Measurement Instruments

BP CASPIAN SEA
WORKSHOP SKILLS
MEASUREMENT INSTRUMENTS & MARKING OUT (MD-008)
Unauthorized Reproduction of Learning Material Is Prohibited!
REVISI0N HISTORY
Revision Number
Rev. 0
Date
16-08-2004
Rev. 1
16-09-2004
Comments
Signed off by J Kaiser 17-09-2004
ISSUE 1
REV 1: Measurement Instruments & Marking out (MD-008)
Page 2 of 60
TOPICS COVERED INCLUDE
Reading Scales accurately
Reading Imperial and Metric Micrometers and Verniers
Tool handling and care
Safety
Page 3 of 60
CONTENTS
MEASUREMENT INSTRUMENTS (MD-008)
1.
INTRODUCTION
2.
TYPES OF CALIPERS
3.
VERNIER CALIPERS
3.1.
MAIN FEATURES
3.2.
READING A CALIPER: ENGLISH

3.2.1. WHERE DO YOU START?
3.2.2. EXAMPLE 1
3.2.3. SUMMARY
4.
5.
READING A CALIPER: METRIC

4.1.
EXAMPLE 1
4.2.
EXAMPLE 2
4.3.
EXAMPLE 3
MICROMETERS
5.1.
MICROMETER PARTS
5.2.
IMPERIAL MICROMETER
5.3.
READING THE METRIC: MICROMETER
6.
DIAL INDICATORS: MAIN PARTS
7.
INTRODUCTION TO LIMIT FITS & TOLERANCES
8.
DIMENSION TOLERANCES
9.
INTRODUCTION TO FITS
9.1.
EXAMPLE OF FITS
Page 4 of 60
9.2.
CLEARANCE FIT
9.3.
EXAMPLE OF FITS
9.4.
INTERFERENCE FIT
9.5.
EXAMPLE OF FITS
9.6.
TRANSITION FIT
10.
LIMITS & FITS STANDARDS
11.
GO-NO-GO GAUGES
MEASUREMENT INSTRUMENTS: MEASURING & MARKING OUT (MD-008)

12. INTRODUCTION
13. BASIC MEASURING TOOLS
14. READING SCALES ACCURATELY
15. MARKING OUT EQUIPMENT
15.1.
PREPARATION FOR MARKING OUT
15.2.
METHOD
15.3.
MARKING TABLE
15.4.
PARALLELS
15.5.
VEE BLOCKS
15.6.
SCRIBING BLOCK (SURFACE GAUGE)
15.7.
UNIVERSAL SURFACE GAUGE
15.8.
CENTER POP (DOT PUNCH)
15.9.
DIVIDERS
15.10. ODD LEGS (JENNIES) HERMAPHRODITE CALIPERS

15.11. ENGINEERS TRY SQUARE
15.12. COMBINATION SET
15.13. ANGLE PLATE
15.14. RULE STAND
15.15. SCREW JACK
15.16. SCRIBER
15.17. PROTRACTORS
MEASUREMENT INSTRUMENTS (MD-008)
Page 5 of 60
1.
INTRODUCTION
Calipers are tools used in the home, small shops, and industrial settings, they
are used to make precise length measurements. Some reasons for their
popularity include:
A wide measuring range (usually between 0 - 6)
Both English and metric scales are usually found on the

same instrument
Many different kinds of measurements can be made
While both micrometers and calipers can make outside length

measurements, calipers can also make inside measurements and also depth
measurements.
Figure 1 Outside Length Measurement
Figure 2 Inside and Depth Measurements
Page 6 of 60
2.
TYPES OF CALIPERS
Figure 3 Vernier Calipers
Figure 4 Dial Calipers
Figure 5 Digital Electronic Calipers
Page 7 of 60
3.
VERNIER CALIPERS
3.1.
MAIN FEATURES
Small jaws (for inside measurements)

Metric vernier scale
Metric fixed scale
Beam
English vernier scale English fixed scale
Depth Gauge
Jaws (for outside measurements)
Figure 6
3.2.
READING A CALIPER: ENGLISH
To determine the length of an object in inches, you must be able to read the
English scale on the caliper
Figure 7 English Scale is on the Upper Edge of this Caliper
Page 8 of 60
Most of the measurement information is going to come from the fixed English
scale, which can be thought of as a ruler
Figure 8
3.2.1. WHERE DO YOU START?
Use the zero line on the vernier scale
Figure 9
The zero line acts as a pointer, and tells you where to look on the fixed scale.
Reading a caliper is a process of collecting measurements from the fixed
scale and the vernier scale
To stay organized; write down each measurement in a column, being careful
to keep the decimal points lined up.
Page 9 of 60
3.2.2. EXAMPLE 1
The largest fixed scale divisions are the one-inch intervals, so start there first
Since the zero line is

between 1 and 2, we
know the object being
measured is at least 1
long.
Measurements
1
Figure 10
Page 10 of 60
The one-inch intervals are broken down into ten smaller ones. Each of these
is worth a tenth of an inch (0.1)
0.1
0.2
0.3
0.4
0.5
Etc.
Because the zero

line did not go
beyond any of the
one-tenth lines,
you wont add any
of these to the
measurement total.
Measurements
1
0.00
Figure 11
Page 11 of 60
The last step is to get a reading from the vernier scale
0.003
0.002
0.004
0.001
0.005
Etc...
Each line on the

vernier scale is
worth 0.001
Measurements
1
0.00
0.050
Figure 12
Page 12 of 60
What you are looking for is a place where one of the lines on the vernier lines
up with a line on the fixed scale
It might be difficult to
see on the computer
screen, but notice
how the 0.020 line
from the vernier
coincides (lines up)
with a line on the fixed
scale.
Measurements
1
0.00
0.050
Figure 13
Page 13 of 60
Add the vernier scale number to your list - the last step is to add up all of the
measurements
Measurements
1
0.0
0.050
+
0.020
1.070
Figure 14
Page 14 of 60
3.2.3. SUMMARY
Example 1
Locate the zero line on the vernier...
Figure 15
Determine the number of whole inches...
Figure 16
Page 15 of 60
...The number of tenths (0.1)...
The zero line did not go beyond

any of the 0.1 lines.
1
0.0
Figure 17
...The number of 0.025 lines...
The zero line is beyond the

second 0.025 line but not the
third.
1
0.0
0.05
Figure 18
Page 16 of 60
and finally the vernier reading
The 0.020 line seems to

line up best with a division
on the fixed scale.
1
0.0
0.050
Figure 19
The sum of all these measurements is 1.070
0.0
0.050
+ 0.020
Figure 20
Page 17 of 60
Example 2
Lets obtain a reading from this caliper:
Figure 21
Figure 22
Page 18 of 60
The zero line has not

gone beyond the 1
line, so there are no
0
whole inches.
Figure 23
The number of tenths (0.1)...
The zero line on the

vernier scale has gone
beyond the 0.5 line.
0
0.5
Figure 24
Page 19 of 60
The number of 0.025 lines...

The zero line on the
vernier scale has gone
beyond the first 0.025
line but not the second.
0
0.5
0.025
Figure 25
and finally the vernier reading.

The 0.019 line seems
to line up best with a
division on the fixed
scale.
0.5
0.025
0.019
Figure 26
Page 20 of 60
The sum of all these measurements is 0.544.
0
0.5
0.025
+ 0.019
0.544
Figure 27
Example 3
Lets obtain a reading from this caliper:
Figure 28
Page 21 of 60
Figure 29
The zero line has gone beyond

the 1 mark but not the 2 mark.
1
Figure 30
Page 22 of 60
the number of tenths (0.1)...
The zero line on the vernier

scale has gone beyond the 0.6
line but not quite to the 0.7 line
1
0.6
Figure 31
the number of 0.025 lines...
The zero line on the vernier

scale has gone beyond
three of the 0.025 lines.
This is equal to 0.075.
1
0.6
0.075
Figure 32
Page 23 of 60
and finally the vernier reading
The 0.014 line

seems to line up best
with a division on the
1
fixed scale.
0.6
0.075
0.014
Figure 33
The sum of all these measurements is 1.689

1
0.6
0.075
+ 0.014
1.689
Figure 34
Page 24 of 60
4.
READING A CALIPER: METRIC
As you are about to see, working with the metric portion of a vernier caliper is
a bit easier to deal with. You only need to make two readings; one from the
fixed scale and one from the vernier portion
4.1.
EXAMPLE 1
Start by obtaining a measurement from the fixed scale...
This is the fixed scale

used for the metric
readings.
Figure 35
Page 25 of 60
Use the zero line on the vernier to locate your position on the fixed scale
Figure 36
However, since your final reading is supposed to be in millimetres, you need

to view these amounts as millimetres
6 cm
7 cm
8 cm
9 cm
10 cm
Etc.
Each number printed on

the metric scale represents
centimeters.
Figure 37
Page 26 of 60
One trick is to mentally add a 0 (zero) behind each centimetre number.
80 mm
70 mm
90 mm
60 mm
100 mm
Figure 38
Since there are ten spaces between each numbered interval, these smallest
spaces must be 1 mm each.
this is
For example,
92 mm
93 mm
this would be
The smallest
etc.
91 mm...
interval on this
For example, note
scale is 1mm.
the ten spaces in

this interval.
Figure 39
Page 27 of 60
As you can see in this problem, we have a fixed scale measurement of 63

mm.
The reading is 63 mm since the zero line has gone just

beyond the 63 mm mark, but hasnt reached the 64 mm
mark.
Figure 40
To finish we must obtain a reading from the metric vernier scale.
.20
.15
.25
.10
.30
.05
.35
On this scale, each line represents 0.05 mm.
Figure 41
Page 28 of 60
Just as we did on the English vernier scale, we need to look for a place where
a line from the fixed scale lines up with a line on the vernier.
This is read as .50 mm
It appears that these two

lines, line up the best.
Figure 42
So based upon the two readings (one from the fixed scale, and one from the
ruler) the length must be 63 mm + .50 mm = 63.50 mm
63 mm
+ 0.5 mm
Figure 43
Page 29 of 60
4.2.
EXAMPLE 2
Lets try another one for practice
Figure 44
First take a reading from the fixed scale and using the zero line from the
vernier to help
The zero line is close, but not quite up to the 20 mm

line. It has gone beyond the 19 mm line however.
Remember that we
need to read the
fixed scale in terms
of millimeters.
19 mm
Figure 45
Page 30 of 60
To finish, read the vernier scale
This is read as .35 mm

It appears that these
19 mm
two lines, line up the

best.
.35 mm
Figure 46
The final reading then is 19.35 mm

19
mm
+ .35 mm
19.35 mm
Figure 47
Page 31 of 60
4.3.
EXAMPLE 3
Lets go through one more examples
Figure 48
Use the zero line from the vernier scale to help get a reading on the fixed
scale
The zero line is directly

above the 18 mm line.
Remember that we need to read the

fixed scale in terms of millimeters.
18 mm
Figure 49
Page 32 of 60
Thats it! Since the zero line on the vernier matched up with a line on the
fixed scale, you quit right there
The final reading is 18.00 mm
Figure 50
Page 33 of 60
5.
MICROMETERS
Micrometers are precision measuring instruments. They are manufactured in

both the imperial and metric systems. They are usually accurate to 0.01 mm
(0.0005 inch).
5.1.
MICROMETER PARTS
ANVIL
SPINDLE
BARREL
THIMBLE
FRAME
RACHET
LOCK
Figure 51
Figure 52 Types of Micrometers (Left to Right) Outside, Inside and Depth
Page 34 of 60
5.2.
IMPERIAL MICROMETER
1.
Start by verifying zero with the jaws closed. Turn the ratcheting knob
on the end till it clicks. If it isn't zero, do not use.
Figure 53
2.
Carefully open and close the jaws around the specimen using the
ratcheting knob till it clicks.
3.
First, identify it is between 3 and 4 (0.3).
4.
Next, see that it's just past the quarter mark (0.325).
5.
Also see that the dial reads between 4 and 5, so add 0.004 to the
0.325 to get 0.329.
0.329
0.3
0.325
Figure 54
Page 35 of 60
6.
To get the ten-thousandths place, read the venier scale
7.
Look for the line that best aligns with a mark on the dial - in this case 4
8.
So add 0.0004 for a final reading of 0.3294
0.3294
Figure 55
5.3.
READING THE METRIC: MICROMETER
The thimble rotates around the cylinder, which has markings every 0.5 mm on
the left hand side of the thimble there are markings right around. The line
labelled 0 is the primary pointer and when this lines up with the central
horizontal line on the cylinder the distance moved is 7mm
Figure 56
Page 36 of 60
If we rotate the thimble one complete revolution, the reading will then be
7.50mm (the downward line is not visible in figure 57)
Figure 57
One more complete revolution the reading is now 8mm
Figure 58
We have increased the distance by 0.120mm from 8.000mm, this means that
the reading now is 8.120mm.
Page 37 of 60
Figure 59
If we now rotate the thimble one complete additional rotation, the reading is
now 8.120mm + 0.500mm = 8.620mm
Figure 60
Page 38 of 60
6.
DIAL INDICATORS: MAIN PARTS
Dial indicators are manufactured in the imperial and metric system
Dial face
Revolution dial
Plunger
Figure 61
Dial indicators are precision measuring tools; a plunger moves in and out
from the body and rotates the measuring needle on a dial face. They can
have one or two inch measuring range and can be calibrated in increments of
0.001.
A smaller dial on the face reads each revolution of the larger dial in
increments of 0.100. the outer bezel rotates and turns the numeric scale with
it so that you can set the indicator to zero at any plunger position.
The important thing to remember when using dial indicators is that when the
plunger is depressed the gauge reads positive and when the plunger is
extended the gauge reads negative.
It is also important to remember that when a dial indicator is zeroed prior to
taking readings, the plunger should be in the mid-range position and the
plunger can now move in either direction.
The dial indicators have many uses in the engineering field, and could
include:
Performing Shaft Alignment
Checking Shaft Run-Out
Page 39 of 60
Check Bearing Endplay
Checking surface flatness
Machine shop operations
The dial test indicators are manufactured in both the metric and imperial
systems
Dial
Lever
Figure 62
The dial test indicators are similar to dial indicators but are typically more
precise. They have a smaller range of movement, however instead of a
plunger, they have a small lever arm that moves up and down, which enables
the tip to be inserted in small diameter holes (useful when centring a work
piece in a four jaw chuck for example). The indicator shown has a measuring
range of 0.030, which is much less that a dial indicator. When the tip is at
rest, at its neutral point, it can be moved 0.015 in either direction. The tip of
the dial test indicators can be set at differing angles.
Page 40 of 60
Extension bar
Dial
Clamp
Magnetic
base
Figure 63
Both dial and dial test indicators can be supplied with mounting attachments
such as:
Magnetic bases
Clamps
Extension rods
Page 41 of 60
Beam
Fine adjustment
Fine adjustment
screw
clamp
Finger
Base
clamp
Finger
Figure 64
The vertical height gauge has a vertical beam fixed to a flat base. This is
usually used on a marking out table (the datum face). The instrument can be
used for measuring absolute height above the datum surface.
The vernier scale is read in the same way as the vernier calliper. An
allowance may have to be made for the height of the finger. Before use,
lowering the finger onto the datum surface should check the zero reading.
When using a vernier height gauge, make sure that the base of the height
gauge, the surface table and the work piece are kept clean at all times. Bed
the surface gauge and the work piece firmly onto the datum surface.
Secure the fine adjustment clamp and use the fine adjustment screw to bring
the finger lightly into contact with the item being measured, you need to take
the reading in good light to obtain an accurate reading.
Page 42 of 60
7.
INTRODUCTION TO LIMIT FITS & TOLERANCES
To ensure the assemblies function properly their component parts must fit
together, however no component can be manufactured to an exact size. A
designer has to decide on an appropriate upper and lower limit for each
dimension.
8.
DIMENSION TOLERANCES
If a dimension is specified in millimetres as 10 0.02, the part will be

acceptable if the dimension is manufactured to an actual size of between:9.98 mm (the lower limit) and 10.02 m (which is the upper limit)
9.
INTRODUCTION TO FITS
The fit represents the tightness or looseness resulting from the application of
tolerances to mating parts, e.g. shafts and holes
9.1.
EXAMPLE OF FITS
Clearance fit (the shaft is always smaller than the hole)
1.495
1.493
1.500
1.502
Figure 65
Page 43 of 60
9.2.
CLEARANCE FIT
Enables assembly and disassembly by hand. This creates:
9.3.
Running and sliding assemblies
Free running on high temperature change applications
EXAMPLE OF FITS
The definition of interference fit is when the shaft is always larger in diameter
than the hole.
Assembly of this is by pressure or heat expansion
2.003
2.002
2.000
2.001
Figure 66
9.4.
INTERFERENCE FIT
Parts need to be forced or shrunk fitted together this creates permanent

assemblies that retain and locate themselves.
Page 44 of 60
9.5.
EXAMPLE OF FITS
Transition fit exists when:
Largest shaft is larger than the largest hole
But smallest shaft may fit in the largest hole
1.007
1.002
1.000
1.005
Figure 67
9.6.
TRANSITION FIT
Assembly usually requires press tooling or mechanical assistance of some

kind. This creates close accuracy with little or no interference.
10.
LIMITS & FITS STANDARDS
Fits have been standardised. BS 4500 standard ISO limits and fits. ANSI
(American National Standards Institute). BS4500 uses a letter code to
determine the limits, a capital letter denotes a hole and a small letter indicates
a shaft.
Page 45 of 60
11.
GO-NO-GO GAUGES
Figure 68
These gauges are made for simple pass/fail inspection. There are two
separate or combined gauges for each feature, one gauge must fit inside the
feature and the second must not, so therefore the GO gauge must fit. If the
GO gauge does not fit, the tolerance is above maximum metal tolerance and
if the NO-GO gauge goes, then the feature is below the minimum metal
tolerance.
Page 46 of 60
MEASUREMENT INSTRUMENTS: MEASURING & MARKING OUT
12.
INTRODUCTION
There are many types of measuring tools used in industry.

The accuracy of measurements depends on the way these tools are used and
treated.
Measuring tools are delicate instruments. They must be used carefully so as
to retain their accuracy.
Page 47 of 60
13.
BASIC MEASURING TOOLS
There are two methods used for taking measurements:
1.
The direct reading of a scale by eye
2.
By direct contact of the measuring tools on the work-piece
Figure 69 Ruler and Caliper
Page 48 of 60
14.
READING SCALES ACCURATELY
Parallax Error
Parallax is the apparent change in position of an object viewed against a
more distant object.
To avoid parallax error:
Hold the scale so that its graduations are close as possible to

the part being measured
Sight the graduations squarely off the scale
Figure 70 Measuring Using Graduations Carefully
Page 49 of 60
15.
MARKING OUT EQUIPMENT
The term Marking out means scribing lines on a metal surface to indicate
the profile or outline of the finished component.
The profile or outline of any holes that are to be cut in the component and the
position of any hole centres.
Note:
It is essential that when marking out or scribing that an accurate datum
or base-reference line be used to ensure correct measurements along
the length of the datum. If a base-reference line is not used a compound
error may result.
15.1. PREPARATION FOR MARKING OUT
In order that the scribed lines will show up clearly, the metal surface is usually
coated in a contrasting colour.
Whitewash
Spectre colour (blue)
Copper sulphate solution
15.2. METHOD
The first and most important thing is to establish a datum point and datum
lines on the metal. The long edge of the metal should be checked for
straightness with the ruler by holding one against the other and holding them
up to the light. Correct any faults with a file. File a second edge at right
angles to the first. Check with the set square.
This right angled corner is your zero point or datum and the two edges are
your datum lines.
All measurements will be taken from these datum.
Page 50 of 60
(Alternatively, you can scribe a line, say 5 mm, parallel to each edge, and use
these as your datum. The point that the two lines cross will be the zero
datum point.)
Take a minute to plan the sequence in which you will work. For example,
start with the main outline, including any radii that the profile might have, then
any cut outs, and then the centers of any drill holes.
15.3. MARKING TABLE
A cast iron table, heavily ribbed for rigidity. It is level and its edges are square
to its face and to each other. It provides a datum surface from which work
may be marked off or inspected. Rough surfaces should not be allowed in
contact with it, nor should articles be dropped, bounced or tapped on its
surface.
Marking tables should be protected when not in use.
Figure 71 Marking Table
Page 51 of 60
15.4. PARALLELS
Machine strips, square and parallel, used for supporting a surface parallel to
the table, made in various sizes, (matched pairs).
Figure 72 - Parallels
15.5. VEE BLOCKS
Machined blocks in pairs with vee grooves for supporting cylindrical work
parallel to table.
Figure 73 Vee Blocks
Page 52 of 60
15.6. SCRIBING BLOCK (SURFACE GAUGE)
Used on marking table to scribe centres and other lines which need to be
parallel to a common base.
Figure 74 - Scribing Block
15.7. UNIVERSAL SURFACE GAUGE
Used to scribe centre lines and other lines to common bases, both the top
surface and edge of marking table. The spindle can be adjusted to various
angles. The scriber point is positioned using a sensitive adjusting screw.
Figure 75 Universal Surface Gauge
Page 53 of 60
15.8. CENTRE POP (DOT PUNCH)
Used for making small indentations or dots along scribe lines and at the
centre of hole positions. Their function is to locate the leg of a pair of dividers
and to witness the position of scribed lines which may be obliterated.
Figure 76 Centre Pop (Dot Punch)
15.9. DIVIDERS
Use to scribe circles and arcs, setting out and checking distances. For large
arcs, distances trammels are used.
Figure 77 - Dividers
Page 54 of 60
15.10. ODD LEGS (JENNIES) HERMAPHRODITE CALIPERS
Used to scribe lines parallel to an edge, find centres of bores, but truth of
lines depends on skill in keeping angles constant while in use.
Figure 78 Hermaphrodite Calipers
15.11. ENGINEERS TRY SQUARE
Used for checking, setting or scribing at right angles. Stock is provided with a
slot to accommodate small burrs. Needs to be accurate to 90 and therefore
must be handled carefully and checked regularly.
Figure 79 Try Square
Page 55 of 60
15.12. COMBINATION SET
The combination set is a versatile measuring and testing tool and consists of
a graduated straight edged or blade which can be clamped to several
different heads.
Figure 80 Combination Sets
The protractor allows the blade to be set at an angle to the flat face.
The square head has one face that forms a right angle with the blade while
the other face forms a 45 angle with the blade.
Figure 81 Square Head
Page 56 of 60
The centre head is designed to allow one edge of the blade to pass through
the centre of two faces at right angles. The centre head and blade are used
for:
a)
Finding or making the centre of circular work
b)
Checking 45 angle
Figure 82 Using Combination Sets
Page 57 of 60
15.13. ANGLE PLATE
Two surfaces machined at 90 with slots and holes for the supporting of a
work piece at 90 to the table. Box angles are a variation being hollow cubical
boxes machined on all faces with slotted holes.
Figure 83 Angle Plate
15.14. RULE STAND
Fixture for holding an engineers steel rule at 90 to the table.
Figure 84 Rule Stand
Page 58 of 60
15.15. SCREW JACK
Use to raise/level the work pieces at varying heights upon a table, other aids
being steel shims and wedges.
Figure 85 Screw Jack
15.16. SCRIBER
Made from tool steel hardened and tempered at the pit. Used to scribe
straight lines with the aid of a rule, try square or straight edge.
Figure 86 - Scriber
Page 59 of 60
15.17. PROTRACTORS
Protractors have a dial face, graduated in degrees, with straight blade that
can be swivelled to an angle then locked in position. They are used for:
Setting work to an angle
Testing angles
Marking out the position of holes
Protractors are graduated in degrees only and should not be used for the
accurate measurement of angles:
Figure 87 Protractors
Page 60 of 60

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Unauthorized Reproduction of Learning Material Is Prohibited!

REV 1: Measurement Instruments & Marking out (MD-008)

TOPICS COVERED INCLUDE

Reading Scales accurately

Reading Imperial and Metric Micrometers and Verniers

Tool handling and care

REV 1: Measurement Instruments & Marking out (MD-008)

READING A CALIPER: ENGLISH

READING A CALIPER: METRIC

READING THE METRIC: MICROMETER

DIAL INDICATORS: MAIN PARTS

INTRODUCTION TO LIMIT FITS & TOLERANCES

REV 1: Measurement Instruments & Marking out (MD-008)

LIMITS & FITS STANDARDS