Surface plates

 A surface plate, in the context of metrology, is a flat and precision-engineered reference plane used
as a benchmark for measuring the flatness, straightness, and parallelism of other objects. It serves
as a fundamental tool in various industries, including manufacturing, engineering, and quality
control.
 Surface plates are typically made from high-quality granite, cast iron, or steel, which have excellent
stability, wear resistance, and dimensional stability. They are meticulously lapped and polished to
achieve a high degree of flatness and surface finish. The working surface of a surface plate is usually
protected by a protective coating or cover to maintain its accuracy and prevent damage.
 The primary purpose of a surface plate is to provide a reliable reference surface against which other
work pieces or measurement tools can be compared.

Some key characteristics and applications of surface plates in metrology:

1. Flatness: Surface plates are designed to have a high degree of flatness, typically within a specified
tolerance range. They serve as a reference plane to assess the flatness of other objects, such as
measuring instruments, gauges, or work pieces.

2. Straightness: Surface plates are also used to check the straightness or alignment of linear objects. By
placing a straightedge or a measuring instrument along the surface plate, the deviation from
straightness can be observed and measured.

3. Parallelism: Surface plates provide a reliable reference for verifying the parallelism of two surfaces
or objects. By comparing the contact between the surface plate and the workpiece or reference
object at multiple points, any deviation from parallelism can be determined.

4. Measurement Support: Surface plates provide a stable and flat platform for performing precision
measurements. They are often used in combination with various measurement tools, such as height
gauges, dial indicators, and coordinate measuring machines (CMMs), to ensure accurate and
repeatable measurements.

5. Inspection and Layout: Surface plates are widely used for inspection and layout tasks. They provide a
known reference surface for setting up and aligning workpieces, as well as for inspecting the
dimensional accuracy and flatness of machined or fabricated parts.

6. Calibration: Surface plates themselves require periodic calibration to verify and maintain their
flatness and accuracy. This calibration process may involve the use of specialized equipment and
techniques to assess deviations from the nominal flatness and establish corrective measures if
needed.

Care and Use of Surface Plates

(i) When not in use, it should always be kept covered with a wooded cover.
(ii) When in use, the whole surface should be used so as to have uniform wear.

(iii) During use, the top should be frequently wiped clean from dust and other particles.

(iv) When measurements are being made, a wiping cloth should be spread on the surface to receive
small tools and gauge blocks.

(v) Load on surface should be distributed evenly.

(vi) Use should be made of the full available area.

(vii) Point engagement should be made with intermediate precision gauge blocks.

(viii) Variation in flatness should be checked occasionally.

(ix) Grease should be applied on the top surface when not in use for a long time.

Inspection Gauging

Also known as Limit Gauges.

They are simply used to find whether the component is within the specified limits of size or not.
Gauging

Gauging is a process used to measure and inspect the dimensions of manufactured components to
ensure they meet the required specifications and tolerances. Gauges are devices or tools designed to
check the conformity of a part to its desired dimensions.

They play a crucial role in quality control and ensuring the interchangeability of parts.

- In general, gauges are fixed dimension instruments. They are made so that a minimum of time and skill
is required in their use.

- Gauges differ from measuring instruments because they have no graduations for length or angles and
no adjustment can be made in their use

- Gauges are specially made for some particular job which is to be produced in large quantities.

- The limit gauges also known as ‘GO’ and ‘NOT GO’ gauges are made to control the sizes to a definite
amount above and below the standard size. 'GO' and 'NOT GO' gauges, also known as Go/No-Go gauges
or fixed limit gauges, are a type of inspection gauges used to determine whether a manufactured part or
component meets specified dimensional tolerances.
 ‘GO’ and ‘NOT GO’ Gauges
 These gauges are widely used in quality control and production environments to quickly and
accurately verify the acceptability of parts.
 The 'GO' gauge is designed to represent the maximum allowable size or dimension of a part. If a
part fits or passes through the 'GO' gauge without any interference, it indicates that the part is
within the acceptable range and meets the required dimensional specifications. The 'GO' gauge
acts as a positive or affirmative gauge.
 On the other hand, the 'NOT GO' gauge represents the minimum allowable size or dimension of
a part. If a part does not fit or is unable to pass through the 'NOT GO' gauge, it indicates that the
part is larger than the specified tolerance limit and is considered non-conforming. The 'NOT GO'
gauge acts as a negative or restrictive gauge.
 The combination of 'GO' and 'NOT GO' gauges provides a simple and effective method for
conducting pass/fail inspections on parts. By using these gauges, inspectors can quickly
determine whether a part falls within acceptable tolerances or requires further examination or
rejection.

Here are detailed notes on three important aspects of gauging: Taylor's principle, gauge tolerance, and
construction and operation.

1. Taylor's Principle

Taylor's principle, also known as the Taylor's rule, is a fundamental concept in gauging that helps
determine the size and tolerance of a gauge based on the desired limits of the part being measured.

According to Taylor's principle, the size of a gauge should fall within the limits of the part's dimensions
plus the maximum permissible error. The maximum permissible error represents the allowable deviation
from the nominal size of the part. By applying Taylor's principle, the gauge's size is set to ensure that it
can detect any part that falls outside the acceptable tolerance range.

- It states :-

(i) The GO gauge checks the Maximum Metal Condition and should check as many dimensions as
possible.

(ii) The NOT GO checks the Minimum Metal Condition and should check only one dimension

- Thus a separate NOT GO gauge is required for each individual dimension.

Gauge Size = Part Size + Maximum Permissible Error

This principle ensures that the gauge is capable of identifying both undersized and oversized parts
accurately. It takes into account the manufacturing process capability and the required level of precision
for the specific application.

2. Gauge Tolerance

Gauge tolerance refers to the permissible deviation in the dimensions of a gauge. It is the acceptable
range within which the gauge can measure a part's dimensions accurately. The tolerance of a gauge is
typically specified as a positive and negative limit from the nominal size.

The gauge tolerance is influenced by several factors, including the desired level of accuracy, the
functional requirements of the part, and the manufacturing capabilities. It is crucial to select an
appropriate gauge tolerance to ensure that the measured parts are within the desired specifications.

When determining the gauge tolerance, it is important to consider the following aspects:

a. Part Tolerance: The gauge tolerance should be tighter than the part tolerance to prevent false
acceptances or rejections. It ensures that the gauge can accurately identify parts that fall outside the
acceptable range.

b. Manufacturing Process Capability: The gauge tolerance should be within the capability of the
manufacturing process. If the process is not capable of consistently producing parts within a narrow
tolerance range, the gauge tolerance should be adjusted accordingly.

c. Measurement Uncertainty: The gauge tolerance should consider the measurement uncertainty
associated with the gauging process. It accounts for the inherent variability in measurements and
ensures that the gauge can reliably detect deviations from the desired dimensions.

3. Construction and Operation

Gauges are constructed with precision to ensure accurate measurement and inspection. They are
designed based on the specific requirements of the parts being gauged. Here are some key
considerations in gauge construction and operation:

a. Material: Gauges are typically made from high-quality materials with excellent dimensional stability,
such as hardened steel, carbide, or ceramic. The choice of material depends on factors such as wear
resistance, corrosion resistance, and thermal stability.

b. Design: Gauges are designed to closely mimic the shape and features of the parts being measured.
They may include various elements like pins, slots, threads, or go/no-go features to check specific
dimensions or characteristics.
c. Calibration: Gauges need to be calibrated periodically to ensure their accuracy and reliability.
Calibration involves comparing the gauge measurements with a traceable standard to verify their
performance. If any deviations are found, adjustments or repairs are made to bring the gauge back into
specification.

d. Operation: Proper operation of gauges is essential to obtain reliable measurements. Users must
follow prescribed techniques and procedures while handling gauges. It includes applying appropriate
contact pressure, aligning the gauge properly, and interpreting the results correctly.