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Design of gauges Design of gauges

• In mass production, components are manufactured in accordance with
the permissive tolerance limits, as suggested by the designer

• It is also essential to check whether the dimensions of the

manufactured components are in accordance with the specifications
or not

• In mass production, where a large number of similar components are

manufactured on an interchangeable basis, measuring the dimensions
of each part will be a time-consuming and expensive exercise

• Gauges can be used to check for the compliance of the limits of the
part with the permissive tolerance limits, instead of measuring the
actual dimensions
https://www.indiamart.com/proddetail/limit-gauges-8295179162.html https://www.ypg-ltd.com/plate-gap-gauges/h-type/

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Design of gauges Design of gauges

Metal limits for hole gauging
• Gauges are scale less inspection tools, which are used to check
the conformance of the parts along with their forms and relative
positions of the surfaces of the parts to the limits

• The gauges required to check the dimensions of the components

correspond to two sizes conforming to the maximum and
minimum limits of the components

• They are called GO gauges or NO GO or NOT GO gauges,

which correspond, respectively, to the MML and LML of the
component

Metal limits for shaft gauging

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Design of gauges Design of gauges

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Taylor’s Principle Taylor’s Principle

• Taylor’s principle states that the GO gauge is designed to check • The basic or nominal size of the GO side of the gauge conforms to
maximum metal conditions, that is, LLH and HLS the LLH or HLS, since it is designed to check maximum metal
conditions. In contrast, the basic or nominal size of the NOT GO
• It should also simultaneously check as many related dimensions, gauge corresponds to HLH or LLS, as it is designed to check
such as roundness, size, and location, as possible minimum metal conditions

• The NOT GO gauge is designed to check minimum metal

conditions, that is, HLH and LLS. It should check only one
dimension at a time. Thus, a separate NOT GO gauge is required for
each individual dimension

• During inspection, the GO side of the gauge should enter the hole
or just pass over the shaft under the weight of the gauge without Plug gauge Snap gauge
using undue force. The NOT GO side should not enter or pass.
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Important Points for Gauge Design Gauge Tolerance (Gauge Maker’s Tolerance)

• The form of GO gauges should be a replica of the form of the • Gauges, like any other component, cannot be manufactured to their
opposed (mating) parts exact size or dimensions

• GO gauges enable several related dimensions to be checked • The tolerance that is allowed in the manufacture of gauges is termed
simultaneously and hence are termed complex gauges gauge maker’s tolerance or simply gauge tolerance

• During inspection, GO gauges must always be put into conditions of • Gauge tolerance should be kept as minimum as possible; however,
maximum impassability this increases the gauge manufacturing cost

• NOT GO gauges check a single element of feature at a time • The normal practice is to take gauge tolerance as 10% of the work
tolerance
• In inspection, NOT GO gauges must always be put into conditions of
maximum passability • A wear allowance of 10% of gauge tolerance is widely accepted in
industries (GO gauge)
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Numerical on gauge design Numerical on gauge design

Design the general type of GO and NOT GO gauges as per the

present British system for a 40 mm shaft and hole pair designated as
40 H8/d9, given that

𝑖 = 0.453 𝐷 + 0.001𝐷
40 mm lies in the diameter range of 30–50 mm
IT8 = 25i IT9 = 40i
Upper deviation of shaft = –16D0.44
Wear allowance assumed to be 10% of gauge tolerance

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Numerical Linear measurement

• Distances have to be measured between two lines or two surfaces
A hole and shafting system has the dimension 60 H7/m6. The or between a line and a surface
standard tolerance is given by
𝑖 = 0.45 𝐷 + 0.001𝐷 • When the distance between two engraved lines is used to measure
D = diameter (mm) of geometric mean step of 50 – 80 mm the length, it is called line standard or line measurement
i = standard tolerance (microns)
Grade 6 multiplier is 10 and grade 7 multiplier is 16 • The most common examples are yard and metre
Fundamental deviation for fit ‘m’ is given by
• When the distance between two flat parallel surfaces is considered
𝐹𝐷 = 𝐼𝑇7 − 𝐼𝑇6 for the relevant range of diameter
a measure of length, it is known as end standard or end
(a) Find class of fit measurement
(b) Sketch the fit and show dimensions
• The most common examples are measurements using slip gauges,
ends of micrometer anvils, Vernier calipers, etc.
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Linear measurement Design of linear measurement instruments

Comparison of line and end standards

• Linear measurement instruments have to be designed to meet

stringent demands of accuracy and precision

• At the same time, the instruments should be simple to operate and

low priced to make economic sense for the user

• The following points highlight important considerations that have

to be addressed in the design of linear measurement instruments

 The measuring accuracy of line-graduated instruments depends

on the original accuracy of the line graduations. Excessive
thickness or poor definition of graduated lines affects the
accuracy of readings captured from the instrument.

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Design of linear measurement instruments Design of linear measurement instruments

 Any instrument incorporating a scale is a suspect unless it  Dial versions of instruments add convenience to reading.
provides compensation against wear Electronic versions provide digital readouts that are even easier
to read
 Attachments can enhance the versatility of instruments.
However, every attachment used along with an instrument,  One important element of reliability of an instrument is its
unless properly deployed, may contribute to accumulated readability. For instance, the smallest division on a micrometer
error is several times larger than that on a steel rule of say 0.1 mm
resolution, which is difficult to read. However, the micrometer
 Instruments such as calipers depend on the feel of the user for provides better least count, say up to 0.01 mm, compared to the
their precision. Proper training should be imparted to the user to same steel rule. Therefore, all other things being equal, a
ensure accurate measurements micrometer is more reliable than even a Vernier scale. However,
micrometers have a lesser range than Vernier's.
 The principle of alignment states that the line of measurement
and the line of dimension being measured should be coincident  If cost is not an issue, digital instruments may be preferred
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Design of linear measurement instruments

 Whenever a contact between the instrument and the surface of
the job being measured is inevitable, the contact force should
be optimum to avoid distortion

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Design of linear measurement instruments Surface plate

Surface plate
• A surface plate is a hard, solid, and
horizontal flat plate, which is used as the
reference plane for precision inspection,
marking out, and precision tooling set-up

• Since a surface plate is used as the datum

for all measurements on a job, it should be
finished to a high degree of accuracy. It
should also be robust to withstand repeated
contacts with metallic workpieces and not
be vulnerable to wear and tear

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Surface plate V – blocks

• V-blocks are extensively used for inspection of

• In recent times, granite has
jobs with a circular cross section
replaced cast iron as the preferred
material for surface plates
• The major purpose of a V-block is to hold
cylindrical workpieces to enable measurement
• It is not vulnerable to rusting and
is non-magnetic
• The cylindrical surface rests firmly on the
sides of the ‘V’, and the axis of the job will be
• It is free from burrs or
parallel to both the base and the sides of the V-
protrusions because of its very
block
fine grain structure
• It is made of high-grade steel, hardened above
60 Rc, and ground to a high degree of
precision
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V – blocks Scaled instruments

• Rules are useful for many shop floor measurements

• Measurements of certain components require some mechanical

means to either hold the measuring device steadily against the
component being measured or capture the reading, which can be
read at leisure

 Depth Gauge

 Combination Set

 Calipers

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Depth Gauge Depth Gauge

Depth gauge is the preferred instrument

for measuring holes, grooves, and
recesses

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Combination set Combination set

• While the combination square can be used as a depth or height
gauge, the protractor head can measure the angles of jobs

• The centre head comes in handy for measuring diameters of jobs

having a circular cross section
Combination square
as a height gauge

Use of a centre head for the

measurement of diameter
Use of a protractor
A combination set has three devices built into it: a combination head for angle
square comprising a square head and a steel rule, a protractor measurement
head, and a centre head

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Calipers Calipers

• There are many jobs whose

dimensions cannot be accurately
measured with a steel rule alone

• A typical case in point is a job with a

circular cross section

• An attempt to take measurement

using a steel rule alone will lead to
error, since the steel rule cannot be
positioned diametrically across the
job with the required degree of
accuracy

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Calipers Calipers

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Self-study Linear measurement

• VERNIER INSTRUMENTS
Slip gauges
• Slip gauges, also called gauge blocks,
 Vernier Calliper, Dial Calliper, Electronic Digital Calliper can counter wear and tear and provide
a high degree of accuracy as end
 Vernier Depth Gauge standards

 Vernier Height Gauge • It is made of hardened alloy steel and

are economical with same coefficient
of thermal expansion as a majority of
• MICROMETER INSTRUMENTS Functional features of a slip gauge steel components used in production.

• Hardening is required to make the

slip gauge resistant to wear

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Slip gauges Slip gauges

• Hardening is followed by stabilizing at a
sub-zero temperature to relieve stresses • Carbide gauge blocks are used for their superior wear resistance
developed during heat treatment and longer life

• This is followed by finishing the measuring • They also have low coefficient of thermal expansion
faces to a high degree of accuracy,
flatness, and surface finish • However, they are quite expensive and used when rapid wear of
gauges is to be avoided
• The height of a slip gauge is engraved on
one of the rectangular faces, which also
Functional features of a slip gauge • Slip gauges are classified into grades depending on their
features a symbol to indicate the two guaranteed accuracy. The grade defines the type of application
measured planes for which a slip gauge is suited, such as inspection, reference, or
• The length between the measuring surfaces, flatness, and calibration
surface conditions of measuring faces are the most important
requirements of slip gauges
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Wringing of Slip Gauges Wringing of Slip Gauges

• Wringing is the phenomenon of adhesion of two flat and • When two surfaces are brought into contact, some
smooth surfaces when they are brought into close contact with amount of space exists between them. This is because
each other of surface irregularities and presence of dirt, oil,
grease, or air pockets
• The force of adhesion is such that the stack of a set of blocks
will almost serve as a single block, and can be handled and • Assuming that the two surfaces are perfectly flat with
moved around without disturbing the position of individual highly finished surfaces, free from dirt and oil, and
blocks firmly pressed together, a question arises as to why the
blocks stick together so firmly that even a high
• If the surfaces are clean and flat, the thin layer of film separating magnitude of force acting perpendicular to their
the blocks will also have negligible thickness surfaces will not be able to separate them

• Stacking of multiple blocks of known dimensions will give the • A combination of two factors appears to ensure this
overall dimension with minimum error high adhesion force
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Wringing of Slip Gauges Wringing of Slip Gauges

• An atmospheric force of 1 bar is acting in the
direction shown by the two arrows. This is • A stack of slip gauges will have a length equal to the sum of the
contributing to the adhesion of the surfaces of the individual heights
two slip gauges
• The ability of a given gauge block to wring is called wringability;
• The surfaces are in such close proximity that there is it is defined as ‘the ability of two surfaces to adhere tightly to each
molecular adhesion of high magnitude that creates other in the absence of external means
a high adhesion force
• The minimum conditions for wringability are a surface finish of
• Since the slip gauge surfaces undergo lapping as a super finishing 0.025 μm or better, and a flatness of at least 0.13 μm
operation, material removal takes place at the molecular level

• Since some molecules are lost during the lapping operation, the
material is receptive to molecules of the mating surface, which
creates high molecular adhesion
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Wringing of Slip Gauges Wringing of Slip Gauges

Technique of wringing slip gauges (a) Step 1 (b) Step 2

(c) Step 3 (d) Step 4

• Overlap gauging surfaces by about one-fourth of their length

• Slide one block perpendicularly across the other by applying

moderate pressure

• Now, gently rotate one of the blocks until it is in line with the
other block
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Wringing of Slip Gauges

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