Precision Measuring Tools and Gages: A Primer

There is a wide range of precision measuring tools and gages that should be considered as basic requirements in a metalworking operation for ensuring good quality control (QC) processes. Most gages are available in analog (mechanical readout) or electronic (digital readout with data collecting capabilities), a key requirement for SPC and measurement documentation. Wireless electronic tools are also increasingly an option.

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The following is a reference list covering the basic requirements for precision tools:

1. Micrometers: In the hands of a skilled operator, the precision micrometer is the most accurate hand-held tool available. When close measurements to 0." (0. mm) are necessary, the micrometer is the ideal tool for the job because measurement and reading are on the same axis, and the anvil end is supported by a strong frame. There are many types of micrometers depending on the application—inside, disc, blade—with outside micrometers being most commonly used. Mechanical, electronic and wireless micrometers are available, including electronic models that are IP67 compliant. For use in harsh shop environments where machine coolant, water, oils, dirt, dust and mist are prevalent, measuring tools with IP67-level protection ensure that precision gage accuracy, performance and functionality will remain fully intact when subjected to these elements.

2. Slide calipers are an essential precision measuring tool providing a large measurement range, flexibility and accuracy up to 0.001" (25.4 μm). These tools typically measure outside, inside, depth and step dimensions. Full-featured electronic tools, with or without IP67 protection and optional output, are available. In addition to common 6" (152.4 mm), 8" (203.2 mm) and 12" (304.8 mm) tools, large, light carbon fiber models are available, as well as more specialized tools with long jaws, alternative contacts and other variations. Dial calipers are very popular; high-accuracy, extended-range Vernier scale tools are another option. Highly specialized applications may warrant a custom-built slide caliper. Wireless models are also available.

3. Height gages are an indispensable instrument for QC, measuring the distance from a reference such as a surface plate to some feature of a part with exceptional accuracy. Generally a scriber, test indicator, touch probe or CMM-style probe is used to locate the measured feature.

4. Depth gages are available in varying forms, complexity, cost and accuracy, from the most accurate depth micrometers (electronic, dial and Vernier) to basic rule gages and combination rule gages.

5. Bore gages are used to check inside diameters of holes, cylinders and pipes. When measuring holes, especially when there are a large number of holes, wireless bore gages can easily collect this data. The technology enables users to measure and collect error-free data to output for Statistical Process Control (SPC) analysis and much more. Also, IP67-compliant models are available.

6. Indicators and gages: There are several major classes of gages, including mechanical dial, electronic display, lever-style test and back plunger. Test indicators and dial indicators, in addition to electronic or wireless indicators, are available. Some electronic calipers are IP67 compliant. Indicator requirements can vary widely, from checking runout to measuring tolerances in go/no-go situations, and they are used in multiple applications. It is best to consult a supplier that offers a broad line as well as an extensive range of accessories to configure and position the gage, and, if needed, supply a custom-engineered indicator solution.

7. Hardness and surface testers: Testing the hardness of a material is critical to determining its ability to resist form change, bending, scratching or abrasion. Hardness testers are available in analog and digital bench solutions as well as compact, portable versions. Shore portable hardness testers are targeted for testing materials such as rubber, soft plastics and leather. Versions are also available for testing hard plastics, such as bowling balls and hard hats. Electronic durometers for measuring Shore A and Shore D values in a wide variety of soft materials are offered. Ultrasonic thickness gages measure the thickness of metallic and non-metallic materials. Coating thickness gages use an integrated probe to automatically determine whether the substrate is ferrous or non-ferrous, and then either detect the thickness of non-magnetic coating on a magnetic substrate (ferrous) or the insulating coating on a non-magnetic conductive substrate (non-ferrous). Testing surface roughness is important to determine if a surface is suitable for a particular purpose.

8. Data collection systems: With the IoT and Industry 4.0 being omnipresent new paradigms in manufacturing, increasing the speed, amount and accuracy of data generation is a critical necessity. Precision measurement data acquisition or collection for QC applications benefits significantly from wireless and mobile retrieval. Wireless data collection systems should be mobile and exceptionally robust (with levels of encryption and suitable for multiple needs that include unrestricted distances and gage compatibility) in order to ensure ease of use and practical integration into automated manufacturing operations. Solutions should dramatically increase productivity, reduce errors, provide full documentation and automate the acquisition process.

9. Squares and precision rules, straight edges and parallel: The combination square was invented by the founder of The L.S. Starrett Co., Laroy Starrett, in . The combination square is one of the world’s most practical and versatile tool inventions—the basic tool for every metalworker. A machinist or layout person can use it as a precision rule and measure angles, squares, 45° miters, depths or heights. It can even be used as a scribe. The Starrett Combination Square features high-quality workmanship. The square heads are made of cast iron and a photo-engraved, hardened and tempered steel rule (blade). This remarkable tool is built to last and prized by craftsmen. Accurate, steel precision rules are a staple for a metalworking shop and include photo-engraved graduations. Steel straight-edge versions excel in drawing or scribing straight lines and checking surfaces for straightness. Steel parallels are indispensable for inspection and layout work or for various setups on drill presses, milling and grinding machine shapers and more.

10. Protractors and angle measurements: A variety of tools are available, some with sharply graduated 180° scales intersected by a movable blade, a bevel protractor, protractor for depth gages, special drill point gages and more.

11. Machinist precision levels: The efficiency of today’s high-speed machinery largely depends on the levelness of the machine setup. A machinist’s level is specially designed to set up, check and test machinery of all types.

12. Fixed gage standards are very useful for in-process and final inspection and include a comprehensive choice of standard gages that quickly check dimensions on a variety of workpieces. Products include pin gages, drill gages, sheet and wire gages, center gages, screw pitch gages, radius gages, ball and diameter gages, angle gages, thickness gages and feeler stock.

13. Dividers, calipers and trammels: Dividers are an essential tool for measuring, transferring or marking off distances. Trammel heads are very useful for laying out and scribing circles beyond the capacity of ordinary dividers. Trammels are used for layout, scribing and measuring distances and circles.

14. Other precision shop tools: Devices such as work positioning tools, scribers, punches and vises, as well as layout die lubricants, do not measure but are an integral part of any shop.

Custom Gaging

There will always be exceptions to exactly what a shop needs for its QC setup. Perhaps a unique measurement solution is in order. In these cases, special custom gaging designed and manufactured for a specific application is an excellent solution when standard products cannot perform. For over 50 years, Starrett has provided special gaging solutions to industries that include energy, aerospace, automotive, food packaging, high-technology plastics and medical components. Solutions have also been supplied to NASA and other government agencies.

Another critical requirement is to have precision reference standards in a shop’s metrology department. Such standards include:

• Gage blocks: Precision gage blocks are the primary standards vital to dimensional quality control in the manufacture of parts. Major characteristics necessary for a precision gage block are accuracy, surface finish, wear resistance, dimensional stability and wringability. (Editor’s note: Wringing is the process of sliding two blocks together so their faces bond. This requires flat surfaces on the order of 0.13 μm and a surface finish Ra of at least 0.025 μm.) Other factors are corrosion resistance, hardness, thermal conductivity and coefficient of expansion. Major types available today include traditional gage blocks made from high-grade steel, which generally are used in shop floor environments, as well as gage blocks made from tungsten carbide, ceramic and chromium carbide.
• Surface plates: Every linear measurement depends on an accurate reference surface from which final dimensions are taken. Precision granite surface plates provide this reference plane for work inspection and layout. A high degree of flatness, overall quality and workmanship also make them ideal bases for mounting mechanical, electronic and optical gaging systems.

Why Go Wireless?

There are many benefits to using wireless gages, whether as individual gages only or used together with an advanced data collection system. Wireless gages are gaining acceptance for the highest levels of QC

First and foremost, wireless measuring tools eliminate the need for bulky and cumbersome hardware such as backpacks and cables, which can be safety hazards in a machine shop. That means less equipment to purchase, minimizing startup costs and reducing related maintenance requirements within the manufacturer’s shop tool calibration program.

Collecting and transmitting measurement data is also faster and less error-prone in wireless systems, facilitated simply by measuring and pressing a button to send data to a mobile , tablet or PC. In this way, operator subjectivity is removed compared to manually transcribing data.

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Also, time spent to manually record the data is no longer a concern. Wireless tools eliminate recoding measurement errors that can occur with manual entries. Wireless provides speed, convenience and ease of collecting and storing data.

Wireless precision measuring tools are engineered for efficient data collection in a wide range of uses. Whether it be for International Organization for Standardization (ISO), government, aerospace or medical requirements, or for smaller shops, the need for accurate data is crucial for traceability to demonstrate qualified parts or to trace back any manufacturing errors to their source. Accurate measurement data provides assurance for the end user and insurance for the manufacturer.

Wireless tools and advanced data-collection software systems can efficiently integrate data in Enterprise Resource Planning/Materials Requirement Planning (ERP/MRP) software systems. Also, wireless gages promote a cleaner work environment by removing the need for a log journal and pens/pencils, making an ideal setup for lean manufacturing.

QC is the last step in producing manufactured parts, screening out bad parts that can hinder assembly of the final product. Using wireless precision gages, inspectors can measure with confidence to qualify parts. With the push of a button, measurement data is archived for later use. The time and money saved by going wireless and implementing a data-collection system is easily measured by digital calculators that demonstrate those savings.

Metrology: The Science of Measurement

While often confused with met-e-or-ology, which attempts to predict whether you’ll need an umbrella or a sunhat, metro-logy is all about ensuring accuracy. It may not sound as glamorous as unraveling atmospheric mysteries, but metrology is just as fascinating and essential to our everyday lives. Metrology provides us with a universally accepted understanding of measurement units and is used globally to uphold the integrity of the readings produced by measurement equipment.

From the moment we wake up in the morning, until we go to bed at night, metrology is silently used behind the scenes to ensure that the measurements upon which we rely daily are dependable. It plays a crucial role across various industries, from manufacturing and engineering to healthcare and scientific research. Metrology utilizes many methods, tools, and standards that ensure measurements accurately represent the quantities being assessed.

A Reliable Foundation

Metrology is used to provide traceability, accuracy, and consistency of measurement equipment worldwide. It helps to provide validity and prevent discrepancies between measurement readings. Metrology sets the framework for reliable and consistent measurements across time and space. It establishes a reference point and enables us to trust the accuracy of our measurements.

• Traceability is the key to ensuring the credibility of measurements. It involves establishing a documented unbroken chain of calibration that links the accuracy of a measurement instrument to the SI Units through a National Metrology Institute. By doing so, we can confidently rely upon the measurement readings produced by the instrument.

• Accuracy refers to the degree of conformity between a measured value and the actual value of a measured quantity. The use of metrology minimizes errors and deviations by utilizing traceable, accurate reference standards to which calibration technicians can compare measuring instruments, thus enhancing the accuracy of the readings the instruments produce.

• Reproducibility refers to the principle that if the exact measurement procedure is reproducible under the same conditions, it will yield repeatable results. Reproducibility is achieved through standardized procedures, reliable measuring instruments, and adherence to established practices. Metrology is used to define these procedures and ensure the accuracy of these instruments. In doing so, metrology provides reproducibility, enables meaningful comparisons & facilitates collaboration. It also increases the reliability of scientific studies, manufacturing processes, and various other applications.

Metrology provides a solid framework for reliable measurements. It ensures that measurements are not mere approximations or guesses but are instead grounded in recognized standards. This foundation gives us confidence in the accuracy and reliability of the measurements upon which we rely in a range of diverse fields such as manufacturing, healthcare, research, and countless other applications.

How Metrology Affects Industry

Enhancing Quality Control and Quality Assurance

Metrology is vital to quality operations in manufacturing industries. Precise measurements ensure that products meet specified standards and regulatory requirements. Whether measuring dimensions, tolerances, or material properties, metrology enables manufacturers to maintain consistency throughout the production process. The use of metrology helps to ensure product uniformity, allowing manufacturers to confidently say goodbye to sub-par products with wonky dimensions and inconsistent tolerances—and hello to top-notch products and satisfied customers!

Metrology has led to the development of tools and methods used to provide accurate measurements, such as coordinate measuring machines (CMMs) and optical inspection systems, which allow manufacturers to scrutinize every aspect of production. This attention to detail enables managers to verify equipment performance and proactively schedule maintenance. Metrology also supports quality assurance by providing manufacturers with statistical data and analysis, allowing them to monitor processes and implement improvements.

In a nutshell, metrology brings precision to manufacturing. By utilizing the science of measurement to guide production, manufacturers can confidently deliver high-quality products, strengthening their reputation and increasing customer satisfaction. They are also able to catch errors early, reduce waste, and enhance operational efficiency. With metrology as their trusted ally, manufacturers reduce errors and embrace excellence.

Advancing Scientific Research and Innovation

In scientific research and development, metrology is the cornerstone for advancing knowledge and fueling innovation. It serves as the guiding light, illuminating the path toward accurate measurements that underpin experiments and data analysis. Scientific research depends on the ability to measure and quantify the properties of materials, the behavior of particles, and the intricate workings of the natural world. Metrology equips scientists with the tools and methodologies to produce precise measurements in these endeavors. Whether it’s determining the exact composition of a compound, quantifying the intensity of a signal, or measuring the rate of a chemical reaction, metrology empowers researchers to capture data accurately and reliably.

In the realm of scientific exploration, measurements are more than just numbers. They are the building blocks upon which theories are formulated and tested. The accuracy and validity of measurements directly impacts the credibility and robustness of scientific findings. 

Metrology Enables Global Collaboration

But metrology contributes to scientific research beyond individual laboratories and research groups. It enables the comparison and harmonization of results obtained by different teams across the globe through various mutual recognition arrangements (MRA). Metrology fosters collaboration and the exchange of knowledge by providing a common language of measurements. It allows scientists to build upon each other’s work, replicate experiments, and verify results. This collaborative environment, facilitated by metrology, accelerates the pace of scientific progress, and drives innovation.

Moreover, metrology serves as a catalyst for interdisciplinary research and innovation. It is pivotal in establishing accurate measurements to bridge gaps between scientific domains in fields where different disciplines intersect, such as nanotechnology, biotechnology, and renewable energy. By ensuring consistent and reliable measurements, metrology enables scientists to explore new frontiers and push the boundaries of human knowledge.

The impact of metrology on scientific research and innovation cannot be overstated. Providing precise measurements strengthens the foundation upon which scientific discoveries are made, and theories are built. It lends validity to experimental data to bolster the credibility of scientific findings. In the quest for scientific progress, metrology serves as an indispensable partner, helping scientists uncover the mysteries of the universe, one measurement at a time. 

Metrology in Pharmaceuticals

But the role of metrology in healthcare extends beyond the realm of diagnostics. It also supports medical innovation, as well as the development, production, and quality of pharmaceuticals. In the pharmaceutical industry, precise dosage is imperative to ensure effectiveness and patient safety. Metrology helps pharmacists accurately measure active ingredients and verify both potency and purity. It provides structure for pharmaceutical manufacturing processes to ensure capsules are precisely filled and labels accurately depict medication composition. With metrology as their guiding principle, healthcare providers and patients can trust that medications are correctly compounded and will deliver the intended therapeutic results.

Whether it’s through the calibration of imaging equipment, the measurement of biological samples in the laboratory, or the evaluation of novel diagnostic tools, metrology provides a method of evaluation that is both applicable & crucial to a wide range of healthcare-related activities.

Ensuring Fair Trade and Consumer Protection

Metrology is significant in trade and commerce as the guardian of fair transactions and consumer protection. It helps to ensure that measuring instruments utilized in commercial transactions are producing accurate readings. Not only does this prevent customers from being overcharged, but it also protects sellers from giving away more of a product than was purchased. Metrology is crucial in trade and commerce. It is a fundamental pillar of protection that provides transparency & validity to transactions.

In many countries, regulatory bodies enforce laws that dictate the method used to, and the frequency at which, measurement equipment must be calibrated to be used in commerce. These regulations apply to weighing scales, fuel pumps, electricity meters, and other measuring instruments used in commercial transactions. These regulations require a licensed service provider to calibrate the measurement equipment utilizing traceable measurement standards. This service provider utilizes metrological tools & processes to perform the calibration and ensure the readings produced by the measurement device are within the range of tolerance, or the legally acceptable range of variation from the true value. Once this process is complete, the service provider labels the equipment as “legal-for-trade”.  Through regular inspections, calibrations, and verifications, metrology helps detect and prevent any attempts to manipulate measurements for unfair advantage. Doing so ensures that consumers receive what they pay for without falling victim to deceptive practices. In this way, metrology also contributes to the broader economy by promoting confidence, encouraging increased consumption and economic growth.

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