Module 7.

Precision
Measuring
Tools
 Precision Measuring
Instruments
• These instruments are used to measure dimensions
to a much greater accuracy than an engineers rule.
• Precision Measuring Instruments can measure to
0.001 mm or 0.0001”.
• Theses items are normally used in Workshops or
‘Clean Rooms’ and will be kept in a dedicated box to
protect it when not in use.
• Most companies will provide and maintain these type
of measuring devices due to the high costs involved.
 External Micrometers

• Used for measuring external dimensions of an object.

• The principle of a micrometer is based on the lead of

a screw thread, which is the distance the thread
moves during one complete revolution of the thimble.

• If the lead is known we can calculate the distance

between two accurately machined faces known as
the anvil and spindle.

Continued...
 Graduated Barrel with Ratchet
Datum Line Stop

Machined
Spindle Graduated
Faces
and Bevelled
Anvil Thimble

Locking Ring
(or Lever)

Frame

Continued...
• The object is placed between the anvil and spindle
faces and the thimble is turned to enclose the object
being measured.

• The ratchet stop prevents over tightening of the

micrometer to ensure consistent readings.

• The circumference of the thimble and the length of

the barrel are graduated to indicate the dimension.

• The barrel has a datum (fiducial) line from which the

measurements and settings are made.

Continued...
• The thimble is bevelled to place the graduations close
to the datum line to reduce parallax error.

• A lock ring or lever secures the spindle when the

required anvil to spindle distance has been set.

• Standard micrometer range is either 0-25mm or 0-1”

rising in 25mm or 1” increments.

End
 Metric Micrometers

• Metric micrometer has a lead of 0.5mm, so one

complete rotation equals 0.5mm.

• Datum line marked in 0.5mm and 1.0mm increments

with numbers every 5mm (5, 10, 15 etc.)

• Thimble has a total of 50 marks making one division

equal 1/50 of 0.5mm or 0.01mm.

Continued...
 Reading Metric Micrometer
Barrel
Fiducial Line Thimble
0.5mm 30 0.01mm
divisions divisions

0 5 25

C = 0.28
B = 0.50
A = 8.00
Total = 8.78 mm
End
 Imperial Micrometers

• Imperial micrometer has forty threads per inch, so

the lead is 1/40” (0.025”) or one thimble revolution.

• Thimble has a total of 25 equal divisions, so one

division reads 1/25 of 1/40” or 1/1000” (0.001”).

• Barrel marked at each 1/10” increment (1,2,3 etc.)

with four sub-divisions between each mark.

Continued...
 Reading Imperial Micrometer
1/10”
divisions
13
12
Thimble
11
1/1000”
0 1 2 3 4 10
9
8
divisions
7
6
5
4

1/40” 3

divisions
C = 0.008”
B = 0.075”
A = 0.400”
Total = 0.483” End
 Micrometer Care
• To ensure integrity of the measurements the faces
should be kept scrupulously clean.
• They are stored in protective cases, with desiccant if
possible and not used in extremes of temperature.
• The anvil and spindle faces should not be touching
when they are stored as temperature change may
cause the frame to distort.
• Before use inspection should include a zero check
and some sample measurements with slip gauges.
• Basic adjustments are possible using special tools
supplied, but the calibration may then be invalid.
 Internal Micrometers

Handle

Collar

0 9 8

Extension Rod
(if required) Micrometer Head
Continued...
 Internal Micrometer

• Works on the same principal as external micrometer,

available in Metric and Imperial the most common
being the ‘Stick’ type.
• An Imperial set consists of a two inch micrometer
head, nine extension rods and a half inch collar.
• The Metric set has a head and collar of 10mm range
and again a set of extension rods.
• Imperial ranges from 2” to 12”, and the Metric from
20mm to the extent of the maximum rod in the set.

End
Micrometer Depth Gauge

Ratchet

Thimble
or Sleeve
Barrel
8
9
0

Base Plate Spindle

Continued...
• Micrometer Depth Gauges are used for precision
measuring of cracks, grooves or recesses.

• It consists of a standard micrometer head mounted on

a precision ground bar.

• The bar is placed over the groove and the spindle

turned until it contacts the bottom of the groove.

• The spindle may be a sharpened point for measuring

into the very narrow recesses caused by cracks and
chips.

End
 Vernier Micrometers

• Some micrometers use the Vernier system to

increase the accuracy of the instrument.
• Utilises two accurately graduated scales, a fixed main
scale and an adjustable Vernier scale.
• Ten divisions on the Vernier scale equal nine on the
main scale.
• So one Vernier scale division equals one tenth of nine
millimetres (0.9 mm).
• The difference between one main scale division and
one Vernier scale division is therefore 0.1 mm.

Continued...
 Vernier Principle

Main
0 10 Scale
mm

0 1 2 3 4 5 6 7 8 9 10
Vernier
Scale

Continued...
• When the Vernier scale is moved so that the first of
the smaller Vernier divisions is aligned with the first
main-scale division, the zeros will be displaced by
exactly one tenth of one millimetre.

• If this principle is continued until the second division

of each scale is coincident, then the zeros will have
moved exactly two tenths of a millimetre apart.

• Whichever line on the main and Vernier scale align,

then the zero (or datum) marks will be displaced by
the small amount shown on the Vernier scale.

Continued...
 Vernier Micrometer Reading
Vernier Scale marked on barrel
(only lines 0 to 4 on view)

Vernier scale
marks align with
30 thimble marks to
produce a
reading.
0 5 25

This Vernier Micrometer

is set to 8.783 mm. End
 Vernier Callipers
Jaws for Internal
Measurement
Main Scale

Vernier Scale

Jaws for External

Measurement Continued...
 Vernier Callipers
• Uses the same Vernier principle as the Vernier
Micrometer, is more versatile but less accurate,
Metric to 0.02mm or 0.001” for Imperial.

• One instrument can measure inside and outside

dimensions, the smallest one having a range six
times greater than a micrometer.

• Calliper does not have the micrometer ‘ratchet’

mechanism to ensure continuity of measurement, so
care must be taken when taking the measurement.
 Vernier Calliper Nibs
• Some callipers have external measuring jaws only,
with nibs to allow internal measurements.
• The nibs have a value stamped on them which must
be added to the measurement from the scale.

Add Total Jaw

Thickness to
Measurement
 Vernier Height Gauge

Fine Adjustment

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Control
Vernier Scale

9
8
7
6
Precision
5
4
3
Scriber 2
1
Ground Base
and Beam
6 7
4 5
2 3

Distance to
1

Measure
 Vernier Height Gauge

• Vernier Height Gauge (VHG) is used in conjunction

with a surface plate or table.
• It utilises the Vernier principle with an accurately
machined base replacing the fixed jaw.
• The scales are marked on a beam set perpendicular
to the base.
• Most VHG have a Metric scale on one side of the
beam and an Imperial scale on the other.
• It can be used for accurate marking (scribing),
comparing height dimensions or as a depth gauge.
 Vernier Protractor

Grooved
Blade
Vernier Scale
Blade Locking under Magnifier
Device

Stock Main Scale

on Head

Fine Adjustment
Scale Locking
Device
 Vernier Protractor
• Vernier Protractor is an bevel protractor that can
measure to an accuracy of five minutes of arc (5’).

• The Vernier Scale is formed into 12 equal parts,

spread over 23 main scale divisions, 23°/12 = 1° 55’.

• Difference between two protractor scale divisions

(2°) and one Vernier scale division (1° 55’) is 5’.

• The protractor has a magnifying glass over the

Vernier scale to enable easier reading.
 Any Questions on
Precision Measuring
Instruments?
 Gauge Blocks

• Gauge Blocks or Slip Gauges are precision ground

blocks of metal.

• They are supplied in a protective box in sets of 50,

78 or 105 pieces.

• Manufactured from high-carbon steel or cemented

carbide, they are hardened, ground and lapped for
an accuracy of 0.00025mm (0.00001”).

Continued...
• This makes the opposite faces of the block flat,
parallel and set to an accurate distance.

• These precision surfaces enable them to be ‘wrung’

together (pressed and twisted simultaneously) so
they will remain firmly attached to each other.

• This enables one set of gauge blocks to make an

accurate distance of any dimension within the range
of the set.

• The prescribed distance should be made using the

smallest number of blocks possible.

End
 Dial Test Indicator
Plunger
Rotatable Bezel
and Dial
Bezel Clamp

Pointer
Revolution
Counter
Spigot

Removable Plunger
Anvil Continued...
• A DTI (or Clock Gauge) is used to indicate small
differences or eccentricity of components.

• The DTI has a plunger set in a spigot that protrudes

from the lower part of the dial.

• The plunger movement is transmitted to a gear train

which rotates a needle inside the dial face.

Continued...
• The scale is graduated in Metric or Imperial units in
increments of 0.01 or 0.001mm depending on
sensitivity.

• The rotating bezel can be rotated so the zero mark

can be adjusted to the required position.

• DTI’s can be secured to a Surface Gauge to give it

stability when checking components.

End
 Checking Gauges
• Feeler Gauges are thin, flexible steel blades of
various thickness 0.04mm - 1.0mm (0.0015" - 0.15")
• They are classified by the length of the blade are
usually secured together in sets of convenient sizes.
• Used to measure very small fixed gaps between
faces, can be used individually or combined to
achieve the required thickness.
• Screw Pitch Gauges used to determine the profile of
threaded fasteners, available in all thread systems.
• Radius Gauges used to check internal and external
radius profiles
 Checking Gauges

0.5
-1
0.0
mm

Radius Gauge
Feeler Gauges

.5 mm
5 -2
0.3

Screw Pitch Gauge

 Go/No-Go Gauges
• A comparator-type gauge used to check dimensions
that are repeated, very common on production lines.
• The gauge has two dimensions, the maximum and
minimum values of the required item.

Snap or
NOGO

GO NOGO
GO

Calliper Type
Plug
Type

• The dimension should be satisfactory using the GO

side and unsatisfactory with the NOGO side.
 Straight Edges
• Straight edges can be found in many forms.
1. Precision Ground Rule
2. Engineers Square
3. Cast Iron Heavy Duty Camel Back Type
• The rule and square are used in conjunction with
surface plates or tables and feeler gauges to
measure deviation of a flat surface.
• They can also utilise a strong light source to visually
check for straightness.
• The heavy duty types are often used with engineers
blue and a flat surface.
Any Questions on
Miscellaneous
Measuring Tools?