Limit Gauging

In mass production, components are manufactured in accordance with the permissive tolerance
limits, as suggested by the designer. Production of components within the permissive tolerance
limits facilitates interchangeable manufacture. It is also essential to check whether the
dimensions of the manufactured components are in accordance with the specifications or not.
Therefore, it is required to control the dimensions of the components. Several methods are
available to achieve the control on dimensions. Various precision measuring instruments can
be used to measure the actual dimensions of the components, which can be compared with the
standard specified dimensions to decide the acceptability of these components.

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. In addition, the actual or absolute size of a component, provided that it is
within the limits specified, is not of much importance because the permissible limits of
variations in dimensions would have been specified by the designer in a logical manner, giving
due consideration to the functional requirements. Therefore, in mass production, gauges can be
used to check for the obedience of the limits of the part with the permissive tolerance limits,
instead of measuring the actual dimensions. The term ‘limit gauging’ signifies the use of
gauges for checking the limits of the components. Gauging plays an important role in the
control of dimensions and interchangeable manufacture.

Definition of interchangeable manufacturing

: the making of the parts of machines with such tolerances that any of the parts will properly
function in any of the machines.

Limit gauges ensure that the components lie within the permissible limits, but they do not

determine the actual size or dimensions. Gauges are scaleless 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(maximum metal limit) and LML(minimum or least metal limit) of
the component, as depicted in Figures bellow
 Figure: Metal limits for hole gauging

Figure: Metal limits for shaft gauging

MML is the lower limit of a hole and higher limit of the shaft and LML corresponds to the
higher limit of a hole and lower limit of the shaft. The GO gauge manufactured to the maximum
limit will assemble with the mating (opposed) part, whereas the NOT GO gauge corresponding
to the low limit will not, hence the names GO and NOT GO gauges, respectively.

To inspect hole size of a part, the Go gage is inserted into the hole. If the gage can be
entered into the hole, then the hole is considered to be above its low limit. Following that,
the No Go gauge is used: if it enters the hole, then the hole is too big.

Practically, every gauge is a replica of the part that mates with the part for which the
gauge has been designed. Consider an example of the manufacture of a cylinder that mates
with a piston. The plug gauge, using which the cylinder bore is checked, is a copy of the
opposed part (piston) as far as its form and size are concerned. When a gauge is designed as a
replica of the mating (opposed) part so far as the dimension to be checked is concerned, it is
known as ‘standard gauge’. The main intention in the design of gauges is simplicity, which
helps in making continuous and accurate measurements.

It is important to note that normally clearance fits are preferred for a majority of the
assembly operations. Allowance or minimum clearance is determined by the algebraic
difference of the MMLs of the mating parts. Therefore, for clearance fits, the MMLs of the
mating parts become more critical than the LMLs. This assumes importance for the following
two reasons:

1. MMLs are crucial for effective functioning of the parts.

2. If the MMLs slightly exceed the specified values then assembly itself becomes
impossible.

As discussed earlier, for gauging the MMLs of the mating parts, GO gauges are used.
Therefore, it becomes imperative that special attention needs to be given when GO gauges are

designed for gauging these limits. Whenever the components are gauged for their MMLs, if
the GO gauges fail to assemble during inspection, the components should not be accepted under

any circumstances. The minimum limits in a clearance fit of a product are not so critical
because even if they exceed the specified limits and the NOT GO gauge assembles, its
acceptance may result in functional degradation and because of the reduced quality the useful
life of the product may get affected. Hence, it becomes essential that more care is taken
especially when GO gauges are used, when compared to NOT GO gauges during inspection.

Classification of Gauges
1. Plain gauges

(a) According to their type:

(i) Standard gauges, (ii) Limit gauges

(b) According to their purpose:

(i) Workshop ,(ii) Inspection ,(iii) Reference, or master, or control gauges

(c) According to the form of the tested surface:

(i) Plug gauges for checking holes (ii) Snap and ring gauges for checking shafts

(d) According to their design:

(i) Single- and double-limit gauges

(ii) Single- and double-ended gauges

(iii) Fixed and adjustable gauges

2. Adjustable-type gap gauges

3. Miscellaneous gauges

(a) Combined-limit gauges

(b) Taper gauges

(c) Position gauges

(d) Receiver gauges

(e) Contour gauges

(f) Profile gauges

Taylor’s Principle

In 1905, William Taylor developed a concept relating to the gauging of components, which has

been widely used since then. Since World War II, the term Taylor’s principle has generally
been applied to the principle of limit gauging and extensively used in the design of limit gauges.

Prior to 1905, simple GO gauges were used. The components were carefully manufactured to

fit the gauges. Since NOT GO gauges were not used, these components were without tolerance

on their dimensions.

The theory proposed by Taylor, which is extensively used in the design of limit gauges, not

only defines the function, but also defines the form of most limit gauges.

Taylor’s principle states that the GO gauge is designed to check maximum metal conditions,

that is, LLH and HLS. It should also simultaneously check as many related dimensions, such
as roundness, size, and location, as possible.

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 using undue force. The NOT GO side should not enter
or pass. The basic or nominal size of the GO side of the gauge conforms to the LLH or HLS,
since it is designed to check maximum metal conditions. In contrast, the basic or nominal size
of the NOT GO gauge corresponds to HLH or LLS, as it is designed to check minimum metal

conditions.

It can be seen from Figure :D bellow that the size of the GO plug gauge corresponds to the
LLH and the NOT GO plug gauge to the HLH. Conversely, it can be observed from Figure: E
that the GO snap gauge represents the HLS, whereas the NOT GO snap gauge represents the
LLS. the hole simultaneously, the GO plug gauge must have a full circular section and must be
of full length of the hole so that straightness of the hole can also be checked. During
inspection, it can be ensured that if there is any lack of straightness or roundness of the hole a
full entry of the GO plug gauge will not be allowed. Thus, it not only controls the diameter in
any given cross-section but also ensures better bore alignment. However, it should be
mentioned here that the GO plug gauge cannot check the degree of ovality.

Figure D: GO and NOT GO limits of plug gauge

The short GO plug gauge, if used in inspection, will pass through all the curves and is hence
not possible to identify defective parts. Therefore, in order to get good results, this condition
has to be fulfilled during the inspection of the parts. The length of the plug should normally
be more than 1.5 times the diameter of the hole to be checked. Compared to GO plug
gauges, the NOT GO plug gauges are relatively shorter.

Let us consider the gauging of a cylindrical hole. A simple plug gauge is used to gauge this

Figure E: GO and NOT GO limits of snap gauge

hole. During inspection, the GO gauge, which measures the minimum limit of the hole, enters
but the NOT GO gauge, which corresponds to the maximum limit, does not. In this case,
according to Taylor’s theorem, the hole is considered to be within the specified limits and hence
accepted. However, the shape of the hole has not been taken into account here. Most of the
methods used in the manufacture of the holes are capable of producing truly circular holes.
When these holes are gauged, they are accepted if they are within the specified tolerance zone.
As long as there are no circularity errors, there is no problem. However, when the holes deviate
from circularity, the problem starts. Consider an elliptical hole as shown in Fig. F. It can be
clearly observed from Fig. F that the NOT GO gauge does not enter because the minor axis of
the ellipse is smaller than the HLH, which corresponds to the diameter of the NOT GO gauge.
Therefore, even if the hole is slightly elliptical, the gauge does not take into account this
variation of the hole shape and it still gets accepted as the GO gauge assembles and the NOT
GO gauge does not. One way of overcoming this problem is to employ the NOT GO, which is
in the form of a pin. Any error in the circularity can easily be detected by placing the pin at
different cross-sections of the hole, as depicted in Fig. G. Hence, it can be said that Taylor’s
principle does not take care of the error of form, circularity, or straightness, and some
modifications are needed to overcome these limitations.

Important Points for Gauge Design

The following points must be kept in mind while designing gauges:

1. The form of GO gauges should be a replica of the form of the opposed (mating) parts

2. GO gauges enable several related dimensions to be checked simultaneously and hence are

termed complex gauges.

3. During inspection, GO gauges must always be put into conditions of maximum

impassability.

4. NOT GO gauges check a single element of feature at a time.

5. In inspection, NOT GO gauges must always be put into conditions of maximum passability

Material for Gauges

The material used to manufacture gauges should satisfy the following requirements:
1. The material used in the manufacture of gauges should be hard and wear resistant for a
prolonged life. This is one of the most important criteria that should be fulfilled.

2. It should be capable of maintaining dimensional stability and form.

3. It should be corrosion resistant.

4. It should be easily machinable, in order to obtain the required degree of accuracy and surface

finish.

5. It should have a low coefficient of expansion, in order to avoid temperature effect.

High-carbon steel is the most suitable and inexpensive material used for manufacturing gauges.
It can be heat treated suitably to provide stability and high hardness. It can easily be machined
to a high degree of accuracy.

Mild steel gauges are the most suitable for larger gauges. They are suitably heat treated by
carburizing to the required depth and then case hardened on their working surfaces to allow for

final grinding and finishing. After hardening, internal stresses are relieved to improve stability.

Chromium-plated gauges are very popular and extensively used for gauging. Chromium
plating makes the surface of the gauge very hard, and resistant to abrasion and corrosion. It is
also very useful in reclaiming worn-out gauges. For gauging aluminium or other materials
having an abrasive action, chromium-plated gauges are extensively used. The plug gauges
employed for gauging have satellite ribs that are inserted in the gauging surface.

Glass gauges are not very popular although they have good wear and corrosion resistance
properties. The problem with these gauges is that they either get damaged or are easily broken

if dropped. They are not affected by changes in temperature and have very low coefficient of
thermal expansion.

Although Invar, which contains 36% of nickel, has a low coefficient of expansion, it is not
suitable over a long period. Elinvar has 42% of nickel, is more stable than Invar, and also has
a low coefficient of expansion.

Gauge Tolerance (Gauge Maker’s Tolerance)

We know that gauges have to be manufactured to their required dimensions corresponding to

their maximum metal conditions. Gauges, like any other component, cannot be manufactured
to their exact size or dimensions. In order to accommodate these dimensional variations, which
arise due to the limitations of the manufacturing process, skill of the operator, etc., some
tolerance must be allowed in the manufacture of gauges. Thus, the tolerance that is allowed in
the manufacture of gauges is termed gauge maker’s tolerance or simply gauge tolerance.
Logically, gauge tolerance should be kept as minimum as possible; however, this increases the
gauge manufacturing cost. There is no universally accepted policy for deciding the amount of
tolerance to be provided on gauges. The normal practice is to take gauge tolerance as 10% of

the work tolerance.

Wear Allowance

According to Taylor’s principle, during inspection the NOT GO side should not enter or
pass. The NOT GO gauge seldom engages fully with the work and therefore does not
undergo any wear. Hence, there is no need to provide an allowance for wear in case of NOT
GO gauges. Taylor’s principle also states that the GO side of the gauge should enter the hole
or just pass over the shaft under the weight of the gauge without using undue force. During
inspection, the measuring surfaces of the gauge constantly rub against the mating
surfaces of the workpiece. Therefore, the GO gauges suffer wear on the measuring surfaces
and thus lose their initial dimension. Hence, wear allowance is provided for GO gauges to
extend their service life. As a consequence of this wear, the size of the GO plug gauge
decreases while that of the ring or gap gauge increases. Ring or Gap gauges are used for
checking the shaft component. The wear allowance provided for the GO gauges are added in
a direction opposite to wear. This allowance is added in for a plug gauge while subtracted for
a ring or gap gauge. A wear allowance of 10% of gauge tolerance is widely accepted in
industries. If the work tolerance of a component is less than 0.1mm, no wear allowance on
gauges is provided for that component, since a wear allowance of less than 0.001mm will not
have any practical effect on the gauges. The allowance on new gauge is made by fixing the
tolerance zone for the gauge from the MML of the work by an amount equal to the wear
allowance. A new gauge is then manufactured within the limits specified by the tolerance zone
for the gauge in this position. The gauge is then allowed to wear with use until its size coincides
with the maximum material limit for the work.