PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Measurement
Section 5

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History
Egyptians used length called cubit
Equal to length of forearm (middle finger to elbow)

James Watt measured tolerances of steam engine with thickness of thin shilling International System of Units (SI) developed in 1960 Two major systems of measurement
Inch system in US and Canada Metric system for 90% of world

Metric (Decimal) Systems

Jan 16, 1970, Canada adopted SI for implementation throughout Canada by 1980 Dec 8, 1975, US Senate passed Metric Bill Will take long time to convert
All machine tools and measuring devices will have to be redesigned Long life expectancy of costly machine tools People resistant to change

Fractional/Inch System
Increased use of CNC and digital data make fractional sizes impractical
ANSI recommends decimal dimensions

Fractional dimensions still used to identify sizes of holes produced by drills, standard taps, and screw thread sizes

PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Basic Measurement
UNIT 7
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Objectives
Identify several types of steel rules Measure round and flat work to 1/64-in. accuracy with a rule Measure with spring calipers and a rule

Inch System
Unit of length is the inch
May be divided into fractional or decimal fractions Fractional system based on binary system
Common fractions: 1/2, 1/4, 1/8, 1/16, 1/32, 1/64

Decimal-fraction system uses base 10

Number written as product of 10 or fraction of 10

Inch System
Value
one-tenth one-hundredth

Fraction
110 1100

Decimal
.1 .01

one-thousandth
one ten-thousandth one millionth

11000
110,000 11,000,000

.001
.0001 .00001 .000001

one hundred-thousandth 1100,000

Inch/Metric Conversion
Metric Size mm cm 25.4 2.54 304.8 30.48 914.4 91.44
dm 0.254 3.048 9.144 m 0.0254 0.3048 0.9144

1 in. 1 ft 1 yd

Fractional Measurement
Measured with rulers or calipers Steel rules graduated
Binary-fractional divisions
1, , , 1/8, 1/16, 1/32, 1/64

Decimal fractional divisions

decimeters, centimeters, millimeters, half-millimeters

1/64 in. or 0.50 mm. smallest used

Precision instruments
Micrometers and verniers used for dimensions of less than 0.50 mm

Steel Rules
Metric steel rules graduated in millimeters and half-millimeters
Linear measurement without great accuracy Lengths from 15 c. to 1 m.

Factional steel rules graduated in common binary fractions (1/8 1/64 in.)
Several varieties (spring-tempered, flexible, narrow, and hook) Lengths range from 1 to 72 in.

Fractional Steel Rules

Spring-tempered quick reading 6 in. rules
Most frequently used in shop work

Hook rules
Used to make accurate measurements from edge of workpiece and also flanges and circular pieces Use for setting inside calipers to a dimension

Decimal rules
Used for linear measurements smaller than 1/64 in.

Fractional Steel Rules

Short-length rules
Used to measure small openings and hard-to-reach locations Five small rules in set: range between and 1 in.

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Measuring Lengths
Fairly accurate measure with steel rules
Butt end of rule against shoulder or step

Steel rules become worn with constant use

Can make measurements taken from end inaccurate Compensate by measuring from 1-in or 1-cm mark and subtracting 1 from measurement

Keep edge of rule parallel to edge of work Rule used as straightedge to test flatness of workpieces
Edges ground flat: place, hold to light and view

Outside Calipers
Not precision tools Used to approximately measure outside surface of either round or flat work Several styles
spring joint firm joint

Do not use when accuracy < .015 in.needed

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Using Outside Calipers

Hold both legs of caliper parallel to edge of rule. Turn adjusting nut until end of lower leg just splits desired graduation line on rule Place caliper on work with both legs of caliper at right angles to centerline of the work Diameter correct when caliper just slides over work by own weight

Inside Calipers
Used to measure diameter of holes or width of keyways and slots Several styles
Spring joint Firm Joint

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Measuring An Inside Diameter

Place 1 leg of caliper near hole's bottom edge Hold caliper leg in position with finger Keep caliper legs vertical or parallel to hole Move top leg in direction of arrows and turn adjusting nut until slight drag felt on leg Find size of setting by placing end of rule and one leg against flat surface Hold legs of caliper parallel to edge of rule and note reading

Transferring Measurements
Check caliper setting with outside micrometer for accurate measurement
Hold micrometer in right hand Place one leg of caliper on micrometer anvil and hold position Rock top leg of caliper in direction of arrows Adjust thimble until slight drag felt as caliper leg passed over measuring face
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PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Squares and Surface Plates

Unit 8
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8-21

Objectives
The machinists combination square
Three types of solid and adjustable squares

Two types of surface plates

8-22

Square
Used for layout, inspection and setup Manufactured to various degrees of accuracy
Range from semiprecision to precision squares

Precision squares are hardened and accurately ground

8-23

Machinist's Combination Square

Used for quick check of 90 and 45 degree angles and measure of length Part of combination set that includes square head, center head, bevel protractor and graduated grooved rule

8-24

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8-25

Precision Square
Used chiefly for inspection and setup purposes Hardened and accurately ground Must be handled carefully to preserve accuracy Great variety manufactured but all variations of either solid square or adjustable square

8-26

Beveled-Edge Square
Better quality standard squares used in inspection Beveled edge allows blade to make line contact with work
More accurate check

Work is square (90 degrees) if both sides touch surface of work

8-27

Toolmaker's Surface Plate Square

Provides convenient method of checking work for squareness on surface plate

One-piece construction
Little chance of any inaccuracy developing

8-28

Adjustable Squares
Not as accurate as good solid square Used where impossible to use fixed square Diemaker's square
Used to check clearance angle on dies Blade adjusted to angle of workpiece by bladeadjusting screw, then angle checked with protractor Direct-reading type indicates angle of blade

8-29

Adjustable Micrometer Square

Used to check part for squareness accurately

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8-30

Straightedges
Used to check surfaces for flatness and act as guide for scribing long, straight lines in layout work Rectangular bars of hardened and accurately ground steel Edges flat and parallel Plain or beveled edges Generally made of cast iron with ribs

8-31

Surface Plates
Rigid block of granite or cast iron Flat surface used as reference plane for layout Generally have three-point suspension to prevent rocking when mounted on uneven surface Two types
Cast-iron plates Granite surface plates

Trivia (Extra Credit)

Why is a granite surface plate preferred?

8-33

Surface Plates
Cast-iron plates
Well ribbed and high strength Good wear-resistance qualities After machined, surface scraped by hand to flat
Operation long and cost high

Granite surface plates

Manufactured from gray, pink, or black granite Several degrees of accuracy Extremely flat finishes produced by lapping

8-34

Advantages of Granite Plates

Not appreciably affected by temperature change Will not burr, therefore, accuracy not impaired Nonmagnetic Rustproof Abrasives will not embed themselves as easily in the surface

8-35

Care of Surface Plates

Keep surface plates clean at all times Clean occasionally with solvent to remove film Protect with wooden cover when not in use Use parallels whenever possible to prevent damage to plates by rough parts or castings Remove burrs from workpiece before placing it on plate

8-36

Care of Surface Plates

Slide heavy parts onto the plate rather than place them directly on the plate Remove all burrs from cast-iron plates by honing When not in regular use, cover cast-iron plates with thin film of oil to prevent rusting Center punching or prick punching layout lines should not be done on a surface plate

PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Micrometers
Unit 9

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9-38

Objectives
Identify the most common types of outside micrometers and their uses Measure the size of a variety of objects to within .001-in. accuracy Read vernier micrometers to .0001-in. accuracy Measure the size of a variety of objects to within 0.01-mm accuracy

9-39

Precision Measuring Tools

Five categories of tools based on the dimension being measured
Outside Inside Depth Thread Height

9-40

Micrometer Caliper
Standard inch micrometer accurate to .001 in.

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9-41

Principle of the Inch Micrometer

Zero line on thimble lined up with index line on sleeve (barrel)
Measuring faces just touch

Pitch is 1/40 (.025) in.since 40 threads

One complete revolution of spindle, one line appears Every fourth line longer (represents .100 in.)

Thimble has 25 equal divisions

Represents .001 in.

9-42

To Read Standard Inch Micrometer

Note last number showing on sleeve and multiply by .100 Note number of small lines visible to right and multiply by .025 Note number of divisions on thimble from zero to line that coincides with index line on sleeve and multiply by .001 Add three products to get total reading
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9-43

Sample Reading
Note last number showing on sleeve and multiply by .100

2 x .100 .200

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9-44

Sample Reading
Note number of small lines visible to right and multiply by .025

3 x .025 .075 3

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9-45

Sample Reading
Note number of divisions on thimble from zero to line that coincides with index line on sleeve and multiply by .001
13 x .001 .013

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9-46

Sample Reading
Add three products to get total reading

.200 .075 .013 .288 in.

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9-47

Vernier Micrometer
Added to sleeve

Scale consists of 10 divisions that run parallel to index line. Friction thimble

Each division on vernier scale has a value of .0001 in.

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9-48

To Read Vernier Micrometer

Read as would a standard micrometer Note line on vernier scale that coincides with one on thimble
Indicates number of ten-thousandths Multiple the line number times .0001

Add to total of the other readings

9-49

Micrometer Adjustments: Remove Play in Threads

Back off the thimble Insert C-spanner into slot or hole of adjusting nut Turn adjusting nut clockwise until play between threads has been eliminated
Note: After adjusting, spindle should advance freely while ratchet stop or friction thimble is being turned

9-50

Testing Accuracy of Micrometers

Test periodically to ensure accuracy Clean measuring faces before testing Turn thimble using friction thimble or ratchet stop until measuring faces contact each other
Zero line on thimble coincides with center index line on sleeve = accuracy

Can also check by measuring gage block or other known standard

9-51

Adjusting Accuracy of a Micrometer

Clean measuring faces; inspect for damage Close measuring faces carefully by turning ratchet stop or friction thimble Insert C-spanner into hole or slot in sleeve Carefully turn sleeve until index line on sleeve coincides with zero line on thimble Recheck accuracy

9-52

Special-Purpose Micrometers
Direct-reading micrometer
Additional digital readout built into frame

Large-frame micrometer
Made for measuring large outside diameters up to 60 in. Interchangeable anvils give range of 6 in.
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9-53

Other Micrometers
Indicating micrometer
Uses indicating dial and movable anvil Accurate to ten-thousandths of an inch Can be used as a comparator with gage blocks

Mul-T-Anvil micrometer
Used for measuring tubing and distances from a slot to an edge

Round and flat anvils

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9-54

Digi-Matic Micrometer
Used as hand gage for inspecting small parts Accurate up to 50 millionths of an inch and displays both inch or metric sizes Statistical process control when added provides stand-alone inspection system
Interface with PC
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9-55

Screw Thread Micrometers

Measures pitch diameter of threads Pointed spindle and double-V swivel anvil
Shaped to contact pitch diameter of thread
Equal to outside diameter less depth of one thread

Limited to certain range

Four ranges for one-inch
8-13 TPI 14-20 TPI 22-30 TPI 32-40 TPI

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PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Vernier Calipers
Unit 10

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10-57

Objectives
Measure workpieces to within an accuracy of .001 in. using a 25-division inch vernier caliper Measure workpieces to within an accuracy of .001 in. using a 50-division inch vernier caliper Measure workpieces to within an accuracy of 0.02 mm using a metric vernier caliper

10-58

Parts of the Vernier Caliper

Used to lock readings into place

Bar of 25-division vernier scale graduated same as micrometer

Manufactured with both 25- and 50-division vernier scales

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10-59

Measuring a Workpiece
Remove all burrs from workpiece Clean surface to be measured Open jaws enough to pass over work Close jaws against work and lock right-hand clamp screw Turn adjusting screw until jaws just touch work surface Lock clamp screw on movable jaw Read measurement

10-60

Reading the Measurement

1 x 1.000= 1.000 4 x 0.100= .400 1 x 0.050= .050 14 x 0.001= .014 1.464 in.

A 50-division inch vernier caliper reading of 1.464 in.

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10-61

Metric Vernier Caliper

Many have both metric and inch graduations Parts same as inch vernier Main scale graduated in millimeters
Every main division numbered, equal to 10 mm Fifty graduations on sliding scale with every fifth one numbered
50 graduations occupy same space as 49 graduations on main scale (49 mm) 1 vernier division = 0.98 mm so difference between 1 main scale division and 1 vernier division = .02 mm

10-62

Reading a Metric Vernier Caliper

Last numbered division on bar to left of vernier scale represents number of millimeters multiplied by 10 Note how many full graduations showing between this numbered division and zero
Multiply number by 1 mm

Find line on vernier scale that coincides with line on bar and multiply by 0.02 mm Add for total reading

10-63

Direct-Reading Dial Caliper

Dial indicator, hand attached to pinion, mounted on sliding jaw Metric: 1 revolution of hand = 2 mm of travel Inch: 1 revolution = .100 or .200 in. of travel
Depends on manufacturer

Most have narrow sliding blade attached to sliding jaw (and dial) used depth gage

10-64

Digital Electronic Caliper

Can provide readings to resolution of .0005 in. or 0.01 mm at touch of button No rack, pinion or glass scale Can connect to Statistical Process Control (SPC) equipment for inspection purposes Measurements
Inside diameter Outside diameter Step Depth

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PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Inside-, Depth-, and HeightMeasuring Instruments

Unit 11

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11-66

Transfer-Type Instruments
Size of object taken with instrument not capable of giving direct reading Small hole gages for small measures
Sets of four Range: .125 - .500 in.

Have small, round end or ball

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Have flat bottom

11-67

Transfer-Type Instruments
Telescope Gages
Used to obtain size of holes, slots, and recesses from .3125 to 6.000 in. (8 to 152 mm) T-shaped: pair of telescoping tubes connected to handle Knurled knob on handle end locks plungers into position

11-68

Vernier Height Gage

Precision instrument Variety of sizes:
12-72 in. or 300-1000 mm.

Height within .001 in (0.02 mm) Digital height gage

zero function, display .0001 in.

Offset scriber
Attachment that permits setting heights from face of plate

Depth gage attachment

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11-69

To Measure with a Vernier Height Gage and Dial Indicator

1. Thoroughly clean plate, base, work surface 2. Place finished edge of work on surface plate 3. Clamp against angle plate if necessary 4. Insert snug-fitting plug into hole with .500 in projecting 5. Mount dial indicator on movable jaw 6. Adjust movable jaw until indicator almost touches surface plate

11-70

To Measure with a Vernier Height Gage and Dial Indicator

7. Lock upper slide of height gage, use adjusting nut to move indicator until dial registers turn 8. Set indicator dial to zero 9. Adjust vernier height gage until indicator registers zero on top of plug 10. Subtract initial reading plus half diameter of plug