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Handbook of Dimensional Measurement 5th Edition
Mark Curtis Digital Instant Download
Author(s): Mark Curtis
ISBN(s): 9780831134655, 0831134658
Edition: 5
File Details: PDF, 21.48 MB
Year: 2013
Language: english
Handbook of
Dimensional
Measurement
Fif th Edition
Mark A. Curtis, Ed.D.
President, Great Basin College

Francis T. Farago, Ph.D.

The late Senior Research Engineer
General Motors Corporation

Industrial Press Inc.

To my wife Margaret with love
 Preface to First
Edition
Dimensional measurements are a vital link between To facilitate the acquisition and application of
the designer’s intent and the actual product. Thus, needed information on methods and equipment out of
design engineering provides detailed specifications in the myriads of facts and data available, ample usage has
the form of dimensioned and toleranced drawings. been made of a highly efficient method of topic discus-
Manufacturing engineering converts these into fin- sion: presentation of significant aspects in tabular form.
ished products with the aid of a wide variety of Over eighty tables with diagrammatic illustrations and
dimensional measurements; and quality engineering brief synopses are provided for rapid scanning and
maintains a continuing control on the product output review. Thus, important topics of dimensional measur-
by still more dimensional measurements carried out ing techniques and equipment can be quickly located
with the aid of more or less complex instrumentation. and evaluated by means of the comparative analyses
Phenomenal progress has been achieved during the arranged for synoptic observation both in words and
past decades in the fields of product design, manufac- pictures. More detailed information, together with elab-
turing and quality control. New and improved oration of the concise statements of the tables, can then
materials, better machines and more sophisticated be found in the adjoining text portions of the book.
inspection methods and techniques are all contribut- Emphasis has been laid on the discussion of sev-
ing to technological changes that are taking place with eral important, yet only recently improved systems
almost bewildering rapidity. To keep pace with the of measurement which either have not been de
demands from industry for greater accuracy, repeata- scribed at all or have been mentioned only tangen-
bility, reliability, ease of use and continuous process tially in other books on dimensional metrology. In
control, new and improved dimensional measuring addition to such subjects and the current state-of-
techniques and equipment have had to be developed. the-art topics, even a brief discussion of methods and
As in most present-day fields of science and tech- tools which are considered rudimentary, might
nology, however, it is extremely difficult for the appear unnecessary. However, aside from the
practitioner engaged in everyday work to keep abreast author’s attempt toward completeness, the covering
of the new methods and equipment in the many ram- of such an extended range of levels is held to be war-
ified areas of dimensional measurement. It may be ranted because of the many common fundamentals
even more difficult for the beginner, the fledgling engi- throughout. Both the basic and the most advanced
neer or technician, who has not been exposed to the methods of dimensional measurements rely on simi-
current practices and equipment of a modern manu- lar principles in such aspects as, e.g., part staging
facturing plant or laboratory, to collect and absorb the datum definition, specimen orientation, referencing,
huge amount of know-how on which advanced geometric interrelationship, etc. An understanding of
dimensional measurement technology rests. One of the fundamentals of a routine operation obtained by
the major purposes of this handbook is to provide a reviewing generally known and practiced methods,
readily accessible reference for both the neophyte and can assist both new and experienced engineers in
the experienced engineer and technician. improving their analytical approach toward the more

xxv
x x vi PREFACE TO FIRST EDITION

complex measurement problems which, too, must be In the light of the considerable extent of the sub-
examined and resolved as geometrical propositions. ject, the attempt to embrace in a single book the whole
Many reputable manufacturers of measuring field of dimensional measurement would appear a far
instruments were helpful in supplying photographic too ambitious undertaking. Recognizing the physical
material for illustrating this handbook. The author limitations of a handbook, the emphasis was laid con-
wishes to express his thanks for their cooperation. sistently on principles and general characteristics,
Unfortunately, space requirements do place definite which are applicable to whole families of processes
limits on the inclusion of illustrations in any hand- and instruments. While completeness, even within
book. Therefore, while the contributors of the judiciously set limits can only be approached, it is
book’s illustrations are prominent in the discussed hoped that this book, by providing access to many
lines of products, neither the selection nor the omis- principles and practices of modern dimensional
sion of a particular instrument or manufacturer measurements, will prove of value to its readers at
should be construed as an indication of product many different levels of individual experience and
evaluation. responsibility.
 List of Tables
1-1 Comparison of the Responsibilities and Objectives
of the Two Branches of Dimensional Metrology 10
2-1 Systems of Line Graduated Measuring Instruments 13
2-2 Accuracy Requirements for Different Grades of Line Graduated
Measuring Bars and Rules 16
3-1 Categories of Commonly Used Fixed Gages 34
3-2 Application Examples for Master Type Fixed Gages 37
3-3 Basic Designs of Cylindrical Plug Gages 43
3-4 Basic Designs of Cylindrical Ring Gages 45
3-5 Gage-Maker Tolerances for Cylindrical Plug and Ring Gages 49
3-6 The Allocation of Wear Allowances and Gage-Maker Tolerances
in the Dimensioning of Fixed Gages 50
4-1 Cross-Sectional Dimensions and Tolerances of Gage Blocks 55
4-2 Length Tolerances of Gage Blocks 57
4-3 Flatness and Parallelism Tolerances of Gage Blocks 59
4-4 Average Coefficient of Thermal Expansion of Materials Commonly Used for the
Manufacture of Gage Blocks and for Component Parts in Engineering Production 61
4-5 The Composition of Typical Gage Block Sets 64
4-6 Assembly of Gage Block Stacks 65
4-7 Length Measurement of Gage Blocks by Light Interference 73
5-1 Characteristic Applications of Indicator Instruments 79
5-2 Characteristic Advantages of Mechanical Indicators 82
5-3 Systems of Displacement Amplification Used in Mechanical Indicators 83
5-4 Nominal Dial (Bezel) Diameters and Classes of Marking for Agd Dial Indicators 87
5-5 Characteristic Applications for Test Type Indicators 99
5-6 Systems of Indicator Gages for Internal Measurements 109
6-1 Systems of Air Gages—Operational Principles of Different Circuits 126
6-2 Application Advantages of Pneumatic Gaging 128
6-3 Air Gage Sensing Members—The Principles of Their Operation 142
6-4 Examples of Conditions Warranting the Use of Contact Type Air Gage Sensing Members 145
6-5 Applications for Air Gages—Diverse Categories of Geometric Conditions with Examples
of Frequently Measured Dimensions 147
6-6 Examples of Geometric Forms Whose Interrelated Dimensions
Are Effectively Measured with Dual Circuit Air Gages 150

xi
xii TA B L E S

7-1 Favorable Properties of Electronic Gages 155

7-2 Comparison of Conditions Affecting Gaging Techniques in External and Internal Length
Measurements (Diameter Measurements on a Plug and on a Ring) 166
7-3 Operational Principles of Different Types of Internal Comparator Gages 169
7-4 Secondary and Auxiliary Functions Derived from Electronic Displacement Measuring Gages 172
8-1 Referencing for Length Measurements by Transmitted Light 185
8-2 Referencing for Length Measurements by Reflected Light 188
8-3 Referencing for Length Measurements with Optically Indicating Mechanical Contact Sensor 189
8-4 Referencing for Length Measurements by Grazing-Incidence Light Beam 193
8-5 Referencing for Length Measurements by Double-Image Sighting 195
8-6 Optical Measurement of Angular Separation (Mutually Referenced Angles) 197
8-7 Optical Measurement of Angular Divisions (Circular Spacings Referenced
from a Common Center) 200
8-8 Optical Inspection by Contour Form Comparison 202
8-9 Examples of Preferential Applications for Engineering Microscopes 207
9-1 Potential Applications of Optical Projectors 215
9-2 Types and Applications of Optical Projector Screen Chart 227
9-3 Examples of Preferential Applications for Optical Projectors 230
9-4 Operational Characteristics and Adaptability of Optical Projectors 234
10-1 Examples of Geometric Conditions Measured in Angular Units 241
10-2 Systems and Techniques of Angular Measurements 244
10-3 Taper Terminology 248
10-4 Examples of Angle Measurements by Comprison to an Angular Reference Body 249
10-5 Tolerances for Sine Bars, Blocks and Plates 253
10-6 Methods of Taper Angle Measurement by Comparison to a Virtual Cone 256
10-7 Systems of Circular Dividing Instruments 261
10-8 Systems of Angular Displacement Control in Circular Dividing Devices 263
11-1 Examples of Engineering Measurements by Optical Tooling 275
11-2 Examples of Methods for Inspecting Straightness 277
11-3 Examples of Methods for the Measurement of Flatness 289
11-4 Examples of Surface Plate Applications for Dimensional Measurements 292
11-5 Currently Used Sizes of Granite Surface Plates With Values
of Flatness Accuracy Required by Federal Specification Ggg-P-463c 294
11-6 Examples of Methods for the Measurement of Perpendicularity 299
11-7 Examples of Autocollimator Applications in Dimensional Metrology 305
12-1 Measuring Machines and General Characteristics 319
12-2 Characteristic Capabilities of Single-Axis Measuring Machines 322
12-3 Examples of Coordinate Measuring-Machine Applications 330
12-4 Examples of Targeting (Contact) Members for Coordinate Measuring Machines 335
12-5 Example of Multiple-Axis Measuring-Machine Application 342
12-6 Example of Multiple-Axis Measuring-Machine Application 343
12-7 Example of Multiple-Axis Measuring-Machine Application 343
13-1 Methods of Profile Measurement 349
13-2 Applications of Profile Tracing for the Measurement of Geometric Conditions—Based
on the Conceptual Role of the Straight Line 362
13-3 The Principles of Work Staging for Inspection and Measurement by Profile Tracing 367
13-4 The Interpretation of Chart Lines Produced by Profile Tracing 374
14-1 Characteristic Irregularities of Basically Round Forms 379
14-2 Application Examples of Engineering Parts with Functional Need for Roundness 382
14-3 Basic Varieties of Vee-Block Supported Roundness Measurements 390
14-4 Potential Sources of Error in Roundness Inspection Between Centers 393
 TA B L E S xiii

14-5 Examples of Geometric Conditions Examined by Circular Contour Tracing 397

14-6 Examples of the Chart Representation of Geometric Conditions Inspected by Circular Tracing 404
15-1 Examples of Application Categories Requiring Controlled Surface Texture 413
15-2 Methods of Surface-Texture Measurement 419
15-3 Operational Characteristics of Different Systems of Stylus
Type Surface-Texture Measuring Instruments 423
15-4 Selected Design Characteristics of Pickup Heads, Styli and Skids 425
15-5 Design Principles of Extraneous Guidance Systems for Surface-Texture Measuring Instruments 427
15-6 Surface-Texture Analysis by Chart Recording—Examples of Chart Types
and Aspects of Assessment 435
16-1 Examples of Purpose-Related Screw Threat Measurements 448
16-2 Screw Thread Dimensions Inspected by Gaging 451
16-3 Inspection of Screw Thread Variables with Indicating Gages 456
16-4 System-Related Characteristics of Engineering Microscopes and Optical Projectors 477
17-1 Parameters and Methods of Analytical Gear Measurements 483
18-1 Applications of Dimensional Measurements for Controlling Machining Processes 511
18-2 Commonly Used Types of Gaging Units for the In-Process Control of Workpiece Diameters 517
20-1 Maximum Material Condition and how deviations from it effects the allowable 571
positional tolerance
20-2 Methods of Inspection for Geometric Dimensions and Tolerances 574
 Preface to Second
Edition
In the years following the original publication of this Screw Thread Gaging and Measurement. Since the
book, several objectives have become increasingly principles of screw thread measurements are similar
important in industrial production and, more specif- to those of general length and profile measurements,
ically, in metalworking. Manufacturing methods that subject was not discussed separately in the first
introduced recently, and particularly those expected edition. However, the growing emphasis on ease of
to be applied in the course of this decade, reflect assembly, prompted also by the expanding applica-
growing emphasis on: tion of automated assembly processes, together with
the need for improved functional performance of
Assured ease of assembly and interchangeability threaded components, often designed in reduced
of the majority of product components; sizes, have widened the requirements for rigorously
Highest degree of performance reliability; toleranced product screw threads. Consequently, the
application of special screw thread measuring
Compact overall dimensions without affecting
processes has progressed significantly with regard to
extended service life;
both the volume of products and the degree of accu-
Substantial reduction of rejectable parts, even racy. Dimensions controlling the functional adequacy
closely approaching “zero-defects”; and of screw threads are being inspected more generally,
and very tightly toleranced screw threads are being
Automation in every area of production, includ-
used in a rapidly growing number of applications.
ing the inspection of manufactured parts and
In view of the expanding role and significant up-
assembled products.
grading of screw thread measurements in many
These trends in the present, and predictably to an areas of industrial production, a thorough discus-
even greater extent in the future, will have a signifi- sion of that field of dimensional measurements has
cant effect on the choice of the applicable methods been provided in Chapter 16.
of dimensional measurement. While the basic prin- Measurement of Gears. The measurement of gears
ciples and methods discussed in the original requires particular techniques and instruments, which
chapters that appeared in the first edition are still have been used in machinery production for a long
valid and will continue to be used widely through- time. More recent advances toward the wide scale use
out the industry, the effects on dimensional of precision gears, assuring quieter operation, depend-
measurements of these new developments must be able rates of motion transmission, and extended
recognized. Accordingly, four new chapters have service life, have expanded substantially the applica-
been added in this second edition. The general con- tion of gear measurements with regard to the number
tents of those new chapters, as well as their of products inspected, as well as to the range of char-
relationship to the new directions of technological acteristics considered critical, thereby increasing the
progress, are outlined in the following. demand for specialized instruments. Many advanced

xxi
xxii PREFACE TO SECOND EDITION

types of gear measuring instruments are designed to Automated Dimensional Measurements. The
supply data on various gear parameters in the form of term automation is used in manufacturing to desig-
displays, charts or alphanumeric printouts, all facili- nate operations of mechanical devices that perform
tating rapid and dependable evaluation. power-actuated functions without requiring human
The continuously growing importance of gear control. In the application of automation for dimen-
inspection, both functional and analytical, has sional measurements, usually two major categories
necessitated the addition of Chapter 17, which pro- of self-controlled actions are preformed in a mutually
vides a systematic description of gear measurements coordinated manner:
as a distinct branch of modern industrial metrology.
Positioning of the sensing member and/or of the
Process Control Gaging. The concept, “The best
specimen; and
way to prevent rejects is by avoiding the manufac-
ture of faulty parts,” translates into practice as the Signaling and/or recording of the determined
continuous monitoring of the production process for dimensional conditions, commonly in relation to a
assuring that each single part produced is in com- preset nominal size.
pliance with the pertinent design specifications. The Complementary functions of automated dimen-
product parameters most subject to variations are sional measuring equipment often include the
the tightly toleranced dimensions, consequently, disposition of the workpiece by its physical trans-
process monitoring generally requires the continual fer, after measurement, to a given receptacle or
measurement of critical part dimensions during the location in accordance with the determined dimen-
actual processing. The commonly used designation sional conditions. Such dispositional functions
of such measurements is in-process gaging or, when may even be the principal purpose of the equip-
combined with controlling functions, process con- ment’s operation, other actions having supporting
trol gaging. roles only.
Again, the general developmental trends of While automated processes for dimensional meas-
industrial production brought the importance and urements have developed in conjunction with
expanded applications of process control gaging into similar trends in the operation of production equip-
the foreground, as important contributing means in ment, the rate of progress in the field of measurement
accomplishing: has further been accelerated by the need for more
Maintenance of rigorous dimensional tolerances comprehensive inspection, in compliance with
in the production process; endeavors toward assuring upgraded product quality.
Automation is widely applied to modern inspec-
Assurance of defect-free products, specifically tion operations for the purpose of sorting and
with respect to controlled geometric dimensions; and segregation, by measuring a single or a few significant
Realizing of significant savings by eliminating the dimensions. Special equipment for the automatic
need for subsequent part inspection for the purpose inspection of workpieces with a considerable number
of segregation, rework, and, most importantly, rejec- of critical dimensions are also in use in various
tion of manufactured parts. branches of modern industry, typically, but not exclu-
sively, that of automotive engines produced in large
In-process gaging, or even its advanced applica- quantities with tightly toleranced components. The
tion as process control gaging, is a dimensional evaluation function of the inspection process may also
measuring method of not very recent origin, but it be automated, such as the performance of statistical
definitely belongs to a category of rapid technologi- analyses. The wide availability of multi function cal-
cal advances. Actually, general developments in culators and compact computers has opened new
methods and equipment of modern machinery pro- vistas for the expanded and highly efficient applica-
duction, characterized by the increasing use of tions of coordinate measuring machines; these have
tightly toleranced parts, highly accelerated produc- become valuable complements of the most advanced
tion rates of up-to-date machine tools, often numerical controlled (NC) machine tools, besides
designed for un-attended operation, combined with many other applications for the dependable dimen-
the growing emphasis on defect-free products, have sional measurement of complex components in a wide
resulted in a rapidly expanding use of process con- range of sizes. Finally, various functions of optically
trol gaging. Consequently, a detailed discussion of aided measurements have also been automated, thereby
the pertinent processes and instruments is given in raising the efficiency of that category of dimensional
the new Chapter 18. measurement.
 PREFACE TO SECOND EDITION xxiii

During the past few years significant advances chapters of the original edition. A few changes were
have taken place in all the above-indicated fields of needed in the original text, to assure compliance with
automated measurements. A comprehensive review new and revised national standards brought out since
of that development in methods and equipment is the book’s original publication date. Reference are
presented in the new Chapter 19. made in the new chapters to the preceding ones where
The structure and contents of the new chapters such ties contributed to combining the original, as well
were designed to be in harmony with the fifteen as the new chapters of the book into an organic whole.
 Preface for the
Fifth Edition
Over the years Geometric Dimensioning and Tol- imagine there are several ways to check a parts geo-
erancing, as documented in the international standard metric dimensions and tolerances. The extent to
ASME Y14.5 -2009, has continued to grow in popu- which special gages can be designed and built is
larity and use. As such, many individuals have in- mostly dependent on the annual production volume
quired about the possibility of addressing this subject and length of the contract. When a special gage can-
from a production gaging standpoint in this updated not be justified economically, one or more of the uni-
edition of the Handbook of Dimensional Measure- versal measuring devices and machines must be
ment. Therefore, Chapter 20 on “The Measurement considered.
of Geometric Dimensions and Tolerances” has been In preparation for the updating of this handbook
added. Chapters ten, eleven and twelve deal exten- an extensive survey of metrology (gage manufactur-
sively with the measurement of common geometric ing) companies and industry-wide innovations was
characteristics. These chapters have been tied into made. Most of the improvements were on the soft-
chapter twenty as has much of the rest of the hand- ware side of the house with better user interfaces,
book through Table 20-2 entitled: Methods of Inspec- three dimensional graphics, and easier programming.
tion for Geometric Dimensioning and Tolerancing. On the hardware side better ergonomics, and where
Of course product designers have long since un- appropriate increased speed and accuracy were
derstood the benefits of GD&T in accurately docu- touted. Yet, the fundamentals described and the im-
menting their design intent while providing for the ages displayed herein have remained largely un-
maximum allowable functional variation in a manu- changed and will continue to provide the user with an
factured piece-part. Once the process plan has been exhaustive treatment of the field and its many facets.
determined Manufacturing Engineers, Tool Designers In describing many of the inspection devices and
and Inspectors must figure out how each dimension methods, one or more national or international stan-
and tolerance will be gaged and verified. Chapter 20 dard has been referenced; those standards have been
was added to assist engineers, designers and inspec- brought up to date throughout the handbook and are
tors in the gage selection process. As one might later listed in Appendix B.
 Preface for the
Fifth Edition
Over the years Geometric Dimensioning and Tol- imagine there are several ways to check a parts geo-
erancing, as documented in the international standard metric dimensions and tolerances. The extent to
ASME Y14.5 -2009, has continued to grow in popu- which special gages can be designed and built is
larity and use. As such, many individuals have in- mostly dependent on the annual production volume
quired about the possibility of addressing this subject and length of the contract. When a special gage can-
from a production gaging standpoint in this updated not be justified economically, one or more of the uni-
edition of the Handbook of Dimensional Measure- versal measuring devices and machines must be
ment. Therefore, Chapter 20 on “The Measurement considered.
of Geometric Dimensions and Tolerances” has been In preparation for the updating of this handbook
added. Chapters ten, eleven and twelve deal exten- an extensive survey of metrology (gage manufactur-
sively with the measurement of common geometric ing) companies and industry-wide innovations was
characteristics. These chapters have been tied into made. Most of the improvements were on the soft-
chapter twenty as has much of the rest of the hand- ware side of the house with better user interfaces,
book through Table 20-2 entitled: Methods of Inspec- three dimensional graphics, and easier programming.
tion for Geometric Dimensioning and Tolerancing. On the hardware side better ergonomics, and where
Of course product designers have long since un- appropriate increased speed and accuracy were
derstood the benefits of GD&T in accurately docu- touted. Yet, the fundamentals described and the im-
menting their design intent while providing for the ages displayed herein have remained largely un-
maximum allowable functional variation in a manu- changed and will continue to provide the user with an
factured piece-part. Once the process plan has been exhaustive treatment of the field and its many facets.
determined Manufacturing Engineers, Tool Designers In describing many of the inspection devices and
and Inspectors must figure out how each dimension methods, one or more national or international stan-
and tolerance will be gaged and verified. Chapter 20 dard has been referenced; those standards have been
was added to assist engineers, designers and inspec- brought up to date throughout the handbook and are
tors in the gage selection process. As one might later listed in Appendix B.
 Preface to Fourth
Edition
Three significant forces continue to shape the world In many industries, cellular manufacturing has
of dimensional measurement. They are the necessity to replaced the old batch and queue style of produc-
remain cost competitive in the global marketplace, the tion. Assuring quality within the manufacturing
continuous drive for higher quality, and the seemingly cell, as opposed to trying to control it after the fact,
endless increases in computer/software sophistication has seen the integration of the dimensional measur-
being applied in the field of metrology. ing center as an identifiable operation on the shop
Since the third edition of the handbook was pub- floor. This means, like other value adding opera-
lished in 1994, global competition has become ever tions, the process of dimensional measurement must
more acute. No manufacturing sector is immune, cer- be cost effective. As these trends in production
tainly not the one involved in producing dimensional methodology are coupled with requirements for ever
measurement products, equipment and machinery. tighter product and process tolerances, the need for,
As this edition was being prepared, I endeavored to as well as the existence of vastly improved dimen-
contact over one hundred leading names in the field; sional measurement equipment became a reality.
the number of companies that no longer exist, have This is further evidenced by the present day and
merged, or have been absorbed to become another often casual discussion of measurement on the sub-
company’s brand name product line was indeed star- nanometer scale.
tling. Some of this industry-wide compression is due, The improvements in dimensional measurement
in part, to the need to lower overhead, reduce cost techniques demanded by current and future products
and in-turn price, while other pressures emanate from has been facilitated, if not made entirely possible, by
the high quality and timeless nature of so many computerization of many inspection devices and the
metrology products. The figures contained in this development of metrology specific software. The use of
handbook and the companies who contributed them, CNC in dimensional measurement allows for lengthy
span some forty years of dimensional measurement measurement routines to be completed accurately
history. New figures and old alike, contained herein, without minute-by-minute operator involvement. Con-
are meant to provide the reader with modern day rep- necting almost any class of measurement device to a
resentations of each important class and type of computer permits automatic data capture and statisti-
dimensional measurement product as well as their cal analysis without the introduction of human error.
capabilities. Then, by taking either contact or non-contact measure-
On some level, quality has always been impor- ments and comparing them to CAD or mathematical
tant. However, as the concept of lean manufacturing data, complex surfaces can be inspected completely
continues to be embraced worldwide, the need to and efficiently. Ultimately, all of this information
make the first piece of a production run dimension- can be creatively displayed in a graphic format to
ally correct has increased significantly. Set-up scrap, enhance understanding. All of these improvements
large inventories and long change-over times are no have been made possible by applying modern computer
longer tolerated. “Single piece flow” and “gage it hardware and software to the field of dimensional
where you make it” are becoming the orders of the day. measurement.

xvii
xvii PREFACE TO FOURTH EDITION

Many national and international standards This revision simply could not have been possible
have been referenced in this revision of the hand- without the assistance of scores of manufacturing
book. As I spoke to experts in the field, I was companies who contributed photographs and detailed
advised to remove the year suffix on all such ref- technical information for inclusion in the handbook.
erences and refer the reader to the most current Alan Barrows of Kennametal Greenleaf IPG was par-
standard. This has been done. Yet, Appendix B ticularly helpful as he reviewed Chapter 16 and made
has been provided to include the year referenced many solid suggestions. Several staff member within
for each standard mentioned as well as the stan- the ASME and the National Institute of Standards and
dard’s location in the text. Within this revision, over Technology were also very helpful as various updated
two hundred individual changes, seventy seven new and old standards were reviewed. And finally, the
figures and fifty one new index entries have been research assistance and support provided by my
included. Many of these changes are highlighted in wife Margaret has been invaluable to me during the
Appendix A. completion of this project.
 Preface to Third
Edition
During the twelve years between the publication of concept can be demonstrated using the traditional
the second and third editions of this handbook, many line graduated vernier caliper introduced in Chapter 2.
significant developments affecting the field of dimen- It became the dial caliper and more recently evolved
sional measurement have taken place. Increased into the form known as the digital electronic caliper;
global competition and ever-increasing demands by both are pictured and discussed in Chapter 2.
consumers for higher-quality products has grown into Although the dial caliper has an indicator in addi-
what is being called a “quality” revolution. This tion to line graduations (which could have placed it
emphasis on quality has naturally focused importance in Chapter 5 on indicators) and the digital caliper is
on improving methods of dimensional measurement. electronic (which could have placed it in Chapter 7
Simultaneously, a second revolution involving com- on electronic gages), the evolutionary form of organ-
puter and video technology, as well as digital ization for each major type of device was decided
electronics, was taking place, touching virtually every upon.
facet of modern life. Inevitably, these two revolutions Over two hundred changes and additions, includ-
met in the manufacturing arena and led to the appli- ing seventy-five new figures, have been made in this
cation of computer, video and electronics technology edition. All of the referenced standards have been
to the instruments and machines used in dimensional updated and much in the way of completely new
measurement. The result, the latest technology as it technology is introduced.
applies to metrology, has been carefully integrated A special thank you must go to the many fine
into this third edition. gage manufacturing companies who generously pro-
Prior to the computer/electronics revolution of vided information and photographs for inclusion in
late, the term electronic gage referred to a relatively the handbook. Also, I would like to acknowledge the
small portion of the dimensional measurement field. support of my colleagues at Ferris State University,
However, today virtually every type of inspection especially Professor Clare Cook, Department of Elec-
instrument and machine has an electronic or computer tronics, throughout this revision effort. In addition, I
version. Therefore, in this edition of the Handbook of very much appreciate the support and patience
Dimensional Measurement, the natural evolution of shown to me by Woodrow Chapman, Editorial Direc-
an inspection device is explored within the chapter in tor at Industrial Press, during the completion of this
which it is first introduced. This organizational project.

x ix
 Contents
List of Tables xi
Preface to Fifth Edition xv
Preface to Fourth Edition xvii
Preface to Third Edition xix
Preface to Second Edition xxi
Preface to First Edition xxv
1. Introduction I
2. Line Graduated Measuring Instruments 11
Essential Properties 11
Line Graduated Bars, Rules and Tapes 12
Line Graduated Caliper Gages 19
Micrometers 23
3. Fixed Gages 33
Classification of Fixed Gages 33
Advantages of Fixed Gages 33
Master Gages 36
The Principles of Limit Gage Measurements 36
Limit Gages for Length Dimensions 38
Cylindrical Limit Gages 41
Fixed Gages for Multiple Dimensions 42
Construction and Dimensioning of Fixed Gages 47
4. Gage Blocks 53
General Aspects 53
Description and Technical Requirements 54
The Material of Gage Blocks 60
The Manufacture of Gage Blocks 62
Gage Block Sets and Accessories—the Handling of Gage Blocks 63
Applications for Gage Blocks 67
Calibration of Gage Blocks 70
Special-Purpose end Standards 74
viii CONTENTS

5. Comparative Length Measurements with Mechanical and Electronic Indicators 77

General Evaluation of the Measuring System and Instruments 77
Systems of Mechanical Amplification 78
Dial Indicators 78
Electronic Indicators 91
Test Type Indicators 96
Indicator Gages 98
Internal Indicator Gages 106
High Sensitivity Mechanical Indicators 117
Mechanical Indicators With Electrical Limit-Position Signaling 120
Optically Assisted Mechanical Comparators 121
6. Pneumatic Gaging 125
The Operating Principles and Gage Systems 125
The Principal Elements and Operation of Pneumatic Gaging Systems 130
The Pneumatic Control Units 133
The Sensing Members of Air Gages 140
Applications for Pneumatic Gaging 146
7. Electronic Gages 153
Basic Characteristics and Application Advantages 153
Operational Systems and Principal Elements 154
Electronic Comparator Gages 161
Electronic Instruments in Height Gage Applications 163
Electronic Comparator Gages for Internal Measurements 165
Diverse Applications of Electronic Gages 171
Noncontact Gages 174
8. Engineering Microscopes 177
The Optical Observation System of Engineering Microscopes 179
The Staging and Displacement Measuring Memebrs 180
Length Measurements With the Microscope 182
Goniometric Measurements With the Microscope 194
Inspection by Contour form Comparison 199
Survey of Engineering Microscopes 201
9. Optical Projectors 213
The Operating Principles of Optical Projectors 214
The Principal Elements of Optical Projectors 219
Complementary Equipment of Optical Projectors 223
Applications of Optical Projectors 226
Appraisal of Optical Projector Characteristics 238
10. Angle Measurements 239
Units of Angle Measurement 239
Geometric Conditions Measured in Angular Units 239
Survey of Angle Measuring Systems and Techniques 240
Angle Measurements by Comparison to Angular
Reference Bodies 240
Angle Measurements with Directly Indicating Instruments 255
Measurement of Angular Spacings by Circular Division 258
The Measurement of Inclines 269
11. The Measurement of Straightness, Flatness and Perpendicularity 273
Straightness and Alignment Measurements 274
The Measurement of Flatness 288
The Measurement of Perpendicularity 298
 CONTENTS ix

The systems and Applications of Autocollimators 302

Coaxial Alignment of Rotating Shafts 315
12. The Systems and Applications of Measuring Machines 317
Definition and General Evaluation 318
Single-Axis Measuring Machines 318
Coordinate Measuring Machines 326
Jig Borer Type Measuring Machines 338
Optical Measuring Machines 342
13. Profile Measurements 347
Profile Tracing 348
The Verification and Calibration of Profile-Tracing Instruments 358
Process Techniques of Profile Tracing 365
Recorder Charts and the Interpretation of Chart Tracings 370
Contour and Form Scanning 373
14. The Measurement of Roundness and Circular Contours 377
The Concept of Roundness 377
Characteristic Forms of Roundness Deficiency 378
The Functional Need for Roundness 381
The Different Systems of Roundness Measurement 384
Roundness Measurements by Referencing From the Surface of the Object 386
Roundness Measurements by Comparison to a Reference Circle—The Circular
Tracing Process 394
The Instruments and Technology of Roundness Measurement by Circular Tracing 400
The Assessment of Roundness Tracings 406
15. Surface-Texture Measurements 411
Definition of Concepts and Terms 412
The Methods of Surface-Texture Measurement 417
Surface-Texture Measurement with Stylus Type Instruments 418
Representative Models of Stylus Type Surface-Texture Measuring Instruments 429
The Assessment of Surface Texture with Stylus Type Instruments 432
Surface-Texture Inspection by Area Sampling 433
16. Screw Thread Gaging and Measurement 441
General Considerations 441
Basic Concepts of Screw Thread Design 442
The Dimensioning of Screw Threads 444
Size Limits of Screw Thread Elements 445
The Purpose of Screw Thread Measurements 447
Screw Thread Inspection by Attributes and Variables 449
Screw Thread Gaging and Measurement 449
Solid Screw Thread Gages 450
Indicating Screw Thread Gages 454
Indicating Screw Thread Gaging Instruments 455
Indicating Gages for Product Internal Threads 463
Hand-Measuring Tools for Screw Threads 469
Screw Thread Single-Element Measurements 470
Screw Thread Inspection with Optical Instruments 475
Lead Measurement 479
Helical Path Analyzer 480
17. The Measurement of Gears 481
The Application and Operational Requirements of Gears 481
The Purpose of Gear Measurement 481
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 Geography - Revision Notes
Winter 2021 - Center

Prepared by: Dr. Williams

Date: August 12, 2025

Test 1: Interdisciplinary approaches

Learning Objective 1: Study tips and learning strategies
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 1: Diagram/Chart/Graph]
Learning Objective 2: Critical analysis and evaluation
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 2: Diagram/Chart/Graph]
Learning Objective 3: Key terms and definitions
• Practical applications and examples
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Learning Objective 4: Problem-solving strategies and techniques
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Learning Objective 5: Literature review and discussion
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Key terms and definitions
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Note: Research findings and conclusions
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Study tips and learning strategies
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Key Concept: Historical development and evolution
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Assessment criteria and rubrics
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 10: Diagram/Chart/Graph]
References 2: Assessment criteria and rubrics
Remember: Current trends and future directions
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Definition: Interdisciplinary approaches
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Theoretical framework and methodology
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Theoretical framework and methodology
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Example 14: Assessment criteria and rubrics
• Case studies and real-world applications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Key Concept: Assessment criteria and rubrics
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 16: Diagram/Chart/Graph]
Example 16: Critical analysis and evaluation
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Note: Practical applications and examples
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Remember: Comparative analysis and synthesis
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 19: Experimental procedures and results
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Section 3: Fundamental concepts and principles
Practice Problem 20: Theoretical framework and methodology
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 21: Diagram/Chart/Graph]
Key Concept: Problem-solving strategies and techniques
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Ethical considerations and implications
• Learning outcomes and objectives
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Critical analysis and evaluation
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Learning outcomes and objectives
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Key Concept: Key terms and definitions
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 26: Theoretical framework and methodology
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
[Figure 27: Diagram/Chart/Graph]
Definition: Learning outcomes and objectives
• Assessment criteria and rubrics
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Best practices and recommendations
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Example 29: Theoretical framework and methodology
• Practical applications and examples
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Methodology 4: Ethical considerations and implications
Practice Problem 30: Fundamental concepts and principles
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Note: Best practices and recommendations
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Important: Current trends and future directions
• Assessment criteria and rubrics
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Literature review and discussion
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Problem-solving strategies and techniques
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Critical analysis and evaluation
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Critical analysis and evaluation
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
[Figure 37: Diagram/Chart/Graph]
Note: Research findings and conclusions
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 38: Practical applications and examples
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Statistical analysis and interpretation
• Case studies and real-world applications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Introduction 5: Key terms and definitions
Remember: Fundamental concepts and principles
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
[Figure 41: Diagram/Chart/Graph]
Example 41: Statistical analysis and interpretation
• Problem-solving strategies and techniques
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Practical applications and examples
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Ethical considerations and implications
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Note: Assessment criteria and rubrics
• Experimental procedures and results
- Sub-point: Additional details and explanations
- Example: Practical application scenario
[Figure 45: Diagram/Chart/Graph]
Note: Case studies and real-world applications
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 46: Diagram/Chart/Graph]
Note: Theoretical framework and methodology
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 47: Problem-solving strategies and techniques
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Fundamental concepts and principles
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Ethical considerations and implications
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
References 6: Best practices and recommendations
Definition: Case studies and real-world applications
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Definition: Fundamental concepts and principles
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Current trends and future directions
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 53: Diagram/Chart/Graph]
Definition: Current trends and future directions
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Historical development and evolution
• Case studies and real-world applications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Example 55: Literature review and discussion
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 56: Diagram/Chart/Graph]
Practice Problem 56: Literature review and discussion
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Ethical considerations and implications
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Critical analysis and evaluation
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 59: Diagram/Chart/Graph]
Important: Historical development and evolution
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Summary 7: Study tips and learning strategies
Practice Problem 60: Historical development and evolution
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Practical applications and examples
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 62: Diagram/Chart/Graph]
Definition: Key terms and definitions
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Practice Problem 63: Best practices and recommendations
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Practice Problem 64: Best practices and recommendations
• Literature review and discussion
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Fundamental concepts and principles
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Definition: Assessment criteria and rubrics
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Note: Experimental procedures and results
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Example 68: Theoretical framework and methodology
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
[Figure 69: Diagram/Chart/Graph]
Key Concept: Learning outcomes and objectives
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Appendix 8: Key terms and definitions
Example 70: Learning outcomes and objectives
• Problem-solving strategies and techniques
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Note: Assessment criteria and rubrics
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 72: Diagram/Chart/Graph]
Definition: Literature review and discussion
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 73: Diagram/Chart/Graph]
Remember: Ethical considerations and implications
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Practice Problem 74: Practical applications and examples
• Problem-solving strategies and techniques
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 75: Diagram/Chart/Graph]
Practice Problem 75: Statistical analysis and interpretation
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Comparative analysis and synthesis
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Experimental procedures and results
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Experimental procedures and results
• Literature review and discussion
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Example 79: Comparative analysis and synthesis
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Methodology 9: Assessment criteria and rubrics
Practice Problem 80: Current trends and future directions
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Remember: Fundamental concepts and principles
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 82: Diagram/Chart/Graph]
Example 82: Critical analysis and evaluation
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 83: Diagram/Chart/Graph]
Important: Ethical considerations and implications
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 84: Diagram/Chart/Graph]
Remember: Historical development and evolution
• Practical applications and examples
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 85: Diagram/Chart/Graph]
Remember: Ethical considerations and implications
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Practice Problem 86: Literature review and discussion
• Problem-solving strategies and techniques
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Example 87: Problem-solving strategies and techniques
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
[Figure 88: Diagram/Chart/Graph]
Remember: Comparative analysis and synthesis
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 89: Diagram/Chart/Graph]
Remember: Key terms and definitions
• Practical applications and examples
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Exercise 10: Historical development and evolution
Remember: Historical development and evolution
• Literature review and discussion
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Historical development and evolution
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
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