Maintenance

Practice

2. METROLOGY

SCALES @ RULES

- have in both 6inch and 12inch lengths.

- measuring devices used for sheet metal layout
- for taking measurements where extreme precision
is not required
- scales are made of either a tempered carbon steel
or satin finished stainless steel
- vailable in both flexible and rigid form
- flexible scale typically has a thickness of about
0.040inch thick

SCALES @ RULES contd

- Graduated either metric measurement or a

fractional measurement
- Fractional graduations divided into increments
of 1/32inch on one side and 1/64inch on the
other side.
- Decimal scale is divided in tenths(10th) or
fifteenths(15th) of an inch on one side while
the other side is divided in increments of
1/100inch
- Metric graduations are measured in 1/2mm
and one millimeters (mm)

SCALES @ RULES contd

-proper use of steel scale requires that the end of

the scale not be used to make a measurement.
- Instead, the one inch mark is used as the starting
point, you must remember to subtract one inch from
the final measurement.

End of a metal scale is not

SCALES @ RULES contd
precisely cut, the cut, or factory
end should not be used as a
measuring guide
begin measuring somewhere
after the first few markings on a
scale to ensure a correct
measurement
one inch mark is typically used
as the starting point because it
is easily subtracted from the
final measurement

SCRIBES
1.

2.
3.
4.
5.
6.

Dimension layout on metal parts, regardless of the

accuracy is typically accomplished by using layout dye
and a marking tool called a scribe
Needle-sharp point end are usually made of hard steel or
are carbide tipped
A layout dye typically applied to the metal first and the
scribe is used to scratch through the dye
However, this procedure will cause stress concentration
on the surface of a bend
Therefore, it is not acceptable to use this method to
indicate bend lines
Instead bend lines should be marked with a soft tipped
marker

SCRIBES contd

-A scribe is typically used with layout dye to

mark reference points on a material.
-scribe marks should never be used for bend
lines as they cause stress concentrations that
can lead to component failure.

COMBINATION SET

-includes a center head, a protractor head, and a

stock head.
-The stock head usually has a level and a scribe built
into it

COMBINATION SET contd

Measuring devices consists of a 12inch steel scale

and three heads that move up and down along the
scale
The heads of a combination set are removable to allow
use of any combination of the individual components.

COMBINATION SET contd

STOCK HEAD

stock head of a combination set
is normally used as a square

One side of the head is exactly
perpendicular to the scale

The other side meets the scale
at a 45degree angle

To determine if something is
level, the stock head can be
removed from the scale and the
built-in bubble level used

COMBINATION SET contd

PROTRACTOR HEAD
1. A bubble level and a 360degree
protractor are built in
2. Has a lock that releases the
protractor and allows it to rotate
3. Useful for measuring control
surface travel
4. Example, the surface of a
protractor head is locked in a
streamline, or neutral position,
and its head is placed on a
control surface that is in its
neutral position
5. Next, the protractor is turned
until its bubble level is centered

COMBINATION SET contd

Now, when the control

surface is fully deflected
the degree of travel is
represented by the
angular difference
between the level and the
scale

COMBINATION SET contd

To determine the total amount of the

surface movement, both extreme
measurement should be taken

The control surface is moved to its other
extreme of travel and the bubble level is
centered

Sum of two extreme readings is the
amount of control surface movement

CENTER HEAD
1.
2.

3.
4.
5.

COMBINATION SET contd

for finding the center of circular

objects
Put the two flats blades of the
center head over the end of a piece
of circular material that is held
perpendicular to the scale
Scale bisects the center head angle
into two equal parts
Scale also bisects the circular
material
Scribe a line along the edge of the
scale that passes through the
center of the circular material

COMBINATION SET contd

Rotate the center head

90degree and scribe
another mark along the
edge of the scale blade

The point where the
two scribe marks
intersect is the center
of the circular material

1.
2.
3.
4.
5.
6.

7.

DIVIDERS
Used to accurately lay out circles and arcs
and for transferring dimensions on metal
Has two legs with needle-sharps points
that are joined in the center with a pivot
Does not have a built-in scale
Does not provide a measurement
Cover the metal with a layout dye and
mark a base line with a very sharp scribe
Make a very light punch mark on the base
line to use as a reference for all
measurements
The divider is set to the desired distance
with the use of a steel machinist scale

DIVIDERS cont, d

One divider leg is placed on

the punch mark and a scratch
is made with the other divider
leg through the transfer dye

More accurate than
measuring a dimension
directly with a steel scale

USES OF DIVIDER

THICKNESS GAUGES

Used to measure clearances between two surfaces

2. Can be used with a surface plate and arbor to check
a part for twist or wrap
3. Thickness gauge consists of a stack of steel or
brass blades varying thickness
4. Each blade is ground to
a precise dimension
5. Accurate to ten thousandth
of an inch
1.

THICKNESS GAUGES

6. Metric thickness gauges are measured in fractions of

millimeters (i.e.. 0.4mm = four-tenths of a millimeter)
7. Many thickness gauge sets are marked with
measurements in both inches and millimeters
8. Select a blade approximately the size of the
clearance to be measured and insert it between the
two surfaces
9. If the blade is too loose, try next larger size
10. Blade slides-amount of friction, the size designation
printed on the blade indicates the clearance

THICKNESS GAUGES contd

If the blade is too loose, try next larger size

Blade slides-amount of friction, the size designation
printed on the blade indicates the clearance

USING OF THICKNESS GAUGE

CALIPERS

-Inside calipers have

legs with ends that
curve to the outside
- Outside calipers
have legs with ends
that curve to the
inside

CALIPERS

1.

2.
3.
4.

Type of measuring device typically

used to measure diameters and
distances or for comparing sizes
Familiar with three types of calipers
The inside caliper, the outside caliper,
and hermaphrodite caliper
Very similar to dividers in that they
have two legs with some type of pivot

CALIPERS

1.

2.

3.
4.

Inside calipers, used to measure the

inside diameter of a hole and have
legs that point outward
Outside calipers, used to measure
outside diameter of an object and
have legs that point inward
Adjust the caliper until it fits snugly
across the widest part of an object
Measure the distance between the
caliper leg points with a steel scale

Uses of internal and external calipers

CALIPERS contd

HERMOPHRODITE
-Hermaphrodite calipers
are used to mark
distances away edges.
-have the straight leg of a
divider and a leg that
curves inward similar to
an outside caliper

HERMAPHRODITE (ODD LEGS) CALIPERS

Used to scribe marks that are specific distance from
radius edge
1. Have one-sharp pointed leg
2. One leg that curves to inside
3. To use, the material covered with layout dye
4. The distance required is adjustable between the two
caliper legs
5. The caliper point is then moved along the radius
edge as the sharp point is drawn across the surface

Uses of Hermaphrodite

MICROMETERS CALIPERS

The precision measuring tool most universally used by the

aviation maintenance technician is the micrometer caliper .


Used to measure the thickness of sheet metal.

Out-of-roundness of cylindrical objects such as piston
pins and the degree of stretch of valve stems.

Can measure the fit of many engine parts.

Basic parts of a micrometer caliper
- frame - resembles a C-clamp
- anvil
- spindle
- sleeve
- thimble

1.

2.

3.

4.

MICROMETERS CALIPERS contd

Sleeve
Internal threads on the spindle
nut of an inch micrometer have
a pitch of 40 threads per inch
and extremely accurate
Sleeve, is marked with a oneinch longitudinal line that is
divided into ten equal
segments, or one-tenth-inch
increments
Between the tenths divisions is
further divided into four equal
parts of 0.025inch each
Each mark on the sleeve of the
micrometer caliper represents
0.025inch



MICROMETERS CALIPERS contd

thimble is marked in 25 equal section with each mark
representing 0.001inch
Thimble, rotated one complete revolution, from zero around
to zero, one line, or 0.025inch is exposed
Made to measure objects larger than one inch
The frame is modified so there is a one-, two-, or three-inch
gap between the anvil and spindle
Measurements between one and two inches reads zero when
the anvil is exactly one inch away from the spindle
Special standard reference gauges are used to check the
zero adjustment on micrometers larger than one inch or
25millimeters

VERNIER SCALE

A - this micrometer shows no

marks on the sleeve and the zeroA
line on the thimble in line with the
reference line on the sleeve
- when set this way, the
spindle and anvil should be
touching
B

B - the thimble on this

micrometer has moved out
0.001inch and the zero mark on
the sleeve just visible

C - four lines visible indicating thimble has

moved out at least 0.100inch
- thimble has also moved out another complete
revolution or 0.025inch added together,
has moved out 0.125inch
D- eight lines visible on the sleeve indicating the
thimble has moved out at least 0.175inch
-the 12 on the thimble is lined up with the reference
line on the sleeve indicating the thimble has moved out
an additional 0.012inch added together, thimble has
moved out 0.187inch
E- each mark on the sleeve
represents 0.025inch

0.000
0.600
0.050
+0.023
----------0.673

0.000
0.300
0.000
0.010
+0.0003
----------0.3103

1.

MICROMETERS CALIPERS contd

Can be be recalibrated by using a very precisely-sized piece
of metal called a standard or gauge block is inserted
between the anvil and the spindle is closed on the block to
create a pressed fit

2.

Pressed fit means that they come together with just enough
force to meet each other squarely.

3.

A Special spanner wrench is then slipped into a hole in the

micrometer sleeve and carefully rotated until the longitudinal
line is in exact alignment with the zero mark on the thimble

4.

Calibration should be accomplished by certified technician

because temperature variation must be taken into account

METRIC MICROMETER

Internal threads of the spindle nut have 50 threads

per 25millimeters
2. Longitudinal line on the sleeve is divided into 25
segments, each segment being one millimeter apart
from 0 to 25 millimeters
3. Each millimeters segment is further divided in half
making the sleeve measurement accurate to
b) 0.5 mm
0.5millimeters
4. The thimble itself
marked 50 equal divisions
1.

a) 7.0 mm

c) 0.22 mm

METRIC MICROMETER

5. Each marked representing 0.01mm or onehundredth of a millimeter

6. When the thimble rotated one complete revolution,
the spindle is moved one-half mm (0.5mm)
7. Two revolutions of the thimble are necessary to
move the spindle one full millimeter
b) 0.5 mm

a) 7.0 mm

c) 0.22 mm

MICROMETERS CALIPERS contd

METRIC MICROMETER CALIPERS 7.72 mm

b) 0.5 mm

a) 7.0 mm
c) 0.22 mm

VERNIER SCALES

To make measurements smaller than
one-thousandth of an inch

Secondary scale are
further divides
the primary scale into
even smaller increments

it has eleven extra lines on the sleeve.

Lines are marked longitudinally above the longitudinal
reference line.

To read begin by reading the sleeve and thimble just like a
standard micrometer.

Then the vernier scale
and identify the horizontal line
that lines up with the horizontal
line is then added to the
measurement.

0.000
0.300
0.000
0.010
+0.0003
----------0.3103

VERNIER SCALES
INCHES

One inch micrometer, vernier scale

divides each one-thousandth of an
inch into ten equal increments with
each increments being equal to one
ten thousandth of an inc
METRIC

The vernier scale divides each onehundredth of a millimeter(0.01) into
five or ten equal increments allowing
for measurements to either twothousandth of a millimeter (0.002mm)
or one-thousandth of a millimeter
(0.001mm) respectively

INSIDE MICROMETERS contd

Construction of inside micrometer

INSIDE MICROMETERS

micrometer head consisting of a

basic micrometer mechanism
and various extensions.

is read the same manner as an
outside micrometer

use place it inside the opening
measured and adjust the
micrometer until same size as
the opening

And read once it is done

INSIDE MICROMETERS cond

VERNIER CALIPERS.

Is

a versatile precision instrument used to

measure both inside and outside dimension.

Faster to use than a micrometer, have a useful
range of up to 6 inches.

To read a Vernier caliper, begin by identifying
the approximate dimension opposite the zero
mark on the sliding scale.

Identify the number on the sliding scale that is
aligned with an increment on the fixed bar scale
and add this to the first dimension.

VERNIER CALIPERS.
English vernier caliper has 25 spaces,
each graduation on the bar represent 25
thousandths of an inch (0.025).

The line on the vernier scale that is aligned
with the one of the bar scale indicates the
number of the thousandths of an inch to add to
the measurement indicated on the bar before
the zero on the vernier scale.

The

VERNIER CALIPERS.
A metric vernier caliper is read the same way as
English caliper in that scale on the movable jaw.

Each number on the metric bar scale represent one
centimeter or 10 mm.

The graduation on a metric vernier scale represents
divisions of 1/50mm .
Before use zeroing check:
- check dirt, closed nips faced against light.
- if no zero, adjust screws. (Calibration by qualify staff)

Internal Measurement

Locking Screw

Cursor

Fixed
Jaw

Moving
Jaw

The adjustment Clipper

Main Scale
Vernier
Scale

Fine Adjustment Screw

External
Measurement

VERNIER CALIPERS

VERNIER CALIPER


Precision

DIAL INDICATORS.

measuring instruments used to

determine the amount of movements existing
between certain engine and airframe parts.

It also used to determine an out of round
condition on a shaft as well as the plane of
rotation disk.

Dial indicator is put in contact with a smooth
parts of the shaft, when crankshaft is turned,
the needle indicates the maximum deviation in
the both direction.

DIAL INDICATOR

SMALL HOLE GAUGE

To

measure a hole that is too small to be

measured with inside micrometer.

The ball end of a hole gauge is placed inside
the hole to be measured and the end of the
shaft is twisted to expand the ball until it fits
the hole.

The gauge is locked so that it can be
measured with micrometer calipers.

used to measure inside diameter range from
1/8 to inch.

SMALL HOLE GAUGES

TELESCOPING GAUGES

Used to measured a hole with diameter between

5/16 to 6 inch.
Has one or two spring loaded arms, that are
collapsed and placed inside the hole to be
measured.
Take measurement lock on the end of the shaft is
then released, allowing the arm to spring outward
against the wall of the hole.
The gauge is maneuvered until it squared inside
the hole then it is locked by twisting the end of the
handle.
The gauge is then form the hole and then
measured with a micrometer caliper.

TELESCOPING GAUGES

RADIUS GAUGE.

is an internal and
external radius is cut
on each blade and
mark with the radius
size.

Metric and English
sets are available.

SCREW PITCH GAUGE.

Each blades has teeth cut on
its edges and marked the
number of t.p.i (teeth per inch)
WIRE GAUGE.

Used to determine the
thickness of wire and sheet
metal.

Made of sheet steel with
accurately ground slot round
the edges, each slot being
numbered according to
specification.

The gauge may be rectangular
or circular.

Go / No Go Gauges
-The most common types of gauges is plug gauges,
is used to test the accuracy of holes.
-The 'Low Limit' or minimum size gauge should be
an easy fit in the hole and is known as the 'GO' gauge
and the 'High Limit' or 'NO GO' gauge should not enter.
- Many plug gauges are combined 'GO' and 'NO GO'.
- Ends of the gauges can be identified by being marked
'GO' and 'NO GO'; also the 'NO GO' end is usually
shorter.

SURFACE PLATES

Made of cast iron and accurately machine
and hand finished to provide a dead flat
surface.

Avoid damaging surface. Do not drop
tools, leave tools and working on the
surface, installed cover after working.
MARKING OFF TABLES
- Function as Surface plate but larger size.

Made of close-grained cast iron and are
strong ribbed on the underside for rigidity;
with 3 legs and they are free standing.

Working surface is accurately machine to
give a true flat surface and the edge are
square.

VEE BLOCKS

To support round work, they made of cast iron or mild
steel and are supplied in identical pairs, stamped with
the same identification number.

Surfaces area accurately machined and Vee angle is
90degree.

SCRIBING BLOCKS

Used to mark out lines parallel to a true surface.

is made of high carbon steel hardened and tempered.

are classified by the height of the pillar.

MARKING OUT

MARKING OUT

Type of fits: 1.

Interference

shaft is larger than the hole

2.

Transition

shaft and hole of approximate size

3.

Clearance

hole is larger than the shaft

FITS AND CLEARANCES

A fits is the difference, before assembly,
between the sizes of two parts which are to be
assembled.

By using various methods of assembly, it is
possible to obtain a fit, whether or not the shaft
is smaller than the hole.

3 classes of fit are:a. Clearance.
b. Transition.
c. Interference.

CLEARANCE FIT.
referred as running fit. Mating components be
assembled by applying a light pressure or
fit together without any force.

TRANSITION FIT.
- referred as a light press or push fit. Interference or
clearance between the mating parts may need a light
press or hammer tap to achieve assembly.

INTERFERENCE FIT.
- referred as a drive fit, press or force fit. The
tightness of the fit is unlikely to damage or overstrain
components but requires a press or hammer
assembly.

Class of fits: 1. Shrink Force - INTERFERENCE

2. Driving Push - INTERFERENCE
3. Running
- CLEARENCE

Remarks: 1. Force - Mechanical pressure is required and once

assemble NO dismantling is likely to be required.
2. Driving - There are a little less tight than Force fits and
one part can be driven into the other.
3. Push - Slight manual effort to assemble the parts.
Suitable for detachable or locating parts but

not for moving parts.

4. Running - for various types of moving parts.

LIMIT SYSTEMS
In the ISO system the amounts by which holes and
shafts deviate from basic size are graded. These
grading are called Fundamental Deviations.
They re graded A to Z for holes and a to z for
shafts.
The letter would be followed by a number which
indicates the grade and by referring to the I.S.O.
Tables of Limits and Fits the engineer could confirm
the actual fit required, tables are shown in B.S. 4500
Examples
Hole = H7
Shaft = p6
Therefore the fit would be H7p6

a. Shrink Fit
- is used when the two parts are
firmly and permanently fixed together.
To assemble, the shaft is shrink e.g.
using dry ice.

b. Force Fit
- is similar to the shrink fit in that it is used where
two parts are to be firmly and permanently fixed
together.
- To assemble a force fit a
press is required.
- When the parts are forced
together, the surface score
and interlock thus giving
a solid joint.

c. Drive Fit
- used when parts have to fit firmly together but
must be capable of being dismantled and
assembled without damage to the parts, such as
a flywheel keyed to a shaft.

d. Push Fit
- is used when parts have to be assembled by hands
and there are no movement between them.
- a very small allowance between the size of
the hole and the shaft.

e. Running Fits
- always clearance between running or sliding fits, the amount
of clearance depending on the class of work required.
- general allowance for a running fit is a clearance of
1 thousandth of an inch per inch of diameter.