DIAL GAUGE / DIAL INDICATOR

It is very versatile and sensitive instrument. It uses gear system together with a rack and pinion.

The Principle of Operation:

“A very slight upward pressure on the spindle at the contact plunger is magnified through a system of gears
and levers and is indicated on dial by pointer and scale.”

The dial has a scale division value of 0.01mm usually. The whole arrangement is housed in a metal case for
its protection. Dial is graduated into 100 divisions.

A suitable spring gives constant plunger pressure, while hair spring may be employed to eliminate play or
backlash.

The necessary high magnification ratio m this instrument is achieved by the use of gears and pinions arrangement in a
small area, by arranging the gear train in a manner similar to a clock movement.
 WORKING PRINCIPLE
There is a plunger which is a perfect sliding fit in its own bearings. This carries a rack
which accurately meshes with a pinion A. The rotation of the plunger about its own axis is
prevented by a pin attached to it, which is located in a slot in a rack guide G. In order to
keep the plunger in an extended or normal position a light coil spring S is employed. The
spring exerts a pressure of approximately 6 oz. A small movement of the contact point
causes the rack to turn the pinion A with which it is meshed. A large gear B is attached to
the same spindle as pinion A. The gear B is further meshed with a pinion C, which thus
magnifies the movement of pinion A. Attached to the second pinion C is another gear D
which meshes with a third pinion E mounted on the same spindle as the indicator pointer.
This magnification is further enlarged at the tip of the pointer by an amount dependent
upon its length. The overall magnification for any dial gauge may be thus calculated by
measuring the distance between division on the scale and dividing this dimension by the
equivalent movement of the measuring plunger. In order to take up the backlash, a light
hair spring H is always fitted to the dial gauge gear trains by meshing a gear F to pinion E
and attaching spring if with F. In order to prevent gear backlash, the gears are precision
cut and the movement assembly resembles that of high-grade watch.
CONSTRUCTION OF DIAL INDICATOR
1. ROTATABLE BEZELS
Most dial indicators incorporate a rotatable bezel for making the final zero setting at any position
throughout the full circle. A clamp for locking it in any position is also provided. The bezel must be
free to rotate and must be exactly concentric as it carries the outer scale. Also when undamped, it
must be securely located on the case. Three equidistant tongues (T) locate the rotatable bezel in a
groove cut in the bezel wall, thus preventing it from being pulled away from the gauge. By careful fitting of the bezel
surface on the case, free rotation of the bezel can be ensured.

2. CONTACT POINTS
In order to make the dial indicator more versatile in its use, arrangement is provided to change the contact points. The
measuring plunger is tapped out and corresponding threads are provided at the end of contact points. The contact points
are generally made of hardened steel and blackened in order to avoid rusting. In order to prevent scratching of workpiece,
the contact end of each point is polished. The general purpose contact point is of hardened spherical-formed shape. This
is very satisfactory in all the applications, if care is taken to renew the ball when a flat is worn at the point of contact.

For measurement over a flat work surface, a flat surface contact anvil
is generally preferred. The contact anvil’s gauging surface is lapped
flat and true in position and this must be parallel to the flat work
surface. The above two contact points are most commonly used. For
some special purposes, as for finding the exact depth of etching in
printing blocks, a needle point can be used. In gauging of continuous
moving stock, the rolling contact will be ideal. Similarly for thread
inspection, conical points are used.
Tolerance Pointers.
For rapid checking of parts, tolerance pointers can be attached to the dial face. By these pointers any tolerance, whether
bilateral or unilateral, can be clearly indicated on the dial gauge. These are located in the centre and can be moved
independent of each other by means of projecting knobs.This is very useful in statistical quality control. The parts below
and above the minimum and maximum limits can thus be easily sorted out.

Special Stems.
Where deep recesses are to be inspected, long-stem indicators are available.

Shock-Proof Cushioned Movement.

Some dial indicators are designed to withstand sudden shocks due to rough usage and at the same time it reads
correctly. In such indicators, before the impact reaches indicator movement, it is cushioned by a specially loaded
attachment on the plunger. Thus the small and sensitive parts like gear, jewels, points etc. are protected.

Lever Attachments.
Lever attachments are very useful and facilitate the work of machine settings. The right angle offset attachment enables
internal measurements to be made. Also the awkward corners and recesses can be easily gauged by this attachment.
The attachment transfers motion at right angles’ to the indicator spindle directly. There is provision to avoid any errors due
to wear or play in bearings etc.
APPLICATION
1. Comparing two heights or distances between narrow limits.
2. To determine the errors in geometrical form such as ovality, roundness and taper.
3. For taking accurate measurement of deformation such as in tension and compression.
4. To determine positional errors of surface such as parallelism, squareness and alignment.
5. To check the alignment of lathe centers by using suitable accurate bar between the centers.
6. To check trueness of milling machine arbors and to check the parallelism of shaper arm with table surface.