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Dial Gauge

Dial indicators are instruments used to accurately measure small linear distances. They display measurements magnified on a dial. A dial indicator measures displacement along its axis, while a dial test indicator (DTI) measures displacement perpendicular to its axis and is used in machine setups. Dial indicators typically measure ranges from 0.25 mm to 300 mm with graduations of 0.001 mm to 0.01 mm. They are used in manufacturing and other applications requiring precise small measurements.

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888 views3 pages

Dial Gauge

Dial indicators are instruments used to accurately measure small linear distances. They display measurements magnified on a dial. A dial indicator measures displacement along its axis, while a dial test indicator (DTI) measures displacement perpendicular to its axis and is used in machine setups. Dial indicators typically measure ranges from 0.25 mm to 300 mm with graduations of 0.001 mm to 0.01 mm. They are used in manufacturing and other applications requiring precise small measurements.

Uploaded by

EnChick Pe'Ot
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOC, PDF, TXT or read online on Scribd
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Dial Indicator

Dial indicators, also known as dial gauges and probe indicators, are instruments used
to accurately measure small linear distances, and are frequently used in industrial and
mechanical processes. They are named so because the measurement results are
displayed in a magnified way by means of a dial.

A special variety of the dial indicator is the dial test indicator (DTI) which is
primarily used in machine setups. The DTI measures displacement at an angle of a
lever or plunger perpendicular to the axis of the indicator. A regular dial indicator
measures linear displacement along that axis.

Dial indicators may be used to check the variation in tolerance during the inspection
process of a machined part, measure the deflection of a beam or ring under laboratory
conditions, as well as many other situations where a small measurement needs to be
registered or indicated. Dial indicators typically measure ranges from 0.25 mm to
300 mm (0.015 in to 12.0 in), with graduations of 0.001 mm to 0.01 mm (metric) or
0.00005 in to 0.001 in (imperial).

Application

 To check for runout when fitting a new disc to an automotive disc brake.
Runout can rapidly ruin the disc if it exceeds the specified tolerance (typically
0.05 mm or less).
 In a quality environment to check for consistency and accuracy in the
manufacturing process.
 On the workshop floor to initially set up or calibrate a machine, prior to a
production run.
 By toolmakers (moldmakers) in the process of manufacturing precision
tooling.
 In metal engineering workshops, where a typical application is the centering of
a lathe's workpiece in a four jaw chuck. The DTI is used to indicate the run
out (the misalignment between the work piece's axis of rotational symmetry and
the axis of rotation of the spindle) of the work piece, with the ultimate aim of
reducing it to a suitably small range using small chuck jaw adjustments.
 In areas other than manufacturing where accurate measurements need to be
recorded (e.g., physics).

Reading a Dial Indicator

The reading on a dial indicator can be easily determined by paying attention to the
positions of the small and large hands.

The photo above shows the small hand pointing between 3 and 4. So, that means the
measurement is between 0.300" and 0.400". The large hand is pointing at 52. That's
52 thousandths from the last whole number (0.3"). So, combining the reading on the
small hand with that on the large hand results in a value of 0.352".

On some indicators, the small hand will make two full revolutions during the travel of
the plunger. So, you need to keep track of which revolution (the first or the second)
you are reading from.
Step to use it

1. Select the correct gauge and attachment


Select the gauge type, size, attachment and bracket, which fit the part you’re
measuring. Mount the dial indicator on a firm surface to keep it still.
2. Ensure plunger is at 90 degrees
Adjust the indicator so that the plunger is at 90 degrees to the part you’re
measuring.
3. Press the plunger halfway in
Press the dial indicator gently against the part, and rotate the part –in this case
a brake rotor-- one full turn. Keep pressing until the plunger settles about
halfway into the indicator.
4. Lock into position
Lock the indicator assembly into position.
5. Rotate and read
Carefully rotate the brake rotor a couple of times, while you observe the dial
readings face on.
6. Record any movements
If the pointer hovers around a single graduation on the dial, the part has
minimal run out, or surface distortion. If it moves significantly left and right,
you should note these variations. Find the point of maximum movement to the
left and move the dial so that zero is over this point. Continue to rotate the
brake rotor. Find the point of maximum movement to the right, and note the
reading. This will indicate the run out value. Continue this rotation several
times to confirm the points of maximum variation.
7. Check your results
Check your readings against the manufacturers specifications. If the deviation
is greater than the specifications allow, consult your supervisor.

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