adjusting screw rotates on a screw which is in a way fixed to the
movable jaw. After final adjustment has been made, the locking nut A is also tightened
and the reading is noted down
- . The measuring tips are so designed as to measure inside as well as outside dimensions.
1. Outside jaws: used to measure external diameter or width of an object
2. Inside jaws: used to measure internal diameter of an object
3. Depth probe: used to measure depths of an object or a hole
4. Main scale: gives measurements of up to one decimal place (in cm).
5. Main scale: gives measurements in fraction (in inch)
6. Vernier gives measurements up to two decimal places (in cm)
7. Vernier gives measurements in fraction (in inch)
8. Retainer: used to block movable part to allow the easy transferring a measurement
2.3 Reading the Vernier Scale

- For understanding the working of vernier scale let us assume that each small division of
the main scale is 0.025 units.
- Say, the vernier scale contains 25 divisions and these coincide exactly with 24 divisions
of main scale. So now one vernier division is equal to 1/25 of 24 scale divisions, i.e., 1/25
x 24 x 0.025 = 0.024 unit. Therefore, difference between one main scale small division
and one vernier division (least count of the instrument) equals 0.025 — 0.024, i.e. 0.001
unit. It means if the zero of main scale and zero of vernier coincide, then the first vernier
division will read 0.001 units less than the 1 small scale division. Second vernier division
will read 0.002 unit less than 2 small scale divisions and so on. Thus if zero vernier scale
lies in between two small divisions on main scale its exact value can be judged by seeing
as to which vernier division is coinciding with main scale division.
Page 2.4
Figure 2.3 Practical Applications of Vernier Calipers

- Thus to read a measurement from a vernier caliper, note the units, tenths and fortieths
which the zero on the vernier has moved from the zero on the main scale. Note down
the vernier division which coincides with a scale division and add to previous reading the
number of thousands of a unit indicated by the vernier divisions
- e.g., reading in the scale shown in Fig. is 3 units + 0.1 unit + 0.075 unit + 0.008 unit =
3.183 units. When using the vernier caliper for internal measurements the width of the
measuring jaws must be taken into account. (Generally the width of measuring jaw is 10
mm for Metric System).
2.4 Types of Vernier Calipers
- According to IS 3651—1974 (Specification for vernier caliper), three types of vernier
calipers have been specified to meet the various needs of external and internal
measurements up to 2000 mm with vernier accuracy of 0.02, 0.05 and 0.1 mm.
- The three types are called types A, B, C and have been shown in Figs. 2.75, 2.76 and
2.79 respectively. All the three types are made with only one scale on the front of the
beam for direct reading.
- Type A has jaws on both sides for external and internal measurements, and also has a
blade for depth measurements. Type B is provided with jaws on one side for external
and internal measurements. Type C has jaws on both sides for making the
measurements and for marking operations.
Page 2.5
Figure 2.4 Vernier Caliper with Dial

- All parts of the vernier calipers are made of good quality steel and the measuring faces
hardened to 650 H.V. minimum. The recommended measuring ranges (nominal sizes) of
vernier calipers as per IS 3651—1974 are 0—125, 0—200, 0—250. 0—300; 0—500, 0—
750, 0—1000, 750—1500 and 750— 2000 mm.
- On type A, scale serves for both external and internal measurements, whereas in case of
types B and C, the main scale serves for external measurements and for marking
purposes also in type C, but on types B and C internal measurements are made by
adding width of the internal measuring jaws to the reading on the scale. For this reason,
the combined width for internal jaws is marked on the jaws in case of types B and C
calipers. The combined width shou1d be uniform throughout its length to within 0.01
mm.
- The beam for all the types is made flat throughout its length to within the tolerances of
0.05 mm for nominal lengths up to 300 mm, 0.08 mm from 900 to 1000 mm, and 0.15
mm for 1500 and 2000 mm sizes, and guiding surfaces of the beam are made straight to
within 0.01 mm for measuring range of 200 mm and 0.01 mm every 200 mm measuring
range of larger size.
- The measuring surfaces are given a fine ground finish. The portions of the jaws between
the beam and the measuring faces are relieved. The fixed jaw is made an integral part of
the beam and the sliding jaw is made a good sliding fit along with the beam and made to
have seizure-free movement along the bar.
- A suitable locking arrangement is provided on the sliding jaw in order to effectively
clamp it on the beam. When the sliding jaw is clamped to the beam at any position
within the measuring range, the external measurir1g faces should remain square to the
guiding surface of the beam to within 0.003 mm per 100 mm. The measuring surfaces of
the fixed and sliding jaws should be coplanar to within 0.05 mm when the sliding jaw is
Page 2.6
clamped to the beam in zero position. The external measuring faces are lapped flat to
within 0.005 mm. The bearing faces of the sliding jaw should preferably be relieved in
order to prevent damage to the scale on the beam. Each of the internal measuring
surfaces should be parallel to the corresponding external measuring surface to within
0.025 mm in case of type B and C calipers. The internal measuring surfaces are formed
cylindrically with a radius not exceeding one-half of their combined width.
Errors in Measurements With Vernier Calipers
- Errors are usually made in measurements with vernier calipers from manipulation of
vernier caliper and its jaws on the work piece.
- For instance, in measuring an outside diameter, one should be sure that the caliper bar
and the plane of the caliper jaws are truly perpendicular to the work piece’s longitudinal
centre line
- i.e. one should be sure that the caliper is not canted, tilted, or twisted. It happens
because the relatively long, extending main bar of the average vernier calipers so readily
tips in one direction or the other.
- The accuracy of the measurement with vernier calipers to a great extent depends upon
the condition of the jaws of the caliper. The accuracy and the natural wear, and warping
of vernier caliper jaws should be tested frequently by closing them together tightly or
setting them to the 0.0 point of the main and vernier scales. In this position the caliper is
held against a light source. If there is wear, spring or warp a knock-kneed condition as
shown in Fig. (a) Will be observed. If measurement error on this account is expected to
be greater than 0.005 mm the instrument should not be used and sent for repair.
- When the sliding jaw frame has become worn or warped that it does not slide squarely
& snugly on main caliper beam, then jaws would appear as shown in fig. Where a vernier
caliper is used mostly for measuring inside diameters, the jaws may become bowlegged
as in Fig. (c) Or it’s outside edges worn clown as in Fig. (d).
Care inthe Use ofVernierCalliper
- No play should be there between the sliding jaws on scale, otherwise the accuracy of the
vernier caliper will be lost. If play exists then the gib at the back of jaw assembly must be
bent so that gib holds the jaw against the frame and play is removed.
- Usually the tips of measuring jaws are worn and that must be taken into account. Most
of the errors usually result from manipulation of the vernier caliper and its jaws on the
Page 2.7
work piece.
- In measuring an outside diameter it should be insured that the caliper bar and the plane
of the caliper jaws are truly perpendicular to the work piece’s longitudinal centre line. It
should be ensured that the caliper is not canted, tilted or twisted.
- The stationary caliper jaw of the vernier caliper should be used as the reference point
and measured point is obtained by advancing or withdrawing the sliding jaw.
- In general, the vernier caliper should be gripped near or opposite the jaws; one hand for
the stationary jaw and the other hand generally supporting the sliding jaw. The
instrument should not be held by the over-hanging “tail” formed by the projecting main
bar of the caliper.
- The accuracy in measurement primarily depends on two senses, viz., sense of sight and
sense of touch (feel).
- The short-comings of imperfect vision can however be overcome by the use of
corrective eye-glass and magnifying glass. But sense of touch is an important factor in
measurements. Sense of touch varies from person to person and can be developed with
practice and proper handling of tools.
- One very important thing to note here is that sense of touch is most prominent in the
finger-tips, therefore, the measuring instrument must always be properly balanced in
hand and held lightly in such a way that only fingers handle the moving and adjusting
screws etc. If tool be held by force, then sense of feel is reduced.
- Vernier calliper must always be held at short leg of main scale and jaws never pulled.
2.5 Vernier height gauge
- Vernier height gauge is similar to vernier calliper but in this instrument the graduated
bar is held in a vertical position and it is used in conjunction with a surface plate.
 Construction:
A vernier height gauge consists of
1. A finely ground and lapped base. The base is massive and robust in construction to
ensure rigidity and stability.
2. A vertical graduated beam or column supported on a massive base.
3. Attached to the beam is a sliding vernier head carrying the vernier scale and a
clamping screw.
Page 2.8
4. An auxiliary head which is also attached to the beam above the sliding vernier head.
It has fine adjusting and clamping screw.
5. A measuring jaw or a scriber attached to the front of the sliding vernier
Figure 2.5 Vernier Height Gauge
Page 2.9
 Use.
- The vernier height gauge is designed for accurate measurements and marking of vertical
heights above a surface plate datum.
- It can also be used to measure differences in heights by taking the vernier scale readings
at each height and determining the difference by subtraction.
- It can be used for a number of applications in the tool room and inspection department.
The important features of vernier height gauge are:
- All the parts are made of good quality steel or stainless steel.
- The beam should be sufficiently rigid square with the base.
- The measuring jaw should have a clear projection from the edge of the beam at least
equal to the projection of the base' from the beam.
- The upper and lower gauging surfaces of the measuring jaw shall be flat and parallel
to the base.
- The scriber should also be of the same nominal depth as the measuring jaw so that it
may be reversed.
- The projection of the jaw should be at least 25 mm.
- The slider should have a good sliding fit for all along the full working length of the
beam.
- Height gauges can also be provided with dial gauges instead of vernier.
This provides easy and exact reading of slider movement by dial a gauge which is larger and
clear.
 Precautions.
- When not in use, vernier height gauge should be kept in its case.
- It should be tested for straightness, squareness and parallelism of the working faces of
the beam, measuring jaw and scriber.
- The springing of the measuring jaw should always be avoided.
2.6 Vernier Depth Gauge
- Vernier depth gauge is used to measure the depths of holes, slots and recesses, to locate
centre distances etc. It consists of
1. A sliding head having flat and true base free from curves and waviness.
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2.10
2. A graduated beam known as main scale. The sliding head slides over the graduated
beam.
3. An auxiliary head with a fine adjustment and a clamping screw.
Figure 2.6 Vernier Depth Gauge

- The beam is perpendicular to the base in both directions and its ends square and flat.
- The end of the sliding head can be set at any point with fine adjustment mechanism
locked and read from the vernier provided on it, while using the instrument, the base is
held firmly on the reference surface and lowers the beam into the hole until it contacts
the bottom surface of the hole.
- The final adjustment depending upon the sense of correct feel is made by the fine
adjustment screw. The clamping screw is then tightened and the instrument is removed
from the hole and reading taken in the same way as the vernier calliper. While using
theinstrument it should be ensured that the reference surface op which the depth gauge
base is rested is satisfactorily true, flat arid square.
2.7 Micrometers
- The micrometer screw gauge essentially consists of an accurate screw having about 10
or 20 threads per cm and revolves in a fixed nut.
- The end of the screw forms one measuring tip and the other measuring tip is
constituted by a stationary anvil in the base of the frame. The screw is threaded for
Page 2.11
certain length and is plain afterwards. The plain portion is called sleeve and its end is the
measuring surface.
- The spindle is advanced or retracted by turning a thimble connected to the spindle. The
spindle is a slide fit over the barrel and barrel is the fixed part attached with the frame.
- The barrel is graduated in unit of 0.05 cm. i.e. 20 divisions per cm, which is the lead of
the screw for one complete revolution.
- The thimble has got 25 divisions around its periphery on circular portion. Thus it sub-
divides each revolution of the screw in 25 equal parts, i.e. each division corresponds to
0.002 cm. A lock nut is provided for locking a dimension by preventing motion of the
spindle.
Figure 2.7 Micrometers

- Ratchet stop is provided at the end of the thimble cap to maintain sufficient and uniform
measuring pressure so that standard conditions of measurement are attained.
- Ratchet stop consists of an overriding clutch held by a weak spring.
- When the spindle is brought into contact with the work at the correct measuring
pressure, the clutch starts slipping and no further movement of the spindle takes place
by the rotation of ratchet. In the backward movement it is positive due to shape of
ratchet.
Reading a Micrometer:
- In order to make it possible to read up to 0.0001 inch in micrometer screw gauge, a
vernier scale is generally made on the barrel.
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2.12
- The vernier scale has 10 straight lines on barrel and these coincide with exact 9 divisions
on the thimble. Thus one small deviation on thimble is further subdivided into 10 parts
and taking the reading one has to see which of the vernier scale division coincides with
division of the thimble.
- Accordingly the reading for given arrangement in fig. will be,
On main barrel : 0.120”
On thimble :0.014”
On vernier scale :0.0001”
Total reading :0.1342”
- Before taking the reading anvil and spindle must be brought together carefully and initial
reading noted down. Its calibration must be checked by using standard gauge blocks.
Figure 2.8 Practical Applications of Micrometers

- In metric micrometers, the pitch of the screw thread is 0.5 mm so that one revolution of
screw moves it axially by 0.5 mm. Main scale on barrel has least division of 0.5 mm. the
thimble has 50 divisions on its circumference.
- One division on thimble = 0.5 / 50 mm = 0.1 mm
- If vernier scale is also incorporated then sub divisions on the thimble can be estimated
up to an accuracy of 0.001 mm.
- Reading of micrometer is 3.5 mm on barrel and 7 divisions on thimble
= 3.5+7 x 0.001= 3.5 + 0.07 = 3.57 mm
Cleaning the Micrometer:
- Micrometer screw gauge should be wiped free from oil, dirt, dust and grit.
Page 2.13
- When micrometer feels gummy and dust ridden and the thimble fails to turn freely, it
should never be bodily dunked in kerosene or solvent because just soaking the
assembled micrometer fails to float the dirt away.
- Further it must be remembered that the apparent stickiness of the micrometer may not
be due to the grit and gum but to a damaged thread and sprung frame or spindle.
- Every time the micrometer is used, measuring surface, the anvil and spindle should be
cleaned. Screw the spindle lightly but firmly down to a clean piece of paper held
between spindle and anvil.
- Pull the piece of paper put from between the measuring surface. Then unscrew the
spindle few turns and blow out any fuzz or particles of papers that may have clung to
sharp edges of anvil and spindle.
Precautions in using Micrometer
- In order to get good results out of the use of micrometer screw gauge, the inspection of
the parts must be made as follows. Micrometer should be cleaned of any dust and
spindle should move freely.
- The part whose dimension is to be measured must be held n left hand and the
micrometer in right hand. The way for holding the micrometer is to place the small
finger and adjoining finger in the U – Shaped frame.
- The forefinger and thumb are placed near the thimble to rotate it and the middle finger
supports the micrometer holding it firmly.
- The micrometer dimension is set slightly larger than the size of the part and part is slid
over the contact surfaces of micrometer gently. After it, the thimble is turned till the
measuring pressure is applied.
- In the case of circular parts, the micrometer must be moved carefully over
representative arc so as to note maximum dimension only. Then the micrometer reading
is taken.
- The micrometers are available in various sizes and ranges, and corresponding
micrometer should be chosen depending upon the dimension.
- Errors in reading may occur due to lack of flatness of anvil, lack of parallelism of the
anvils at part of scale or throughout, inaccurate setting of zero reading, etc. various tests
to ensure these conditions should be carried out from time to time.
2.8 Bore gauge:
Page
2.14
- The dial bore gauges shown in fig. are for miniature hole measurements.
- The gauge is supplied with a set of split ball measuring contact points which are hard
chrome-plated to retain original spheres.
- Along with the measuring probes, setting rings are also provided to zero set the
indicator whenever the probes are interchanged.
Actual ring size is engraved on the ring frames to the closest 0.001 mm value.
Figure 2.9 Bore gauges
2.9 Dial indicators

 Introduction
- Dial indicators are small indicating devices using mechanical means such as gears and
pinions or levers for magnification system. They are basically used for making and
checking linear measurements.
- Many a times they are also used as comparators. Dial indicator, in fact is a simple type of
mechanical comparator.
- When a dial indicator is used as an essential part in the mechanism any set up for
comparison measurement purposes; it is called as a gauge.
- The dial indicator measures the displacement of its plunger or a stylus on a circular dial
by means of a rotating pointer.
- Dial indicators are very sensitive and versatile instruments.
- They require little skill in their use than other precision instruments, such as micrometer
vernier callipers, gauges etc. However, a dial indicator by itself is not of much unless it is
properly mounted and set before using for inspection purposes.
Uses:
Page 2.15
- By mounting a dial indicator on any suitable base and with various attachments, it can
be used for variety of purposes as follows.
1. Determining errors in geometrical forms, e.g., ovality out-of-roundness, taper etc.
2. Determining positional errors of surfaces, e.g., in squareness, parallelism, alignment
etc.
3. Taking accurate measurements of deformation (extension compression) in tension
and compression testing of material.
4. Comparing two heights or distances between narrow limits (comparator).
The practical applications of the use of dial indicator are:
1. To check alignment of lathe centers by using a suitable accurate bar between
centers.
2. To check trueness of milling machine arbors.
3. To check parallelism of the shaper ram with table surface or like.
Figure 2.10 Dial Indicators
2.10 Slip Gauges

- Slip gauges or gauge blocks are universally accepted end standard of length in industry.
These were introduced by Johnson, a Swedish engineer, and are also called as johanson
gauges
Page
2.16
Figure 2.11 Dimensions of a Slip Gauge

- Slip gauges are rectangular blocks of high grade steel with exceptionally close
tolerances. These blocks are suitably hardened through out to ensure maximum
resistance to wear.
- They are then stabilized by heating and cooling successively in stages so that hardening
stresses are removed,After being hardened they are carefully finished by high grade
lapping to a high degree of finish, flatness and accuracy.
- For successful use of slip gauges their working faces are made truly flat and parallel. A
slip gauge is shown in fig. 3.36. Slip gauges are also made from tungsten carbide which is
extremely hard and wear resistance.
- The cross-sections of these gauges are 9 mm x 30 mm for sizes up to 10 mm and 9 mm x
35 mm for larger sizes. Any two slips when perfectly clean may be wrung together. The
dimensions are permanently marked on one of the measuring faces of gauge blocks
 Gauges blocks are used for:
1. Direct precise measurement, where the accuracy of the work piece demands it.
2. For checking accuracy of vernier callipers, micrometers, and such other measuring
instruments.
3. Setting up a comparator to a specific dimension.
4. For measuring angle of work piece and also for angular setting in conjunction with a
sine bar.
5. The distances of plugs, spigots, etc. on fixture are often best measured with the slip
gauges or end bars for large dimensions.
6. To check gap between parallel locations such as in gap gauges or between two
mating parts.
2.11 Telescopic Gauges
Page 2.17
- The telescopic gauge is used for measuring internal diameter of holes, slots and grooves
etc. It consists of a handle with two rods in a tube at one end and a working screw at the
other end. The rods having spherical contacts can slide within a tube and are forced
apart by an internal spring.
- The locking screw can lock the rods at any desired position through a spring. While
taking measurements, the rods are pressed closer and inserted into the hole to be
measured. The rods then open out to touch the metal surface, of the hole on both sides.
They are then locked in position by means of a locking screw. The telescopic gauge is
then taken out from the hole. The dimension across the tips is measured by micrometer
or Verniercaliper.
2.12 Introduction to Angular Measurement
- Angular measurements are frequently necessary for the manufacture of interchangeable
parts. The ships and aero planes can navigate confidently without the help of the site of
the land; only because of precise angular measuring devices can be used in astronomy to
determine the relation of the stars and their approximate distances.
- The angle is defined as the opening between two lines which meet at a point. If one of
the two lines is moved at a point in an arc, a complete circle can be formed.
- The basic unit in angular measurement is the right angle, which is defined as the angle
between two lines which intersect so as to make the adjacent angles equal.
- If a circle is divided into 360 equal parts. Each part is called as degree ( 0). Each degree is
divided in 60 minutes (‘), and each minute is divided into 60 seconds (“).
- This method of defining angular units is known as sexagesimal system, which is used for
engineering purposes.
- An alternative method of defining angle is based on the relationship between the radius
and arc of a circle. It is called as radian.
- Radian is defined as the angle subtended at the centre by an arc of a circle of length
equal to its radius.
- It is more widely used in mathematical investigation.
2 radians = 360, giving,
1 radian = 57.2958 degrees.
Page
2.18
- In addition linear units such as 1 in 30 or millimeters per meter are often used for
specifying tapers and departures from squareness or parallelism.
2.13 Bevel Protector

- It is probably the simplest instrument for measuring the angle between two faces of
component.
- It consists of a base plate attached to the main body, and an adjustable blade which is
attached to a circular plate containing vernier scale. The adjustable blade is capable of
rotating freely about the centre of the main scale engraved on the body of the
instrument and can be locked in any position.
- An acute angle attachment is provided at the top; as shown in fig. for the purpose of
measuring acute angles. The base of the base plate is made flat so that it could be laid
flat upon the work and any type of angle measured. It is capable of measurement from
00 to 3600
- The vernier scale has 24 divisions coinciding with 23 main scale divisions. Thus the least
count of the instrument is 5’. This instrument is most commonly used in workshops for
angular measurements till more precision is required.
- A recent development of the vernier bevel protector is optical bevel protector. In this
instrument, a glass circle divided at 10’ intervals throughout the whole 360 0 is fitted
inside the main body.
- A small microscope is fitted through which the circle graduations can be viewed. The
adjustable blade is clamped to a rotating member who carries this microscope. With the
aid of microscope it is possible to read by estimation to about 2’.
Page 2.19
Figure 2.12 Bevel Protector

Universal Bevel Protector
- It is used for measuring and laying out of angles accurately and precisely within 5
minutes. The protector dial is slotted to hold a blade which can be rotated with the dial
to the required angle and also independently adjusted to any desired length. The blade
can be locked in any position.
Bevel Protectors as Per Indian Standard Practice
The bevel protectors are of two types, viz.
1. Mechanical Bevel Protector, and
2. Optical Bevel Protector.
1. Mechanical bevel protector:
- The mechanical bevel protectors are further classified into four types; A, B, C and D.
- In types A and B, the vernier is graduated to read to 5 minutes of arc whereas in case of
type C, the scale is graduated to read in degrees and the bevel protector is without
vernier or fine adjustment device or acute angle attachment.
- The difference between types A and B is that type A is provided with fine adjustment
device or acute angle attachment whereas type B is not. The scales of all the types are
graduated either as a full circle marked 0—90—0—90 with one vernier or as semicircle
marked 0—90—0 with two verniers 1800 apart.
- Type D is graduated in degrees and is not provided with either vernier or fine
adjustment device or acute angle attachment.
2. Optical bevel protector:
- In the case of optical bevel protector, it is possible to take readings up to approximately
2 minutes of arc. The provision is made for an internal circular scale which is graduated
Page
2.20
in divisions of 10 minutes of arc.

- Readings are taken against a fixed index line or vernier by means of an optical
magnifying system which is integral with the instrument. The scale is graduated as a full
circle marked 0—90—0—90. The zero positions correspond to the condition when the
blade is parallel to the stock. Provision is also made for adjusting the focus of the
system to accommodate normal variations in eye-sight. The scale and vernier are so
arranged that they are always in focus in the optical system.
Various Components of Bevel Protectors
Body:It is designed in such a way that its back is flat and there are no projections beyond its
back so that when the bevel protector is placed on its back on a surface plate there shall be
no perceptible rock. The flatness of the working edge of the stock and body is tested by
checking the squareness of blade with respect to stock when blade is set at 90 0.
Stock:The working edge of the stock is about 90 mm in length and 7 mm thick. It is very
essential that the working edge of the stock be perfectly straight and if at all departure is
there, it should be in the form of concavity and of the order of 0.01 mm maximum over the
whole span.
Blade:It can be moved along the turret throughout its length and can also be reversed. It is
about 150 or 300 mm long, 13 mm wide and 2 mm thick and ends beveled at angles of 450
and 600 within the accuracy of 5 minutes of arc. Its working edge should be straight upto
0.02 mm and parallel upto 0.03 mm over the entire length of 300 mm. It can be clamped in
any position.
Actual Angle Attachment
It can be readily fitted into body and clamped in any position. Its working edge should be
flat to within 0.005 mm and parallel to the working edge of the stock within 0.015 mm over
the entire length of attachment.
The bevel protectors are tested for flatness, squareness, parallelism, straightness and
angular intervals by suitable methods.
2.14 Sine Principle and Sine Bars
- The sine principle uses the ratio of the length of two sides of a right triangle in deriving a
given angle. It may be noted that devices operating on sine principle are capable of “self
generation.”
Page 2.21
- The measurement is usually limited to 450 from loss of accuracy point of view. The
accuracy with which the sine principle can be put to use is dependent in practice, on
some form of linear measurement.
- The sine bar in itself is not a complete measuring instrument. Another datum such as a
surface plate is needed, as well as other auxiliary equipment, notably slip gauges, and
indicating device to make measurements. Sine bars used in conjunction with slip gauges
constitute a very good device for the precise measurement of angles.
- Sine bars are used either to measure angles very accurately or for locating any work to a
given angle within very close limits.
- Sine bars are made from high carbon, high chromium, corrosion resistant steel,
hardened, ground and stabilized.
Figure 2.13 Use of sine bar
Where, L = distance between centers of ground cylinder (typically 5’’ or 10’’)
H = height of the gauge blocks
Θ =the angle of the plane
Θ = a sin (h/l)
Page
2.22
Figure 2.14 Practical Application of sine bar

Use of sine bar:
1. Measuring known angles or locating any work to a given angle. For this purpose the
surface plate is assumed to be having a perfectly flat surface, so that its surface
could be treated as horizontal.
One of the cylinders or rollers of sine bar is placed on the surface plate and other
roller is placed on the slip gauges of height h. Let the sine bar be set at an angle q.
Then sin = h/l, where l is the distance between the center of the rollers. Thus
knowing, h can be found out and any work could be set at this angle as the top face
of sine bar is inclined at angle  to the surface plate.
The use of angle plates and clamps could —also be made in case of heavy
components.
For better results, both the rollers could also be placed on slip gaugesChecking of
unknown angles. Many a times, angle of a component to be checked is unknown. In
such a case, it is necessary to first find the angle approximately with the help of a
bevel protector.
Let the angle be 8. Then the sine bar is set at an angle  and clamped to an angle
plate. Next, the work is placed on sine bar and clamped to angle plate as shown in
Fig. And a dial indicator is set at one end of the work and moved to the other, and
deviation is noted. Again slip gauges are so adjusted (according to this deviation)
that dial indicator reads zero across work surface. Fig.
If deviation noted down by the dial indicator is ôh over a length l' of work, then
Page 2.23
height of slip gauges by which it should be adjusted is equal to = ôh x l/l'
Checking of unknown angles of heavy component. In such cases where components

are heavy and can’t be mounted on the sine bar, then sine bar is mounted on the
component as shown in Fig.
The height over the rollers can then be measured by a vernier height gauge; using a
dial test gauge mounted on the anvil of height gauge as the fiducially indicator to
ensure constant measuring pressure. The anvil on height gauge is adjusted with
probe of dial test gauge showing same reading for the topmost position of rollers of
sine bar. Fig. Surface plate shows the use of height gauge for obtaining two
readings for either of the Fig. shows the use of height gauge for obtaining two
readings for either of the roller of sine bar.
The difference of the two readings of height gauge divided by the centre distance of
sine bar gives the sine of the angle of the component to be measured. Where
greater accuracy is required, the position of dial test gauge probe can be sensed by
adjusting a pile of slip gauges till dial indicator indicates same reading over roller of
sine bar and the slip gauges.
1.4 Angle Gauges
- The first set of combination of angle gauges was devised by Dr. Tomlinson of N.P.L. With
thirteen separate gauges used in conjunction with one square block and one parallel
straight-edge, it is possible to set up any angle to the nearest 3” In the same way, as slip
gauges are built up to give a linear dimension, I the angle gauges can be build up to give
a required angle.
- Angle gauges PIVOT are made of hardened steel and seasoned carefully to ensure
permanence of angular accuracy, and the measuring faces are lapped and polished to a
high degree of accuracy and flatness like slip gauges. These gauges are about 3 inch
(76.2 mm) long, 5/8 inch (15.87 mm) wide with their faces lapped to within 0.0002 mm
and angle between the two ends to ±2 seconds.
- The secret of this system in having any angle in step of 3'’ is the adoption of a
mathematical series of the values of the angles of various gauges of the set.
- The thirteen gauges can be divided into three series; degrees, minutes and fractions of a
Page
2.24
minute. The gauges available in first series are of angle 10, 30, 90, 270, and 410. Second
series comprises 1', 3', 9’and 27’angle gauges and this series has 0.05’, 0.1', 0.3’and 0.5’
(or 3”, 6”, 18” and 30”) angle gauges.
- All these angle gauges in combination can be added or subtracted, thus, making a large
number of combinations possible. There are two sets of gauges available, designated as
A and B. The standard A contains all the above 13 gauges. Standard B contains only 12
gauges and does not have, the 0.05' angle gauge.
- Direct combination enables computation of any angle up to 810 40.9’and angles larger
than this can be made up with the help of the square block. However, an additional
gauge of 90 can also be supplied with the set to obtain a full 90 0 angle without the use of
the square. Fig. illustrates how the gauges can be used in addition and subtraction. The
procedure used for making various angles is as follows e.g. say, we have to build up an
angle of 570 38’ 9”.
- First we pay our attention towards degree only. So 570 could be built up as 410 + 270 -90
+ 10 - 30
- Next if the minutes are less than 40’, they could be built up directly, otherwise number
of degrees must be increased by 10 and the number of minutes necessary to correct the
total is subtracted. Here now 34’could be built 27’+9’—3’+ 1' and lastly 9” is built up as
0.1'+ 0.05’.
- It may be noted that each angle gauge is marked with engraved V which indicates the
direction of included angle. When the angles of individual angle gauges are to be added
up then the VS of all angle gauges should be in line and when any angle is to be
subtracted, its engraved V should be in other direction.
- Thus it is seen that any angle could be made up but the block formed by the
combination of a number of these gauges is rather bulky and, therefore, cannot be
always directly applied to the work. But these gauges being used as reference and taking
the aid of other angle measuring devices will be a good proposal at many places.
- Angle gauge blocks seem to lack the requisites for use as primary standards because
errors are easily compounded when angle blocks are wrung in combination. Further the
absolute verification of angle blocks is usually dependent on some other primary
standard.
Page 2.25
.
Figure 2.15 Set of angle gauges
Uses of Angle Gauges
- Direct use of angle gauges to measure the angle in the die insert:
- To test the accuracy of the angle in the die insert, the insert is placed against an
illuminated glass surface plate or in front of an inspection light box. The combination of
angle gauges is so adjusted and the built-up combination, of angle gauges carefully
inserted in position so that no white light can be seen between the gauge faces and die
faces. It may be noted that when all the engraved Vs on the angle gauges are in the
same line, all angles are added up. In case some engraved Vs on angle gauges are on
other side, those angles are subtracted.
Use of angle gauges with square plate:
- As already indicated, the use of square plate increases the versatility of the application
of angle gauges. Generally, the square plate has its 90 0 angles guaranteed to within 2
seconds of arc. Where very high degree of accuracy is required, the four corners of the
square plate are numbered as A, B, C and D, and a test certificate are issued with each
set of angle gauges, giving the measured angle of each corner. The whole set up is
placed against an illuminated glass surface plate. It may be noted that the use of slip
gauges has to be made in order to facilitate the testing.
So far, we have used angle gauges to obtain a visual comparison of an angular dimension
under test. It has also been realized that though it may be possible to obtain good results
but it is difficult to give an estimate of the actual angular error. For very precise angular
measurements, angle gauges are used in conjunction with angle dekkor.
Page
2.26
Next Unit
3
Measurement of Force, Torque and
Strain

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1

Mechanical Measurement & Metrology

1.2 Need of Inspection

1.3 Objectives of Metrology

8. Preparation of designs for all gauges and special inspection fixtures.

Figure 1.1 Imperial Standard Yards

Figure 1.2 International Prototype Meter Cross-sections

4. These are not easily reproducible.

3. Territory standards 4. Working standards.

Figure 1.3 Working Line Standards

Figure 1.4 Classifications of Standards in Order

1.4 Precision and Accuracy

Figure 1.5 Precision And Accuracy

1.5 Errors in Measurement

 If however, repeated measurements of a given property using alternate test conditions,

Errors likely to creep in Precision Measurements

Figure 1.6 Effect of support

(a) Line standard and End bars (slope at ends zero)

(b) Straight edges (deflection at ends equals’ deflection).

Figure 1.8 (A) And (B) Effect of Misalignment

Figure 1.9 Combined Sines and Cosine Error

Figure 1.10 Effect of Contact Pressure on Measurement

Figure 1.11 Parallax Errors

Now generally, Ѳ is small therefore, tan Ѳ = Ѳ and error e = dѲ.

Figure 1.12 Surface Displacements

Error due to poor contact

Figure 1.13 Errors Due To Poor Contact

1.6 General Care of Metrological Equipment

1.7 Standardization and Standardizing Organization

International organization of Weights and Measurements

Figure 2.1 Vernier Instrument

Figure 2.2 Vernier Instruments

2.3 Reading the Vernier Scale

Figure 2.3 Practical Applications of Vernier Calipers

Figure 2.4 Vernier Caliper with Dial

Figure 2.5 Vernier Height Gauge

Figure 2.6 Vernier Depth Gauge

Figure 2.7 Micrometers

Figure 2.8 Practical Applications of Micrometers

Figure 2.9 Bore gauges

2.9 Dial indicators

Figure 2.10 Dial Indicators

2.10 Slip Gauges

Figure 2.11 Dimensions of a Slip Gauge

2.13 Bevel Protector

Figure 2.12 Bevel Protector

in divisions of 10 minutes of arc.

Figure 2.13 Use of sine bar

Where, L = distance between centers of ground cylinder (typically 5’’ or 10’’)

H = height of the gauge blocks

Θ =the angle of the plane

Figure 2.14 Practical Application of sine bar

height of slip gauges by which it should be adjusted is equal to = ôh x l/l'

Checking of unknown angles of heavy component. In such cases where components

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