Module 1 Page 11 of 22 Mechanical Measurements & Metrology

Linear Measurements and Angular Measurements

Slip Gauges or Johannson Gauges or Gauge blocks: Gauge blocks are rectangular blocks
of steel having a cross section of 30x10mm (w x d). Slip gauges are the universally
accepted standards of length (l) in industry and are working standards of linear
dimensions. They are used for two main purposes;
o For direct measurement where the accuracy of the work piece demands it.
o For use with high magnification comparators to establish the size of gauge blocks
in general use
These are also used to check the accuracy of measuring instrument, setting up a
comparator to a specific dimension, enabling a batch of components to be quickly and
accurately checked or when a standard of known length is needed.

The top measuring face is that face on which the size is marked. If such marking is on a side face, then the right hand
measuring face is the one which forms the right-hand boundary of the surface on which the size characters are
marked assuming the characters are upright to the observer. The designation of a gauge block set differs from
standard to standard but two basic features are universally used in designating and they are
o Indication of units- Letter E is used to designate inch units and letter M is used for metric units.
o No. of pieces in a set following letter.

A 1mm based set have the smaller length pieces with a base length of 1mm. the industrial practice is to use a 2mm
base set and it designated as M33/2.
In M33/2 – M means the metric units, 33 is number of pieces in the set and /2 means it is a 2mm base set.
M33 means it is a 33 piece metric unit slips gauges with 1mm base set.

Also
AA grade means ±2μm/m accuracy are considered as master slip gauges
A grade means ±4μm/m accuracy are considered as reference slip gauges
B grade means ±8μm/m accuracy are considered as working slip gauges
The guaranteed error is not divided for a block which is less than 25mm/

The 4 commonly used slip gauge sets and the combination of sizes available in each are provided in the tables.

As regards to the grades or classes of slip gauges, these could be designated in five grades as:
o Grade 2: This is workshop grade used for setting up machine tools, positioning milling cutters, etc
Module 1 Page 12 of 22 Mechanical Measurements & Metrology
o Grade 1: Used for precise work like tool rooms, setting up sine bars, checking gap gauges, setting dial
indicators, etc
o Grade 0: This grade is known as inspection grade and only inspection department have access to them. Their
use is confined to tool room or machine shop inspection.
o Grade 00: This grade would be kept in standard room and used for work of highest precision like finding any
errors in grade 2 slips, etc.
o Calibration Grade: This is a special grade with actual sizes of slips stated or calibrated on special chart
supplied with the set. The chart is to be used when making up a dimension and since there are not made to
specific/set tolerances they are cheaper than Grade 00.
Indian Standard on Slip Gauge: According to IS:2984-1966 the size of a slip gauge is defined as the distance ‘l’
between the two plane measuring faces one being constituted by the surface of an auxiliary body with which one of
the slip gauges is wrung and the other by exposed face of the slip gauge.
The definition is conditional on the assumption that:
o measuring face of slip gauges and auxiliary body are of same material with identical finish, condition
o contact surfaces have been cleaned as thoroughly possible and are free from any special preparations
tending to promote adhesion.
Slip gauges are made of steel with (11.5±1.5) x 106/⁰C thermal expansion between 10-30⁰C with hardness more than
800HV.

Wringing: Wringing is defined as the process by which measuring faces of a gauge block adhere to other gauge
blocks or to reference face of datum surfaces by sliding/pressing the gauge against without the use of any
extraneous means.
A truly clean surface though difficult to obtain may not wring satisfactorily. The usual practice is to use silicone or
filtered kerosene as lubricant. A thin coat of lubricant is applied and the excess is wiped out as much as possible
leaving very thin film over the gauge blocks. There is as much danger from too little lubricant as much as from too
much lubricant between the surfaces.
The phenomenon of wringing may be due to molecular adhesion between a liquid film and mating of the surface
flats. The gap between the two wrung flat pieces is of the order of 6.35nm and thus the film thickness contributes no
effect to the total dimension of the wrung blocks.

For separating the gauge blocks, combined sliding and twisting motion should be applied and not attempt should be
made to separate them by direct pull because considerable load would have to be applied which may damage the
slip gauges. The overall thickness of wrung gauges is the sum of the individual sizes in combinations.

Basic forms of Slip Gauges:

o Rectangular form: It is more widely used, less expensive to manufacture and adapt to applications where
there is restricted or excess weight is to be avoided.
o Square form: Due to their large surface area, they wear longer and adhere better to each other when wrung
to high stacks. These are expensive.
o Square block with Center holes: These permit the use of tie rods as an added assurance against the wrung
stacks falling apart while handling.

Desirable features of Slip gauges or end standards:

o The actual size of slip gauge must conform to the nominal size to a high order of accuracy. The length of
gauge is defined as the distance between the midpoints of opposing faces plus one wringing film thickness.
o The end faces of the gauge must be parallel. This is to ensure equality of size over full face of the gauge.
o The end faces must be flat and this flatness must include a high degree of surface finish. These two features
enable the gauges to be wrung together and build up into combinations.
o The material from which the gauges are made must be metallurgically stable to ensure that the gauges
retain size and accuracy over a prolonged period of time.
Module 1 Page 13 of 22 Mechanical Measurements & Metrology

Protector Blocks: These are two additional 2mm blocks with letter P on measuring faces and are provided with high
grade sets of gauge blocks. These are accommodated at each end of a combination so that all wear occurs on them.
These are made from tungsten carbide or other suitable hard and wear resistant material.

Selection of Slip Gauges for Required dimension:

o Start with the last decimal place and deduct this from the required dimension.
o Select the next smallest figure in the same way, find the remainder and continue this step until the required
dimension is completed.
o Minimum number of slips necessary to build up the given dimension should be selected.
o The slip gauges are then cleaned using a lint free cloth, chamois leather or a cleaning tissue to remove dirt,
oil, dust, etc.
o If the slip gauges have been protected with lubricant, it may be removed using solvents such as petroleum,
ether, etc.
o The slip gauges are wrung with the largest sizes first and touching the measuring surfaces must be avoided.
The smaller gauges are then wrung one after another to the already built stack of slip gauges.
o When the dimension to be measured is unknown and is to be found using slip gauges, then first it must be
determined to the nearest 0.1mm size with a micrometer, caliper etc. This will reduce the time required to
build up the required combination of slip gauges.

Care of Slip Gauges:

a) General Care:
o Protect all the surfaces against climatic conditions by applying suitable anti corrosive agents such as
petroleum jelly, etc.
o Keep the lisp gauges in a suitable case in which there is a separate compartment for each gauge and keep
the case closed when not in use.
o Protect the gauge and their case from dust and dirt.
o Gauges should not be magnetized otherwise they will attract metallic dust.
b) Preparation before use:
o Remove the protective coating applied to the slip gauges with petrol.
o Clean the gauges to be used with chamois leather or soft linen cloth even if they are temporarily returned to
the case uncoated.
c) Care in use:
o During the actual use, touching the measuring surfaces should be avoided.
o Handling should be minimum to avoid transfer of heat from hand to gauges.
o For highest accuracy measurements, temperature of 20⁰C is necessary.
o Both work to be tested and gauges wrung together should be allowed to settle down to the prevailing
temperature of the room before doing any test.
o Gauges should not be held above the open case when being wrung together. The required gauges should be
selected and the case should be closed.
o Placing gauges with their working surfaces on surface plate, etc should be avoided.
o While wringing standard procedures should be followed.
o If during wringing process, any sign of roughness or scratching is felt the process of wringing should be
stopped and faces examined for burrs or scratches.
d) Care after use:
o Gauges should not be left wrung together for an unnecessary length of time.
o The gauges should be slid apart, cleaned and the measuring faces are coated with protective layer of jelly,
grease etc with a clean piece of linen. A brush should not be used as this may aerate the jelly and moisture in
the air bubbles so forced may cause rusting of the faces.
o Due to handling in laboratory or inspection room for a considerably long period, slip gauges are liable to
wear and hence they should be checked or recalibrated at regular intervals. Inspection and workshop grade
gauges are calibrated by direct comparison with the calibration grade gauges in a comparator.

Adjustable Slip gauges: It consists of two hardened tapered blocks whose

faces are ground and lapped. The tapered surfaces are finished to wringing
quality. After wringing of a pair of adjustable slip gauges, the two outer
surfaces will be flat and parallel to each other. The tapered surfaces can be
Module 1 Page 14 of 22 Mechanical Measurements & Metrology
made to slide along the length of each other and this enables to obtain different sizes with in a very small range. An
index pin is also fitted into the lower half of the block. Scale divisions are marked in the lower block corresponding to
the rack tooth interval in the upper block. A reference point is marked on the upper block.

Slip Gauge Accessories: With the use of accessories the slip gauges are also used in the following cases:
o When it is desired to use slip gauge combination of considerable length in order to ensure more rigid
assembly.
o For measuring plug and ring gauges
o For the inspection of gauges and precision equipment
o For marking out purposes.
The accessories that are mainly used with slip gauges are:
o Measuring jaws: These are supplied in pairs and are of two types:
o Type-A jaws are used for both internal and external measurement.
o Type-B jaws are used for external measurement only.
The size of the measuring jaw is engraved on the front end face of the jaw. The wringing surface of each
measuring jaw should be flat to within 0.00025mm. The nominal size of the measuring jaw should be
accurate with in ±.00007mm. With such accurate surfaces, when the jaws are used, the overall error would
not exceed ±0.0001mm.
By placing the Type-A jaws in the holder, the internal measurements are made using the curved surfaces.
The external measurements are made between the flat surfaces of the jaws.

o Holder: These are made of suitable design for holding rigidly combination of slip gauges within their ranges.
These are commercially available in three ranges viz. 0-60, 50-110, 100-200mm. The surface upon which the
gauges are wrung should be flat to within 0.0001mm and parallel to the base.
o Base: The base is made with robust construction and designed in such a manner that the holder can be
attached to it, normal with respect to the wringing surface. The wringing surface of the base should be flat to
within 0.0002mm. It should be suitably relieved and an air vent should be provided. The base with scriber
used in conjunction with the holder can be used as an accurate height gauge.
o Scribing and Center Points: These are used in conjunction with the holder and slip gauges for very accurate
marking out purposes.
Module 1 Page 15 of 22 Mechanical Measurements & Metrology

Angle is defined as the opening between two lines which meet at a point. The basic unit of angular measurement is a
right angle and is defined as the angle between 2 lines which intersect so as to make the adjacent angles equal.
Angle is also defined in terms of Radians. Radian is the angle subtended at the center by an arc of a circle of length
equal to its radius.
Angular measurements may be broadly classified as:
o Measurement of angular features on components or gauges.
o Measurement of angular rotation of a divided circle.
In case of angular measurements, the end standard takes the form of either angle gauges or polygons with the angle
defined between the adjacent faces. Line standards take the form of uniformly defined circles with lines engraved at
regular intervals.
Each right angle is divided into 90 degrees and each degree into 60 minutes and each minute into 60 seconds.

Universal Bevel Protractor:

Sine Bars: Sine bars are made from high carbon, high chromium, corrosion resistant steel which is hardened, ground
and stabilized.
Two cylinders of equal diameter are attached at
the ends whose axes are mutually parallel to
each other and also to the upper surface and
equidistant from it. Some holes are drilled in the
body of the bar to reduce the weight and to
facilitate handling. The width of the rollers is less
than the width of the sine bar. There are several
varieties of sine bar based on the type of work to
be measured. The sine bar is designated by the
length or the distance between the rollers.

The sine bar in itself is not a complete measuring

instrument and a datum such as a surface place is
needed as well as other auxiliary equipment like slip
gauges, indicating device to make measurement. The
sine principle uses the ratio of the length of two sides of
a right triangle in deriving a given angle and devices
operating on this principle are capable of self
generation. Using the sine principle the angle
measurement is limited to 45⁰ from loss of accuracy
point of view. The principle of operation of sine bar
relies on the application of trigonometry.

The accuracy of sine bar depends on its constructional features and on maintaining the following:
o The 2 rollers must have equal diameter
o The rollers must be set parallel to each other and to the upper surface
o The center distance between the rollers is precisely known
o The upper face must have a high degree of flatness
Module 1 Page 16 of 22 Mechanical Measurements & Metrology
Types of sine bar
a) This is most commonly used form in which
the rollers are so arranged that their outer
surfaces on side are level with the plane top
surface of sine bar.
b) This form has hollow rollers whose outer
diameter is equal to width of sine bar and is
used where width of side bar enters into
calculation of work height.
c) This form of sine bar is used where ordinary
types cannot be used on top surface due to interruption.
d) This is most preferred as it can be set on steep angle without fouling the underside of the bar.

Uses of Sine bar:

o Measuring of known angles or locating any
work to a given angle: The surface plate is
assumed to be a perfectly flat surface and could
be treated as the horizontal. One of the rollers
of sine bar is placed on the surface plate and the
other on slip gauges of height (h) determined
using the sine principle, h=L.sinθ.
Knowing the value of θ, h can be determined for
the available sine bar. The use of angle plates
and clamps could also be made in case of heavy
components. For better results, both the rollers
could be placed on stacks of slip gauges of heights h1, h2 and then by the sine rule we have (h2-h1)=L.sinθ.

o Checking of unknown angles: Here the approximate

angle is measured using a bevel protractor and let the
angle be θ. The sine bar is set to the angle using the slip
gauge stack of required height h= Lsinθ where L is the
length of the sine bar.
The work piece is placed on top of the sine bar and
clamped in position to a angle plate and a dial indicator
is set at one end of the work and moved to the other
end and the deviation is noted(∆h). The slip gauges are
adjusted according to the deviation so that the dial
indicator reads zero across the work surface. If the dial
indicator is moved over a length of l’, then height of slip
gauges by which it should be adjusted is equal to .

o Checking of unknown angles of heavy

components: For heavier components the
sine bar is mounted on the component as
shown. The height of the rollers can then be
measured using vernier height gauge, using
a dial test gauge mounted on the anvil of
the height gauge as a fiducial indicator to
ensure constant measuring pressure. The
difference of the two readings (h1, h2) and
the length of the bar (L) are needed to
determine the angle of the component (θ)
and is given by
When greater accuracy is needed, the position of the dial test gauge probe can be sensed by adjusting a pile
of slip gauges till the dial indicator indicates the same reading over the roller of the sine bar and slip gauges.
Module 1 Page 17 of 22 Mechanical Measurements & Metrology
Limitations of Sine bars:
o The establishment of angle is lengthy process and the accuracy in practice is limited due to
dependance on measurements of geometrical features, calculations. This limitation alone precludes
the use of sine bar as a primary standard of angle.
o Devices operating on the sine principle are fairly reliable at angles less then 15⁰ but become
increasingly inaccurate as the angle increases. The sine bars become impractical and inaccurate
above 45⁰ due to difficulty to hold in position, obstruction of gauge blocks, etc.

Sine Center: This is basically a sine bar with holding centers which can be adjusted and rigidly clamped in any
position. There are used for inspecting conical objects between centers upto inclinations of 60⁰. The equipment
consists of a self contained sine bar hinged at
one roller and mounted on its own datum
surface. The top surface is provided with a pair
of centers for holding the work. Due to the
work being held axially between the centers the
angle of inclication obtained using the sine rule
will be the half the included of the work. The
use of sine centers provide a convenient
method of measuring the angle of table plug
gauge.
The stack height (h) is initially calculated based
on the approximate angle measurement. The
level of the conical portion is checked using a
dial indicator. If any deviation is indicated by
the dial gauge, then slip gauge stack height can
be suitably adjusted to get zero deviation.

Angle gauges: Angle gauge is a hardened steel block approximately 75mm long and 16mm wide which has two
lapped flat working faces lying at a angle precesely to each other. They are
supplied in sets and can be wrung together to formd esired angles. With
thirteen separate gauges used in conjunction with one surface block and one
parallel straight edge, it is possible to set up any angle to the nearest 3”. The
13 gauges can be divided into 3 series – degrees, minutes, seconds or fractions
of minute and the angle gaulge block sizes are
- Degrees (5gauges)- 1⁰, 3⁰, 9⁰, 27⁰, 41⁰
- Minutes (4gauges)- 1‘, 3’, 9’, 27’
- Seconds (4gauges)- 3”, 6”, 18”, 30”

All the angle gauges in combination can be added or substracted thusmaking the various combinations possible.
Additionally a 90⁰ gauge block can be made to get the full 90⁰ angle without the use of square block. Direction
combination of all gauge blocks in the same direction enables an angle of 81⁰40’57” and larger angles are made with
the help of square block.
Each angle gauge is marked with ‘<’ which indiates the
direction of the included angle. When the individual
gauges are all added, then all “<” markings should be in
line and when any angle is to be sub stracted the
markings should be in opposite directions. A block
formed by combination is bulky and cannot always be
directly to the work. These are used as reference and aid
of other angle measuring devices is taken in several
applications.
Module 1 Page 18 of 22 Mechanical Measurements & Metrology
Uses of of Angle Gauges:
- Direct use of angle gauge to measure angle in die insert: The insert is placed against
an illuminated against a glass surface plate or infront of light box. A angle gauge block
combination is inserted in position so that no white light can be seen between the
gauge face and the die insert and the die insert angle is the angle of the combination
of gauge blocks.
- Use of angle gauges with Square Plate: A square plate has its 90⁰ angles
guaranteed to within 3” of an arc. When a high degree of accuracy is
required the four corners are numbered A, B, C and D and a test certificate
giving the measured angle of each corner using angle gauges.
Also setup for testing the angle of a V gauge of given included angle is
shown. The whole setup is placed against an illuminated glass surface plate.
The use of slip gauges has to be made to facilitate the testing where
necessary.

Spirit Level: It is generally used for the static

levelling of the machinery and other
equipment. But a calibrated spirot level is an
angular measuring device of great precision. If
a liquid fills a tube with a bubble, the bubble
in the liquid will always lie at the highest
position in the tube and it moves proprotional
to the vertical angle of tilt of the tube. The
sensitivity of the spirit level is expressed as
the angle of tilt in seconds for which the
bubble will move by one division on the tube
which is generally 2.5mm. To ensure that the
movement of a bubble is constant for each
position of the tube, the bore of the tube is in the form an arc of a circle (radiius R).
Let l (length B-B’) is the distance by which the graduations are seperated then angle of tilt α = l/R
If L is the length of the base level, h is the height difference then h=Lα
Then we have have α = h/L = l/R

Clinometer: A Clinometer is a special case of application of

spirit level where in the spirit level is mounted on a rotary
member carried in a housing. One face of housing forms the
base of the instrument and in the housing there is a circular
scale for angular measurement.
The angle of inclination of rotary member carrying the level
relative to the base can be measured using the circular scale
and the included angle is found based on two readings
taken from both faces. The instrument base is placed on the
first face and the rotary body is adjusted till zero reading of
the bubble is obtained. The angle of rotation is noted and
similar reading is obtained for the second face to get the
included angle.
Clinometers are used for checking angular faces, relief angles on large cutting tools, milling cutters, setting up
inclinable table on jig boring machines, etc. In some clinometers a graduated scale is supported on an accurate ball
bearing and is so designed that when released it always takes up the position relative to the true vertical. The
reading is taken against the circle to an accuracy of 1” with aid of vernier.

Optical Instruments for Angular Measaurement: Four principles govern application of optics metrology:
- Magnification, provides for the visual enlargement of the object thus enabling easy and accurate
measurement of the attributes of an object.
- A monochromatic light source provides the absolute standard of length and therefore ensures a high
degree of accuracy.
- Light rays are utilized to establish references such as lines and planes and good alignment is possible.
Module 1 Page 19 of 22 Mechanical Measurements & Metrology
- Interferometry is a unique phenomenon associaetd with light.

Some of the optical instrments used in metrology are:

- AutoCollimator: This is an optical instrument used for measurement of small angular difference with
high good sensitivity and accuracy. Auto collimator is an infinity telescope and collimator combined into
one instrument.
- Laser Interferometer: With laser interferometer it is possible to measure length to an high degree of
accuracy. With the help of two retro reflectors, placed at a fixed distance, using sine principle length
measuring laser interferometer can measure angle to an accuracy of 0.1second.
- Photoelectric Microptic Autocollimator: Photoelectric setting makes measuring and checking by
autocollimator far simpler and faster. Micrometer adjustment is provided for seting, but coincidence of
setting graticule and target image is detected photoelectrically and shown on a meter as null reading.
This provides a high degree of sensitivity and repeatability, also reducing eye fatigue to a minimum. The
eye piece is only used to assist in the initial setting up.
- Automatic Position Sensing Autocollimators: Here the angular distplacement of the reflector is
displayed on a digital readout, eliminating any micrometer reading for setting or measuring. These can
be used in cramped positions, where it could be impossible to use a visual instrument and no handling
during measurement minimises the danger of accidental autocollimator movement.
- Angle Dekkor: This is also a type of autocollimator and measurse by comparing the readings obtained
from a standard, a sine bar or a combination of angle gauges with that from the work under test. This is
not a precise instrument in comparison to autocollimator but has wide field of application for general
angular measurement.

Autocollimator: It is used to detect and measure small angular tilts of a reflecting surface placed infront of an
objective lens. Ideally the area of the reflecting surface should be alteast equal to the area of the objective lens.
- Collimator is an optical instrument consisting of a well corrected (accurate focus) objective lens with an
illuminated reticle at tis focal plane. (reticle or graticule is a series of lines used as a measuring scale or
an aid in locating objects). The emerging beam is parallel (collimated beam) so that the image of the
reticle is projected at infinity. The collimator is used as a test chart projector for inspection of infinity
corrected objective lens. In combination with a telescope, the collimator can also be used for aligning
machine elements along the line of sight.

- Principle: A collimating lens is designed to transmit parallel beam of light radiating from a source at its
principal focus. A plane reflector in the path of beam and normal to geometrical axis of lens will reflect
the light back along the transmission path to be refocussed at the source.
If the reflector is tilted by a small angle α, the beam
will get deflected by 2α(principle of reflection) and
will be brought to a focus in the same place as the
light source but at a distance d from it which is given
by
d=2f.α
where f is the focal length of the collimating lens or
objective lens.

The distance of the reflector from collimating lens is not affecting the focussing point. The angle of tilt
must not be large that make the beam of reflected light by-passes the lens completely. For high
sensitivity a long focal length lens is required.
Module 1 Page 20 of 22 Mechanical Measurements & Metrology
Reflectors used in collimators may be made of
glass, quartz, steel but the surface must have
good reflecting qualities. A mirror should
preferably be provided with a film of
aluminium or thodium on its face to increase
the reflection and to avoid other possible
errors caused by light ray passing through the
glass.

Linear displacement of the graticule image in

the plane of the eyepiece (image plane) is
directly proportional to the reflector tilt and
can be measured by an eyepiece graticule, optical micrometer or electronic detector sytem, scaled
directly to angular units. The autocollimeter is set permanently at infinity focus and no device for
focusing adjustment for distance isprovided or desirable. It responds only to the reflector and the
autocollimator, assuming no atmospheric disturbance and the use of a perfectly flat reflector. The
maximum seperation between reflector and autocollimator or “working distance” is governed by the
effective aperture of the objective and the angular measuring range of the instrument becomes reduced
at long working distances. Increasing the maximum working distance by increasing the effective aperture
then demands a larger reflector for satisfactory image constrast. Air currents in the optical path between
the autocollimator and target mirror cause fluctuations in the readings obtained and this effect is more
pronounced as distance from the autocollimator to target mirror increases.

Applications:
o It is is used to measure straightness and flatness of surfaces.
o It is used to measure small linear dimensions.
o For checking the internal right angle.
o Comparative measurement using master angle gauges.
o Also used for assemssment of squareness and parallelism of component

Measurement of Straightness: A line is said to be straight over a

given length if the variation of the distance of its points from two
planes perpendicular to each other and parallel to the general
direction of line remains within the the specified tolerance limits.
The reference planes are chosen such that their intersection is
parallel to the straight line joining the two points suitably located
on the line to be disted and the two points being close to the ends
of the lengths to be measured.

Tests for straightness can be carried using spritlevel or autocollimator. The straightness of any surface should be
determined by measuring the relative angular positions of a number or adjacent sections of the surface to be tested.
- The autocollimator is placed at a distance of 0.5-0.75m from the surface to be tested and a parallel beam
from the instrument is projected along the length of the surface of the tested.
- A block fixed on two feet and fitted with a plane vertical reflector is placed on the surface and the
reflector face is facing the autocollimator.
- The reflector and autocollimator are set such that the image of the cross wires of the collimator appears
nearer the center of the field for complete movement of reflector along the surface straight line
- The reflector is then moved to the other
end of the line in stepa equal to the
center distance between the feet and the
tilt of the reflector is noted down in
seconds from the eye piece. (1sec of arc
in the view piece reading is equal to 6x10-
6
mm/mm or 6nm/mm). Hence 1second
arc will correspond to rise or fall of
6nmxlmm, where l is the distance
betweent the feet of the reflector in mm.
Module 1 Page 21 of 22 Mechanical Measurements & Metrology
- With the reflector feet set at a-b (1st reading), the reading is noted from the collimator and is taken as
datum. Successive readings at b-c, c-d, etc are taken till the length of surface to be tested has been
stepped along. The readings obtained represent the angular position of the reflector relative to the
optical axis of the of autocollimator.

- The errors of any surface may be required relative to the mean plane and by using the below tabulations
the errors can be calculated and plotted as a graph. Here “L” is is the total cumulative error found and
“n” is the number of intervals used to find the straightness.

Measurement of Squareness: Two planes, two straight lines or a straight line and a plane are said to be
perpendicular when the error of parallelism in relation to a standard square doesnot exceed a given value.
Squareness of any two machined surfaces can be easily checked using autocollimator. The axis of the incident bem
from the collimator forms the measuring datum. An optical square is utilised for turning the incident beam through
exactly 90⁰. In this test, it is assumed that the two surface are perfectly straight.
- A stainless steel mirror block with a flat base
is used for horizontal surfaace for aligning
the collimator with the surface. A reading is
thus taken in collimator at position A.
- The mirror with base is then transferred to
the vertical surface at position B and the
optical square placed in the angle as
indicated and the autocollimator reading is
noted.
- The readings of the two mirror positions will indicate whether the machined surfaces are accurately at
right angles, if not the reading will show the direction and amoung of error

AutoCollimator Sketches
Module 1 Page 22 of 22 Mechanical Measurements & Metrology