Metrology 50
Metrology 50
Let's now go into detailed notes on Direct Measuring Instruments – focusing on what they are, types, working principles, advantages,
disadvantages, and why they are used.
📏 1. Steel Rule
📏 Description:
✅ Advantages:
Simple, inexpensive.
No need for calibration.
❌ Disadvantages:
Low accuracy.
Subject to parallax error.
📏 Applications:
📏 2. Vernier Caliper
📏 Description:
📏 Working Principle:
The difference in divisions of the vernier scale and main scale provides a least count (e.g., 0.02 mm).
✅ Advantages:
❌ Disadvantages:
📏 Applications:
Component inspection.
Quality control in machining.
📏 Types:
✅ Advantages:
❌ Disadvantages:
📏 Applications:
📏 4. Height Gauge
📏 Description:
✅ Advantages:
❌ Disadvantages:
📏 5. Depth Gauge
📏 Description:
✅ Advantages:
❌ Disadvantages:
📏 Applications:
📏 Comparison Table
Instrument Accuracy Least Count Measurement Type Ease of Use
Instrument Accuracy Least Count Measurement Type Ease of Use
Steel Rule Low 0.5–1.0 mm General length Very Easy
Vernier Caliper Medium 0.02 mm External, internal, depth Easy
Micrometer High 0.01 mm External, internal Moderate
Height Gauge Medium–High 0.02 mm Height/vertical Moderate
Depth Gauge High 0.02 mm Depth Easy
Would you like me to now continue with Indirect Measuring Instruments or go deeper into one of the direct instruments with illustrations and
working mechanisms?
Certainly! Here's a detailed breakdown of the types of Vernier Calipers and Micrometer Screw Gauges, including their applications and
distinguishing features:
Advantages:
Used in: Intermediate measurement tasks, where digital tools are not preferred.
📏 4. Inside Vernier Caliper
Specially designed to measure the internal diameter of pipes, holes, and slots.
The jaws are facing outward.
📏 2. Inside Micrometer
Used to measure internal dimensions like the inside diameter of a cylinder or hole.
No fixed anvil – uses extensions and jaws to touch inside surfaces.
📏 3. Depth Micrometer
📏 4. Digital Micrometer
📏 5. Blade Micrometer
Has thin blade-shaped jaws for measuring grooves, keyways, or small slots.
Offers high accuracy in narrow regions.
📏 6. Disc Micrometer
Has flat disc-shaped anvils for measuring gear teeth thickness or shoulder diameters.
📏 7. Tube Micrometer
Certainly! Here's a detailed and structured explanation of Slip Gauges and Dial Indicators, covering their definition, types, material,
advantages, disadvantages, and applications.
Slip gauges (also called gauge blocks) are precision-ground rectangular blocks made of specific materials, used for obtaining precise lengths by
stacking them together. They are standardized to known lengths and used for calibration, comparison, and inspection.
📏 Why Are They Called "Slip" Gauges?
They are called “slip” gauges because they are joined together using a technique called "wringing", where two gauges stick due to molecular
adhesion without adhesives.
Type Description
Rectangular Most common, easy to wring together
Square Also used in some regions
Wear blocks Thinner, placed at ends to reduce wear
Angle gauge blocks Precision angle forming blocks
Long gauge blocks Custom or special inspection tools
Optical flat slip gauges For use with interferometry (light-based inspection)
A dial indicator is a mechanical comparative measuring instrument that amplifies small displacements of a plunger and displays the result on a
circular dial. It doesn’t measure absolute dimensions but shows deviation from a standard.
📏 Working Principle:
The plunger moves linearly when in contact with the object.
A gear mechanism transfers this motion to a rotating pointer on a graduated dial.
📏 Materials Used:
Type Description
Plunger Type Most common; linear displacement of plunger shown on dial
Lever Type (Test Indicator) Small lever arm instead of plunger; used for delicate tasks
Dial Depth Gauge Measures depths using a dial mechanism
Back Plunger Type Plunger moves horizontally; used where vertical space is limited
Digital Dial Indicator Digital display for easy, precise reading
1. VERNIER CALIPER
One small division on main scale = 1 mm
= (50 - 49)/50
= (1/50) mm
Least Count of Vernier = = 0.02 mm
a. TYPE-A VERNIER CALIPER
b. TYPE-B VERNIER CALIPER
c. TYPE-C VERNIER CALIPER
2. VERNIER HEIGHT GAUGE
3. VERNIER DEPTH GAUGE
4. MICROMETER
TYPES OF MICROMETER
1. Outside Micrometer
2. Inside Micrometer
3. Depth Micrometer
1. OUTSIDE MICROMETER
•
Can side up & down & perpendicular to axis of hole
•
Range of depth MM is 0 – 225 mm
•
Length of extension rod equal to range of micrometer
1. Slip Gauges
2. Limit Gauges
• Due to do this, hold the two blocks edge-to -edge, and gently push
one of the blocks inside so as to make it sit on the other block,
completely.
• These are also called “GO” and “NO GO” gauges refers to
an inspection tool used to check a workpiece against its
allowed tolerances.
• Its name derives from its use: the gauge has two tests; the
check involves the workpiece having to pass one test (Go)
and fail the other (No Go).
1. Plug gauges
a. Double ended Plug gauges 6. Snap gauges
b. Progressive type of Plug gauges
a. Double ended Snap gauges
2. Taper Plug Gauge
b. Progressive type of Snap gauges
a. Taper plug gauge - Plain
b. Taper plug gauge – tanged
c. Adjustable Snap gauges
3. Ring Gauges d. Plate type Double ended Snap
a. Taper ring gauge - Plain gauges
b. Taper ring gauge – tanged
e. Plate type single ended Snap
4. Combined Limit Gauges gauges
5. Position Gauges
28
© Dr. J.Jeevamalar, Mechanical/EGSPEC
3. RING GAUGES
Ring gauges are mainly used for checking the
diameter of shafts having a central hole.
The hole is accurately finished by grinding and
lapping after taking hardening process.
The periphery of the ring is knurled to give more
grips while handling the gauges.
We have to make two ring gauges separately to
check the shaft such as GO ring gauge and NOGO
ring gauge.
But the hole of GO ring gauge is made to the
upper limit size of the shaft and NOGO for the
lower limit.
While checking the shaft, the GO ring gauge
will pass through the shaft and NOGO will not pass.
To identify the NOGO ring gauges easily, a red
© Dr. J.Jeevamalar, Mechanical/EGSPEC
mark or a small groove cut on its periphery.
1. Sine Bar
3. Auto Collimator
4. Angle Dekkor
56
© Dr. J.Jeevamalar, Mechanical/EGSPEC
USE OF SINE BAR
1. Checking unknown angles of small components:
57
© Dr. J.Jeevamalar, Mechanical/EGSPEC
2. For locating any work to a given angle
For this, assume surface plate is perfectly flat, so that its surface is
perfectly horizontal.
One roller of the sine bar is placed on the surface plate and the other is
placed on the slip gauge rack of height H.
Let the sine bar is set to an angle θ. Sine θ = h/L
where L is the distance between the center.
Thus knowing θ, H can be found and any work can be set out at this angle
as the top face of the sine bar is inclined at angle θ to the surface plate.
For better result both rollers must placed on slip gauge of height h1
and h2 respectively.
58
© Dr. J.Jeevamalar, Mechanical/EGSPEC
3. Checking of unknown angles of heavy component:
When components are heavy and cannot be mounted on the sine bar, the sine bar
is mounted on the component as shown in figure.
The height over the rollers can be measured by a Vernier height gauge using a
dial gauge mounted on the anvil of it.
The difference in the two readings of height gauge divided by the centre distance
of sine bar gives the sine angle of the component to be measured.
59
© Dr. J.Jeevamalar, Mechanical/EGSPEC
ADVANTAGES AND DISADVANTAGES OF SINE BARS
61
© Dr. J.Jeevamalar, Mechanical/EGSPEC
2. BEVEL PROTRACTOR
61
© Dr. J.Jeevamalar, Mechanical/EGSPEC
Vernier or Universal Bevel Protractor
It has a base plate or stock whose
surface has a high degree of flatness
and surface finish and it is placed on
the workpiece whose angle is to be
measured.
An adjustable blade attached to a
circular dial is made to coincide with
the angular surface.
It can be swiveled to the required
angle and locked into position to
facilitate accurate reading of the
circular scale that is mounted on the
dial.
The main scale on the dial is
graduated in degrees and rotates with
the rotation of the adjustable blade.
A stationary vernier scale mounted close to the dial, enables measurements to
a least count of 5’ or less.
An acute angle attachment is provided for the measurement of acute angles. 62
© Dr. J.Jeevamalar, Mechanical/EGSPEC
3. AUTOCOLLIMATOR
63
© Dr. J.Jeevamalar, Mechanical/EGSPEC
WORKING OF AUTOCOLLIMATOR
Auto-collimator is an optical instrument used for the measurement of
small angular differences, changes or deflection, plane surface
inspection etc.
For small angular measurements, autocollimator provides a very
sensitive and accurate approach.
If a light source is placed in the flows of a collimating lens, it is
rejected as a parallel beam of light.
If this beam is made to strike a plane reflector, kept normal to the
optical axis, it is reflected back along its own path and is brought to
the same focus.
If the reflector is tilted through a small angle ‘’. Then the parallel
beam is deflected twice the angle and is brought to focus in the
same plane as the light source.
The distance of focus from the object is given by, x = 2.f
Where, f = Focul length of the lens
= Tilted angle of reflecting mirror/plane
© Dr. J.Jeevamalar, Mechanical/EGSPEC
Here is a detailed explanation of Light Autocollimator and Laser Autocollimator, two high-precision instruments used in
angle and alignment measurement.
📏 Light Autocollimator
📏 What is a Light Autocollimator?
A Light Autocollimator is an optical instrument used to measure very small angular displacements with high accuracy. It
uses a collimated light beam, a beam-splitting mirror, and a reticle or optical sensor to detect angular deviations based on
reflection from a mirror surface.
📏 Working Principle:
Visual Autocollimator: Uses an eyepiece and reticle; user visually reads the shift.
✅ Advantages:
❌ Disadvantages:
📏 Applications:
A Laser Autocollimator is an advanced version that uses a laser beam instead of visible light, providing longer range, higher
resolution, and less beam divergence. It is ideal for remote angular measurements, especially in industrial environments.
📏 Working Principle:
❌ Disadvantages:
📏 Applications:
66
© Dr. J.Jeevamalar, Mechanical/EGSPEC
ANGLE DEKKOR
• This is also a type of auto-collimator.
• This instrument is essentially used as a comparator and measures the
change in angular position of the reflector in two planes.
• It has an illuminated scale, which receives light directed through a
prism.
• The light beam carrying the image of the illuminated scale passes
through the collimating lens and falls onto the reflecting surface of the
workpiece.
• After getting reflected from the workpiece, it is refocused by the lens in
field view of the eyepiece.
• While doing so, the image of the illuminated scale would have undergone
a rotation of 90° with respect to the optical axis.
• Now, the light beam will pass through the datum scale fixed across the
path of the light beam.
• When viewed through the eyepiece, the reading on the illuminated scale
measures angular deviations from one axis at 90° to the optical axis, and
the reading on the fixed datum scale measures the deviation about an axis
© Dr. J.Jeevamalar, Mechanical/EGSPEC
mutually perpendicular to this.
📏 Material Used:
✅ Advantages:
Easy to use and read.
No external power needed (analog).
Portable and durable.
High precision in engineering levels.
❌ Disadvantages:
📏 Applications:
Aligning machinery.
Leveling foundations and surfaces.
Plumbing installations.
Calibration of CNC and mechanical components.
📏 2. Clinometer
📏 What is a Clinometer? © Dr. J.Jeevamalar, Mechanical/EGSPEC
📏 Types of Clinometers:
📏 Material Used:
✅ Advantages:
❌ Disadvantages:
📏 Applications:
📏 V-Block
📏 What is a V-Block?
📏 Types of V-Blocks:
Type Description
Standard V-groove on the top, usually without clamps. Used for
Plain V-Block
simple holding.
Magnetic V- Contains an inbuilt magnet and a switch to activate/deactivate
Block magnetic holding. Used for ferromagnetic materials.
V-Block with Comes with a built-in clamp or strap to hold the workpiece
Clamp securely. Suitable for precise inspection.
© Dr. J.Jeevamalar, Mechanical/EGSPEC
Adjustable V- Allows adjustment of the angle or position to accommodate
Block differently sized components.
📏 Materials Used:
❌ Disadvantages:
📏 Uses of V-Blocks:
Try Square:-
Here is a detailed explanation of Surface Measuring Instruments, which are used to assess the
roughness, waviness, and flatness of a surface—crucial parameters in manufacturing and
quality control.
These use a stylus that physically touches the surface to record deviations.
Examples:
Advantages:
Highly accurate
Good for metal surfaces
Disadvantages:
🔹 Function:
🔹 Example Instruments:
Mitutoyo Surftest
Taylor Hobson Talysurf
🔹 Diagram Includes:
🔹 Working Principle:
🔹 Function:
🔹 Diagram Includes:
Stylus system
Traverse unit
Transducer
Signal processor and printer or digital display
3. Profilometer
🔹 Working Principle:
🔹 Function:
🔹 Diagram Includes:
Stylus path
Vertical sensor unit
Horizontal displacement system
📏 Summary Table:
Instrument Working Principle Function Typical Use
The Mitutoyo Surftest is a stylus-type surface roughness tester, widely used in manufacturing
and quality inspection to measure the surface texture of machined components.
📏 What is Mitutoyo Surftest?
It is an electronic contact-type roughness tester that evaluates the surface finish by moving a
diamond-tipped stylus over the surface and recording vertical deviations.
📏 Working Principle:
1. A stylus (usually diamond-tipped) moves linearly across the surface.
2. The stylus follows surface peaks and valleys, and its vertical movement is converted
into an electrical signal by a transducer.
3. This signal is amplified and analyzed to compute roughness parameters like Ra, Rz, Rq,
Rt, etc.
4. Results are shown on a digital display or printed graph.
📏 Main Components:
Component Function
Stylus/Probe Contacts the surface and moves vertically with roughness
Drive Unit Moves the stylus horizontally at a controlled speed
Transducer Converts mechanical movement into electrical signal
Processing Unit Amplifies and interprets the signal
Display/Printer Shows numerical results or prints roughness graph
These use optical or laser systems to evaluate surface texture without physical contact.
a) Optical Interferometer
Provides 3D topography.
Suitable for roughness, step height, and volume analysis.
Advantages:
Non-destructive
Suitable for soft or polished surfaces
Disadvantages:
More expensive
Requires stable environments
3. Comparison Instruments
These don’t measure values but allow visual or tactile comparison with standard surfaces.
Ra Average roughness
Symbol Meaning
📏 Images Available
Would you like me to prepare a PDF with diagrams, instrument photos, and comparison
tables for these tools?
Surface measurement
It is used to tests the straightness & flatness of flat surfaces. The simple
shape is rectangular, but for precision work, one edge is beveled or made as
to the edge of a thin knife. The©narrow
Dr. J.Jeevamalar, Mechanical/EGSPEC
edge is the working surface, and the
wide edge serves as the base when not in use.
The tools have V-shaped grooves at the bottoms of the base to rest the block
on a round bar to set dimensions from the bar to another part of the work.
4.3. Optical Flat:
Optical flats are optical grade pieces of glass and are polished to be extremely
flats on one or sides both, usually within a few tens of nanometers. They are
used to determine the flatness of other surfaces with a single wavelength of
monochromatic light.
When an optical flat is placed on another’s surface & illuminated, the light
waves are reflected off the flat’s lower surface and onto the surface on which
it is resting. The reflected waves interfere, creating patterns of interferences
fringes visible as light & dark bands.
© Dr. J.Jeevamalar, Mechanical/EGSPEC
Flats surface is represented by a pattern of straight, parallel fringes with equal
spacing, while other patterns indicate uneven surfaces. Typically, only one of
the two surfaces of an optical flat is made flat to a specified tolerance, & this
surface is indicated by an arrow on the edges of the glass.
Planimeter
🔹 What is it?
🔹 Working Principle:
The user traces the outline of the shape with a tracer arm.
The instrument calculates the area based on the movement of the arm and internal mechanical
or electronic integration.
🔹 Applications:
🔹 Principle:
Uses light wave interference patterns created between a reference surface and the test surface.
Fringes produced by the difference in height are analyzed to calculate roughness.
🔹 Instruments:
🔹 Applications:
✅Advantages:
High cost
Sensitive to vibrations and environment
📏 Comparison Table
Method Contact/Non-contact Accuracy Cost Applications
Comparison Contact (Visual) Low Very Low Field inspections, quick checks
Here's a detailed set of notes on Optical Flat + Monochromatic Light, White Light
Interferometer, and Laser Interferometer—three major non-contact, optical interferometry
methods used for surface flatness and roughness measurement.
An Optical Flat is a high-precision flat glass or quartz disc used to test the flatness of
surfaces by observing interference patterns created by monochromatic light.
📏 How It Works:
📏 Applications:
✅ Advantages:
Very accurate
Simple, reliable
Low cost
❌ Limitations:
📏 Working Principle:
📏 Features:
📏 Output:
Semiconductor wafers
Lenses and mirrors
MEMS, biomedical devices
✅ Advantages:
❌ Limitations:
Expensive
Sensitive to vibrations
Limited to smooth, reflective surfaces
📏 3. Laser Interferometer
📏 What Is It?
📏 Principle:
📏 Applications:
❌ Limitations:
📏 Summary Table:
Optical Flat + White Light
Feature Laser Interferometer
Monochromatic Interferometer
Monochromatic (e.g.
Light Source White light Coherent laser (He-Ne)
Sodium)
Displacement/fringe
Output 2D fringe patterns 3D surface profile
count
Resolution High (~0.1 µm) Very high (nm level) Sub-nanometer
Contact/Non-
Non-contact Non-contact Non-contact
Contact
Complexity Simple Complex Highly precise
Cost Low High Very high