Study Notes: MOD 7.3.
3 Measuring Tools 📏
1.0 Fundamentals of Precision Measurement
Importance in Aircraft Maintenance: Accurate measurement is essential in aircraft
maintenance to ensure parts fit correctly, meet dimensional tolerances, and do not exceed
in-service wear limits. The reliability of components, especially engines, depends on this
precision.
Calibration Requirements:
o Purpose: To ensure accuracy, precision measuring tools must be regularly
inspected, serviced, and calibrated.
o Procedure: An organization must have a procedure for regular calibration,
typically following the manufacturer's instructions.
o Labeling: A clear labeling system is used to show the calibration status and the
date the next calibration is due.
o Zeroing: Before every use, a technician must check the instrument's accuracy by
"zeroing" it. If it does not zero correctly, it may need recalibration.
2.0 Layout and Comparison Tools
Mark-out Tools: These tools are used to mark dimensions on metal parts, often after
applying a mark-out dye. Common mark-out tools include Scribers, Dividers, and
the Vernier Height Gauge.
Straight Edges: A tool with a precision straight edge for checking the straightness of a
surface or drawing straight lines. It is often used with feeler gauges to check for flatness.
Engineer's Square: A precision instrument with hardened steel blades used for marking
out lines at right angles, checking for flatness, and squaring up work. It must be handled
with care and used only for its intended purpose.
3.0 Angular Measurement Tools
Bevel Protractor: A circular protractor with a pivoted arm used for measuring or
marking off angles. A Vernier Protractor includes a vernier scale that allows for much
greater accuracy, typically to within 5 minutes (1/12th of a degree).
Inclinometer (Clinometer): An instrument used to measure angles of slope or tilt with
respect to gravity. In aviation, it is often used to measure the angles of flight control
surfaces during rigging operations.
4.0 Clearance and Gap Measurement
Feeler Gauges (Thickness Gauges):
o Use: Feeler gauges are used to measure small spaces or clearances between parts,
such as when fitting components or checking for wear.
o Construction: They consist of a set of thin blades made of hardened steel or
brass, each marked with its thickness.
o Technique: Blades can be used singly or stacked together to measure a specific
gap. When using thin blades, it is better to pull them through the gap rather than
push to avoid damage.
5.0 Micrometers
General Principles: Micrometers are precision tools for making highly accurate
measurements. Imperial versions measure in increments of 0.001 inches, and metric
versions in 0.01 millimeters.
Types:
o Outside Micrometer: Measures external dimensions.
o Inside Micrometer: Measures internal dimensions like the inside of a hole.
o Depth Micrometer: Measures the depth of holes, grooves, or steps.
Care of Micrometers: Micrometers are delicate instruments.
o Before use, clean the measuring faces (anvil and spindle) and the workpiece.
o Check the calibration date and the zero reading.
o Never measure a rotating part.
o Use the ratchet stop for final adjustments to apply consistent, light pressure.
How to Read an Imperial Micrometer
The measurement is the sum of three readings from the sleeve and thimble.
1. Sleeve (Tenths): Read the highest number visible on the sleeve. Each number represents
0.100" (e.g., the number '2' represents 0.200").
2. Sleeve (Thousandths): Count the number of full graduation lines visible past the
numbered division. Each line represents 0.025".
3. Thimble: Read the line on the thimble scale that aligns with the horizontal datum line on
the sleeve. Each line on the thimble represents 0.001".
4. Total: Add the three values together.
How to Read a Metric Micrometer
The measurement is the sum of readings from the upper scale, lower scale, and thimble.
1. Sleeve (Upper Scale): Read the last whole millimeter mark visible on the top scale.
2. Sleeve (Lower Scale): Check if the 0.5 mm mark is visible on the bottom scale past the
whole millimeter mark. If it is, add 0.50 mm.
3. Thimble: Read the line on the thimble scale that aligns with the horizontal datum line on
the sleeve. Each graduation represents 0.01 mm.
4. Total: Add the readings together.
6.0 Vernier Instruments
The Vernier Principle: A vernier scale provides greater precision by using a secondary
sliding scale that compares against a fixed main scale.
Vernier Slide Caliper: A precision instrument for making accurate linear measurements,
consisting of a fixed jaw and beam with a main scale, and a sliding jaw with a vernier
scale.
Vernier Height Gauge: Combines a measuring tool with a scribing tool. It uses a vernier
scale on a vertical beam with a ground base and is used with a surface plate to scribe
accurate parallel lines.
7.0 Indicator Gauges
Dial Indicators (DI):
o Use: Precision instruments used to measure small amounts of movement between
parts. Common checks include shaft out-of-roundness (run-out), flatness,
backlash, and end float.
o Operation: A spring-loaded plunger contacts the work and registers any variation
on the dial.
Dial Test Indicators (DTI): A special type of indicator that measures displacement
using a pivoting lever, making it useful for measuring surfaces that cannot be accessed
directly by a DI's plunger.
Bore Gauges: Used for the quick and accurate checking of hole dimensions, like engine
cylinder bores. They often incorporate a dial indicator with a telescoping gauge to show
the amount of oversize or undersize from a set nominal dimension.
8.0 Limit Gauges and Digital Instruments
Go/No-Go Gauges:
o Function: Used to quickly check if a part is within specified dimensional limits
without taking a numerical measurement.
o Operation: The gauge has two gaps. A correct part will fit into the "GO" gap but
will not fit into the smaller "NO-GO" gap. An oversized part won't enter the GO
gap, and an undersized part will pass through both.
Digital Measuring Instruments:
o Advantages: Electronic digital readouts eliminate reading errors and the need for
calculations, can be zeroed at any point, and can switch between imperial and
metric units.
o Disadvantage: They are battery-powered and require battery replacements.
