❑Measuring of materials and machined work involves
the use of a number of measuring tools to secure sizes of length, width, thickness and diameter. ❑Practically all shops require measuring. ❑A machinists will most likely measure or gauge flat or round objects; the outside diameters of rods, shafts, or bolts; slots, grooves, and other openings; thread pitch and angles; spaces between surfaces or angles and circles. MEASUREMENTS ❑ The term “gage”, as used in this identifies any device which can be used to determine the size or shape of an object. ❑There is no significant difference between gages and measuring instruments. ❑They are both used to compare the size and shape of an object against a scale or fixed dimension MEASUREMENTS MEASURERING AND CHECKING INSTRUMENTS ❑ They are used for comparing and checking the size of the given (Machined) components with the set of or accepted standards ❑ The accuracy of the measurements obtained depends on the accuracy of a given measuring or checking instrument. MEASURING INSTRUMENTS: These are graduated tools provided with a scale intended for direct reading of the value being measured against the scale of the tool. They serve three important functions: i. To layout workpiece to specifications ii. To compare the finished work with known standards iii. Inspect the work and check wheather it meets required specifications Measuring Instruments commonly used are: Steel rule, Tape measure,Vernier calliper, Micrometer, Vernier depth gauge, vernier bevel protector, Vernier height gauge and Dial Indicator. Measuring and Checking Tools Safety 1. Keep clear of moving machinery 2. Avoid laying other tools on top of the measuring tools 3. Frequently wiping with an oily cloth, will prevent from rust 4. The measuring tools are not allowed to come into contact with harmful materials e.g. Filling e.t.c 5. It is not allowed to take measurements in a moving parts 6. Check accuracy regularly Measuring Instruments STEEL RULE AND TAPE MEASURES ❑ Are used for measuring and Marking out purposes. ❑ The reading accuracy is 0.5mm. Measuring Instruments Measuring Instruments VERNIER CALLIPER: ❑ Is used for measuring lengths, depth and diameter of work pieces. ❑ There measuring accuracy depends on design and can be 0.1mm, 0.05mm or 0.02mm. VERNIER DEPTH (CALLIPER) GA UGE ❑ Is used for measuring the depth of blind holes, grooves, recesses, slots e.t.c. ❑ Their measuring accuracy can vary from 0.1mm,0.05mm, 0.02mm.
VERNIER HEGHT GAUGE
❑ Is an important tool for precision LAYOUT ❑ The functions of the vernier is to measure and sribe lines of known height of the workpiece. Also perpendicular lines may be scribed on the workpiece. ❑ Its accuracy ranges from 0.1mm, 0.05mm or 0.02mm. Measuring Instruments Vernier callipers Have own measuring scales built in Very accurate - some can measure to 0.01mm (1/100 of a millimetre)
gaps/ internal diameters. Measuring Instruments Source of errors when using vernier calliper. ❑ Caliper not properly set to zero ❑Test object not inserted far enough into measuring jaws ❑Noticeable play between slide bar ❑Dirty measuring surfaces ❑Too little or too much force applied in pressing the measuring pins against the object Measuring Instruments ❑ Manipulation of the vernier scale reading ❑ Measuring instruments tilted when measuring i.e non-perpendicular plane between bar and jaws, or between jaws and workpiece. Using the vernier calliper
1. Before measuring, close jaws and
check that main scale zero mark lines up exactly with vernier scale zero mark. 2. Adjust jaws. 3. You may need to gently “rock” the jaws to get the right feel – not too tight, not too loose. 4. Lock the slide. Using the vernier calliper cont’d
5. Read number of whole
millimetres on main scale, 16 whole mm before the vernier zero 6. Look for a vernier scale graduation which lines up exactly with any 0.38 mm graduation on the main scale 7. Read fraction number on vernier scale where the marks line up 8. Add fraction to whole Example: 16.00 whole mm millimetres to get final + 0.38 mm on measurement. vernier = 16.38 mm Measuring Instruments Measuring Instruments Measuring Instruments Measuring Instruments Measuring Instruments Measuring Instruments VERNIER BEVEL PRO TECTOR Used for measuring and checking angles from 0 to 180 degrees. It has a vernier scale accuracy of 5minutes (5’).
MICROMETER There are two types of Micrometer 1. Inside Micrometer- Are used to measure the inside diameter (bores) or internal dimensions They are designed to cover different ranges of measurements (by 25mms) 0-25, 25-50. e.t.c. Micrometers • Use to take very accurate measurements • 3 types - may look different but all use the same principle. 1. Outside micrometer 2. Inside micrometer 3. Depth micrometer
1. The outside micrometer
• Measures width and length • Used for precise measurements eg reconditioning an engine, measuring pistons, valves, crankshafts etc. Micrometers
2. Inside micrometer 3. Depth micrometer
• measures the inside of holes or • measures the depth of holes/ bores. grooves/ recesses and the height of shoulders. Using the outside micrometer
Hold micrometer by frame
with your left hand. Open micrometer and clean anvils with a clean cloth.
Check accuracy Gently close micrometer with ratchet until anvils are touching or use a test piece. Look at the scales - they should both read zero. Reading the micrometer scale
The sleeve is marked with
numbered graduations = whole millimetres.
Sleeve also has half Around the thimble - 50
millimetre graduations graduations, beginning and marked. ending at 0. Reading the micrometer scale
One full turn of the thimble
opens the micrometer by exactly 0.50mm. A “half mm” graduation is just visible on the datum line.
Two full turns opens the anvils
by exactly 1.00 mm. The 1 mm graduation is just showing on the datum line. Reading the micrometer scale Remember – 1 thimble division = 0.01 mm.
To get the final measurement:
1. Note the number of whole
millimetres visible on the datum 0.01mm line.
2. Add any half millimetres showing
on the datum line.
3. Add the number of thimble
graduations lined up with the datum line. Reading the Micrometer Scale Example 1
4 whole mm showing = 4.00 mm
1 half mm showing = 0.50 mm 5 indicated on the thimble = 0.05 mm TOTAL = 4.55 mm
Example 2 5 whole mm showing = 5.00 mm 1 half mm showing = 0.50 mm 12 indicated on the thimble = 0.12 mm TOTAL = 5.62 mm Measuring Instruments 2. Outside Micrometer Are used for external measurements and are designed to cover different ranges of measurements. e.g. 0-25, 25-50mm, 50-75mm, 75-100mm. e.t.c. MEASURING INSTRUMENTS DIAL INDICATOR DIAL INDICATOR ❑ Is used to set and inspect size and trueness of finished work as well as of workpieces ❑It is not used for measuring absolute value of a dimension ❑Its reading accuracy can vary between 0.01mm t0 0.001mm. Dial indicator gauge Also called a dial gauge or dial indicator.
• Has a face or dial marked in divisions of 0.01 mm (1/100 mm)
• Does not take a direct measurement - shows variations from the original zero setting • These variations are transferred from the spindle to the pointer. DIAL INDICATOR Vernier Protractor Used to measure obtuse angle (90º-180º) Acute-angle attachment fastened to protractor to measure angles less than 90º Main scale divided into two arcs of 180º Scale divided into 12 spaces on each side of 0 If zero on vernier scale coincides with line on main: reading in degrees VERNIER BEVEL PRO TECTOR VERNIER BEVEL PRO TECTOR Used for measuring and checking angles from 0 to 180 degrees. It has a vernier scale accuracy of 5minutes (5’). Vernier Protractor
Always read the vernier in the same direction from zero that the dial is read and add the vernier minutes to the scale degrees Reading a Vernier Protractor Note number of whole degrees between zero on main scale and zero on vernier scale • Proceeding in same direction, note which vernier line coincides with mail scale line Fourth – Multiply number by 5' and add to degrees on protractor dial
50º 4 x 5'= 20'
Reading = 50º 20'
Reading a Vernier Protractor 12o 50’ Vernier Protractor Vernier Protractor
Figure 1: When reading from 90, these are positions where the angle and its supplement are found
Figure 2: when reading from 0, there is little danger
of confusing the angle and its supplement CHECKING INSTRUMENTS ❑These are instruments with no scale. They cannot be used to measure absolute values of dimensions or angles. ❑Are used to for checking shapes and sizes of different parts. ❑Checking instruments are: squares, slip gauges, feeler gauges, spirit level, snap gauges, limit plug gauges, radius gauges and thread pitch gauges. CHECKING INSTRUMENTS SQUARES: Are used to check squareness and surface flatness or for marking out and setting a workpiece. They are of two types: 1. Flat square 2. Try Square CHECKING INSTRUMENTS Squares Squares CHECKING INSTRUMENTS SLIP GAUGES(BLOCK GAUGES): ❑ They are used to obtain the required size by assembling them with the required combination. ❑ They are available in sets of 9,38, or 83 blocks FEELER GAUGES ❑ Are used to check clearances between mating surfaces. It can also used in adjusting clearances e.g adjusting valve clearances on a car cylinders, checking sparking plug gap ❑ Feeler gauge is a set of thin steel blade of known thickness. They are manufactured with thickness from 0.03mm to 0.1 in 0.01mm intervals and from 0.1 to 1mm in 0.05mm intervals CHECKING INTRUMENTS CHECKING INTRUMENTS CHECKING ISTRUMENTS SNAP AND LIMIT GAUGES: ❑ In mass production the workpiece dimensions are determined by non- adjustable inspection gauge with a view of serving inspection time ❑ The gauges used are manufactured in two sizes to suit maximum and minimum limits required for particular dimensions. SNAP LIMIT GAUGES: ❑ Are used to check cylindrical and prismatic work (Shaft, Bars e.t.c.)’ GO and NOT GO’ ❑ Go side of the snap gauge must pass over the work and NOT GO side of the snap gauge must fail to pass over the work CHECKING INSTRUMENTS CHECKING INSTRUMENTS LIMIT PLUG GAUGES: ❑ Are used for checking holes, slots and grooves CHECKING INSTRUMENTS SCREW PITCH GAUGES: ❑ Are used for checking screw threads for size and fits other means used are plug and thread micrometer SPIRIT LEVELS SPIRIT LEVELS ❑Are used to check the horizontal and vertical positions of workpiece setup on the machines . ❑When the level is held in a perfect horizontal position, the air bubble will be exactly at the middle of the glass tube. SPIRIT LEVELS Outside and Inside Calipers Outside and Inside Calipers Checking Instruments Checking Instruments Other Instruments Other Instruments Other Instruments
