Measurement of Lines & Surfaces

By S K Mondal
 Linear measurements
Some of the instruments used for the linear
measurements are:
Rules (Scale)
Vernier
Micrometer (Most widely used, Working Standard)
Height gauge
Bore gauge
Dial indicator
Slip gauges or gauge blocks (Most accurate, End
Standard)
 Vernier Caliper
A vernier scale is an auxiliary scale that slides along the
main scale.
The vernier scale is that a certain number n of divisions on
the vernier scale is equal in length to a different number
(usually one less) of main-scale divisions.
nV = (n −1)S
where n = number of divisions on the vernier scale
V = The length of one division on the vernier scale
and S = Length of the smallest main-scale division
Least count is applied to the smallest value that can be read
directly by use of a vernier scale.
Least count = S − V = 1 S
n
Vernier Caliper
 Metric Micrometer
A micrometer allows a measurement of the size of a

body. It is one of the most accurate mechanical devices

in common use.
It consists a main scale and a thimble

Method of Measurement
Step-I: Find the whole number of mm in the barrel
Step-I: Find the reading of barrel and multiply by 0.01
Step-III: Add the value in Step-I and Step-II
Micrometer
 ISRO-2009, 2011
In a simple micrometer with screw pitch 0.5
mm and divisions on thimble 50, the reading
corresponding to 5 divisions on barrel and 12
divisions on thimble is
(a) 2.620 mm (b) 2.512 mm
(c) 2.120 mm (d) 5.012 mm
Bore Gauge: used for measuring bores of different
sizes ranging from small-to-large sizes.
Provided with various extension arms that can be
added for different sizes.
Dial indicator: Converts a linear
displacement into a radial
movement to measure over a
small range of movement for the
plunger.
The typical least count that can
be obtained with suitable gearing
dial indicators is 0.01 mm to 0.001
mm.
It is possible to use the dial
indicator as a comparator by
mounting it on a stand at any
suitable height. Principle of a dial indicator
Applications of dial indicator include:
centering workpices to machine tool spindles

offsetting lathe tail stocks

aligning a vice on a milling machine

checking dimensions
 GATE – 2008 S-1
A displacement sensor (a dial indicator) measures the
lateral displacement of a mandrel mounted on the taper
hole inside a drill spindle. The mandrel axis is an
extension of the drill spindle taper hole axis and the
protruding portion of the mandrel surface is perfectly
cylindrical. Measurements are taken with the sensor
placed at two positions P and Q as shown in the figure.
The readings are recorded as Rx = maximum deflection
minus minimum deflection, corresponding to sensor
position at X, over one rotation.
 GATE – 2008 contd… from S-2
If Rp= RQ>0, which one of the following
would be consistent with the observation?
(A) The drill spindle rotational axis is
coincident with the drill spindle taper
hole axis
(B) The drill spindle rotational axis
intersects the drill spindle taper hole axis
at point P
(C) The drill spindle rotational axis is
parallel to the drill spindle taper hole axis
(D) The drill spindle rotational axis
intersects the drill spindle taper hole axis
at point Q
 Slip Gauges or Gauge blocks
These are small blocks of alloy steel.
Used in the manufacturing shops as length standards.
Not to be used for regular and continuous
measurement.
Rectangular blocks with thickness representing the
dimension of the block. The cross-section of the block
is usually 32 mm x 9 mm.
Are hardened and finished to size. The measuring
surfaces of the gauge blocks are finished to a very high
degree of finish, flatness and accuracy.
Come in sets with different number of pieces in a
given set to suit the requirements of measurements.
A typical set consisting of 88 pieces for metric units is
shown in.
To build any given dimension, it is necessary to
identify a set of blocks, which are to be put together.
Number of blocks used should always be the smallest.
Generally the top and bottom Slip Gauges in the pile
are 2 mm wear gauges. This is so that they will be the
only ones that will wear down, and it is much cheaper
to replace two gauges than a whole set.
To make up a Slip Gauge pile to 41.125 mm
A Slip Gauge pile is set up with the use of simple

maths.
Decide what height you want to set up, in this case

41.125mm.
Take away the thickness of the two wear gauges,

and then use the gauges in the set to remove each

place of decimal in turn, starting with the lowest.
To make up a Slip Gauge pile to 41.125 mm
41.125
-4.000
______
37.125
-1.005
_______
36.120
-1.020
_______
35.100
-1.100
_______
34.000
-4.000
_______
30.000
-30.000
_______
0.000
 A Metric slip gauge set (88 Pieces)
Slip gauges size or Increment, mm Number of
range, mm Pieces
1.005 - 1
1.001 to 1.009 0.001 9
1.010 to 1.490 0.010 49
0.500 to 9.500 0.500 19
10 to 100 10.000 10
 Comparators
Comparator is another form of linear measuring
method, which is quick and more convenient for
checking large number of identical dimensions.
During the measurement, a comparator is able to give
the deviation of the dimension from the set dimension.
Cannot measure absolute dimension but can only
compare two dimensions.
Highly reliable.
To magnify the deviation, a number of principles are
used such as mechanical, optical, pneumatic and
electrical.
Fig. Principle of a comparator
 GATE – 2007 (PI)
Which one of the following instruments is a
comparator ?

(a) Tool Maker’s Microscope

(b) GO/NO GO gauge
(c) Optical Interferometer

(d) Dial Gauge

 Mechanical Comparators
The Mikrokator principle
greatly magnifies any
deviation in size so that
even small deviations
produce large deflections of
the pointer over the scale.
 Sigma Mechanical Comparator
The Sigma Mechanical Comparator uses a partially
wrapped band wrapped about a driving drum to turn a
pointer needle. The assembly provides a frictionless
movement with a resistant pressure provided by the
springs.
Sigma Mechanical Comparator
 Mechanical Comparators
The Eden-Rolt Reed system uses a

pointer attached to the end of two

reeds. One reed is pushed by a
plunger, while the other is fixed. As
one reed moves relative to the other,
the pointer that they are commonly
attached to will deflect.
 Optical Comparators
These devices use a plunger to rotate a mirror. A light
beam is reflected off that mirror, and simply by the
virtue of distance, the small rotation of the mirror can
be converted to a significant translation with little
friction.
 Pneumatic Comparators
Flow type:

The float height is essentially proportional to the air

that escapes from the gauge head

Master gauges are used to find calibration points on

the scales
The input pressure is regulated to allow
magnification adjustment
Pneumatic Comparators
 IFS-2015
Define a comparator.

Write at least six desirable features it should possess.

Also name four types of comparators.
[ 8 Marks]
 Angular Measurement
This involves the measurement of angles of tapers and
similar surfaces. The most common angular measuring
tools are:
Bevel protractor

Sine bar
 Bevel Protractor
Is part of the machinist's combination square.

The flat base of the protractor helps in setting it firmly

on the workpiece and then by rotating the rule, it is

possible to measure the angle. It will typically have a
discrimination of one degree.
A Bevel Protractor
 Sine Bar
When a reference for a non-square angle is required, a sine bar

can be used.
Basically a sine bar is a bar of known length. When gauge blocks

are placed under one end, the sine bar will tilt to a specific angle.
Knowing the height differential of the two rollers in alignment

with the workpiece ,the angle can be calculated using the sine
formula.
A sine bar is specified by the distance between the centre of the

two rollers, i.e. 100 mm, 200 mm, & 300 mm. the various part of
sine bar are hardened before grinding & lapping.
 H
s in  
L
 GATE -2012 (PI)
A sine bar has a length of 250 mm. Each roller has
a diameter of 20 mm. During taper angle
measurement of a component, the height from the
surface plate to the centre of a roller is 100 mm.
The calculated taper angle (in degrees) is
(a) 21.1 (b) 22.8 (c) 23.6 (d) 68.9
 Thread Measurements
Threads are normally specified by the major diameter.
Though there are a large variety of threads used in
engineering, the most common thread encountered is
the metric V-thread shown in Fig.
The parameters that are normally measured are:
Major diameter
 Micrometer
Pitch diameter
Floating Carriage micrometer
Wire method (Three wire and two wire)
Pitch
Screw pitch gauge
Pitch measuring machine
Thread form
Optical projector
 Three-Wire Method
 Three wires of equal diameter placed in thread, two

on one side and one on other side

 Standard micrometer used to measure distance over

wires (M)
 Different sizes and pitches of threads require

different sizes of wires

The Three-Wire Method of Measuring Threads

D p  pitch diameter or Effective diameter

p  pitch of thread , and   thread angle
Distance W over the outer edge
  p 
W  D p  d 1  cosec   cot
 2 2 2
For ISO metric thread,   60 and D p  D  0.6496 p
W  D  3d  1.5156 p
Best wire size
p 
d  sec
2 2
For ISO metric thread,   60
d  0.5774 p
 Two-Wire Method
 Two wires of equal diameter placed in thread, two on

one side and one on other side

Pitch Diameter or Effective Dia.
Dp  T  P
p     
 T  cot    d  cosec  1
2 2  2 
T  Dimensions under the wire  D   Dm  Ds 
D  Diameter of master or standard cylinder
Dm  Micrometer reading over standard cylinder with two wire
D s  Micrometer reading over the plug screw gauge with the wire
P = Pitch value

Best wire size

p 
d  sec
2 2
 GATE – 2011 (PI)
The best wire size (in mm) for measuring
effective diameter of a metric thread (included
angle is 60o) of 20 mm diameter and 2.5 mm
pitch using two wire method is
(a) 1.443
(b) 0.723
(c) 2.886
(d) 2.086
 GATE-2013
A metric thread of pitch 2 mm and thread angle 60
inspected for its pitch diameter using 3-wire
method. The diameter of the best size wire in mm is
(a) 0.866 (b) 1.000 (c) 1.154 (d) 2.000
 GATE – 2011 (PI)
To measure the effective diameter of an external
metric thread (included angle is 60o) of 3.5 mm
pitch, a cylindrical standard of 30.5 mm diameter
and two wires of 2 mm diameter each are used. The
micrometer readings over the standard and over the
wires are 16.532 mm and 15.398 mm, respectively.
The effective diameter (in mm) of the thread is
(a) 33.366 (b) 30.397
(c) 29.366 (d) 26.397
Measurement of Surfaces
 Surfaces
No surface is perfectly smooth, but the better the

surface quality, the longer a product generally lasts,

and the better is performs.
Surface texture can be difficult to analyse
quantitatively.
Two surfaces may be entirely different, yet still provide

the same CLA (Ra) value.

Surface geometry can be quantified a few different
ways.

Real surfaces are rarely so flat, or smooth, but most

commonly a combination of the two.
Roughness height: is the parameter with which
generally the surface finish is indicated. It is specified
either as arithmetic average value or the root mean
square value.
Roughness width: is the distance parallel to the
nominal part surface within which the peaks and
valleys, which constitutes the predominant pattern of
the roughness.
Roughness width cut-off: is the maximum width of
the surface that is included in the calculation of the
roughness height.
Waviness: refers to those surface irregularities that have
a greater spacing than that of roughness width.
Determined by the height of the waviness and its
width.
The greater the width, the smoother is the surface and
thus is more desirable.
Lay direction: is the direction of the predominant
surface pattern produced on the workpiece by the tool
marks.
Flaw: are surface irregularities that are present which
are random and therefore will not be considered.
 Lay
Diagram Symbol Description
Parallel lay: Lay parallel to
the Surface. Surface is
produced by shaping,
planning etc.

Perpendicular lay: Lay

perpendicular to the
Surface. Surface is produced
by shaping and planning
Crossed lay: Lay angular in
both directions.
Surface is produced by
knurling, honing.
 Lay Contd..
Diagram Symbol Description
Multidirectional lay: Lay
multidirectional. Surface is
produced by grinding,
lapping, super finishing.
Circular lay:
Approximately circular
relative to the center.
Surface is produced by
facing.
Radial lay: Approximately
radial relative to the center
of the nominal surface.
Representation of Surface Roughness
Roughness Roughness Grade Roughness Symbol
Number
Ra (m)
50 N12 -
25 N11
12.5 N10 
6.3 N9
3.2 N8 
1.6 N7
0.8 N6
0.4 N5 
0.2 N4
0.1 N3
0.05 N2 
0.025 N1
 IES - 1992
Which grade symbol represents surface rough of
broaching?
(a)N12 (b) N8
(c)N4 (d) N1
Waviness height - the distance from a peak to a valley
Waviness width - the distance between peaks or
valleys
Roughness width cutoff - a value greater than the
maximum roughness width that is the largest
separation of surface irregularities included in the
measurements. Typical values are (0.003”, 0.010”,
0.030”, 0.100”, 0.300”)
Lay - the direction the roughness pattern should
follow
Stylus travel is perpendicular to the lay specified.
 Evaluation of Surface Roughness
1. Centre line average (CLA) or arithmetic mean deviation
denoted as Ra.

2. Root mean square value (Rg) : rms value

3. Maximum peak to valley roughness (hmax)

4. The average of the five highest peak and five deepst

valleys in the sample.
5. The average or leveling depth of the profile.
 Determination of Mean Line
M-System: After plotting the characteristic of any
surface a horizontal line is drawn by joining two points.
This line is shifts up and down in such a way that 50%
area is above the line and 50% area is below the line
 Determination of Mean Line
E-System: (Envelop System) A sphere of 25 mm
diameter is rolled over the surface and the locus of its
centre is being traced out called envelope. This envelope
is shifted in downward direction till the area above the
line is equal to the area below the line. This is called
mean envelope and the system of datum is called E-
system.
 Arithmetical Average:
Measured for a specified area and the figures are
added together and the total is then divided by the
number of measurements taken to obtain the mean or
arithmetical average (AA).
It is also sometimes called the centre line average or
CLA value. This in equation form is given by

L
1 1
Ra   y ( x) dx 
L0 N
y i
 GATE-2016 (PI)
The roughness profile of a surface is depicted below.

The surface roughness parameter Ra (in μm) is _______

The other parameter that is used sometimes is the root
mean square value of the deviation in place of the
arithmetic average , This in expression form is
1
RRMS 
N
y 2
i

Fig. Surface roughness parameters

 ISRO-2011
CLA value and RMS values are used for measurement
of
(a) Metal hardness

(b) Sharpness of tool edge

(c) Surface dimensions
(d) Surface roughness
IES - 2008
Methods of measuring Surface Roughness
There are a number of useful techniques for measuring
surface roughness:
Observation and touch - the human finger is very

perceptive to surface roughness

stylus based equipment - very common

Interferometry - uses light wave interference

patterns (discussed later)
 Observation Methods
Human perception is highly relative.

To give the human tester a reference for what they are

touching, commercial sets of standards are available.

Comparison should be made against matched
identical processes.
One method of note is the finger nail assessment of

roughness and touch method.

 Stylus Equipment
uses a stylus that tracks small changes in surface
height, and a skid that follows large changes in surface
height.
The relative motion between the skid and the stylus is
measured with a magnetic circuit and induction coils.
One example of this is the Brown & Sharpe Surfcom
unit.
 Profilometer
Measuring instrument used to measure a surface's

profile, in order to quantify its roughness.

Vertical resolution is usually in the nanometre level,

though lateral resolution is usually poorer.

 Contact profilometers
A diamond stylus is moved vertically in contact with a
sample and then moved laterally across the sample for
a specified distance and specified contact force.
A profilometer can measure small surface variations in
vertical stylus displacement as a function of position.
The radius of diamond stylus ranges from 20
nanometres to 25 μm.
 Non-contact Profilometers
An optical profilometer is a non-contact method for

providing much of the same information as a stylus

based profilometer.
There are many different techniques which are

currently being employed, such as laser triangulation

(triangulation sensor), confocal microscopy and digital
holography.
 Advantages of optical Profilometers
Because the non-contact profilometer does not touch

the surface the scan speeds are dictated by the light

reflected from the surface and the speed of the
acquisition electronics.
Optical profilometers do not touch the surface and

therefore cannot be damaged by surface wear or

careless operators.
 Optical Flats
Optical-grade clear fused quartz or glass structures
lapped and polished to be extremely flat on one or both
sides.
Used with a monochromatic light to determine the
flatness of other optical surfaces by interference.
When a flat surface of another optic is placed on the
optical flat, interference fringes are seen due to
interference in the tiny gap between the two surfaces.
The spacing between the fringes is smaller where the
gap is changing more rapidly, indicating a departure
from flatness in one of the two surfaces, in a similar way
to the contour lines on a map.
When the fringes are perfectly straight and same fringe
width for dark and bright band we conclude that the
surface is perfectly flat.
For convex surface the fringes curve around the point of
contact.
For concave surface the fringes curve away from the
point of contact.

The distance of air gap between two successive fringes is given by 
2
th n
Distance of air gap of interference fringe of n order is 
2
 GATE-2016
Two optically flat plates of glass are kept at a small
angle θ as shown in the figure. Monochromatic light is
incident vertically.

If the wavelength of light used to get a fringe spacing of

1 mm is 450 nm, the wavelength of light (in nm) to get a
fringe spacing of 1.5 mm is _______
For IES Only
Optical flat as a comparator
 n l
h 
2
Wherel  separation of edges
n  number of fringes / cm
h  The difference of height between gauges
  wevlength of monochomatic light
 GATE - 2003
Two slip gauges of 10 mm width measuring 1.000 mm
and 1.002 mm are kept side by side in contact with each
other lengthwise. An optical flat is kept resting on the
slip gauges as shown in the figure. Monochromatic light
of wavelength 0.0058928 mm is used in the inspection.
The total number of straight fringes that can be observed
on both slip gauges is

(a) 2 (b) 6
(c) 8 (d) 13
 GATE – 2011 (PI)
Observation of a slip gauge on a flatness
interferometer produced fringe counts numbering
10 and 14 for two readings. The second reading is
taken by rotating the set-up by 180o. Assume that
both faces of the slip gauge are flat and the
wavelength of the radiation is 0.5086 µm. The
parallelism error (in µm) between the two faces of
the slip gauge is
(a) 0.2543 (b) 1.172
(c) 0.5086 (d) 0.1272
 Talysurf
It is based upon measuring the generated noise due to
dry friction of a metallic blade which travels over the
surface under consideration.
If the frictional force is made small enough to excite
the blade, and not the entire system, then the noise
will be proportional to surface roughness, and
independent of the measured specimen size and
material.
The specimen surface roughness was measured by a
widely used commercial instrument (Talysurf 10), and
the prototype transducer.
 @
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Ans. (d)