Gauges and Gauge Design

5/7/2011
IPE 381 Chapter:10 Gauges and Gauge Design

Abdullah-Al-Mamun Lecturer, Dept. of IPE
Outline
Basics of Gauges Classification of Gauges Gauge Design Screw Gauges Adv & Disadv of Limit Gauges Gauge Design problem
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Gauges
Gauges are inspection tool of rigid design, without a scale, which serves to check the dimensions of manufacturing parts. Gauge do not indicate the actual value of the inspected part of the component. They are used to determine whether the part is made within the specified limit.
Classification of Plain Gauge

Plain gauges are used for checking plain (unthreaded) holes and shafts. Gauges are classified: According to their type : (a) Standard gauges- made as an exact copy of opposed(mating) part (b) Limit gauges- made to the limits of the dimensions According to their purposes : (a) Workshop Gauge: To Check Dimension after manufacture (b) Inspection Gauge: To check part before final acceptance (d) Purchase Inspection Gauge: To check part of other factory (c) Reference or master gauges: To check the dimension of Gauge
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According to the form of the tested surface : (a) Plug gauges for checking holes.
(b) Snap and ring gauges for checking shafts.

According to their design : (a) Single limit and double limit gauges (b) Single ended and double ended gauges, (c) Fixed and adjustable gauges.
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Limit Gauge
Limit gauges are made to the limits of the dimensions of the part to be tested. There are two limit of dimensions, so we need two limit gauge. Go gauge should pass through or over a part while Not Go gauge should not pass through or over the part.
Design of Limit Gauge

Allocation of Tolerance
Manufacturing Tolerance Wear Allowance
Taylors Principle of gauge Design Fixing of Gauge elements with handles

Taper lock design Trilock Design
Provision of Guards Provision of PilotCorrect Centering Materials Hardness and Surface finish Rigidity Alignment of Gauge faces
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Manufacturing Tolerance It is economically impractical to attempt to make Go and Not Go gauges exactly to the two limits of work tolerance. Limit gauges are made 10 times more accurate than the tolerances they are going to control.
Allocation of Mfg Tolerance
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Allocation of Mfg Tolerance
Wear Allowance
The surface of Go gauge is constantly rub against the surface of the part in inspection and loose their initial size The size of plug gauge is reduced but size of snap gauge is increased. 5% wear allowance is provided if working tolerance is greater than 0.09 mm.
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Allocation of Wear Allowance
Taylors Principle
Go Gauge should always be so designed that it will cover the maximum Metal Condition(MMC) of as many dimensions as possible in the same limit gauge, whereas Not Go gauge to cover the minimum metal condition of one dimension only.
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To Check Circular Holes

Go Plug Gauge Should Have a Full Circular Section. Length should be equal to the length of the hole.
To Check Circular Holes

Not Go Plug Gauge should be In the form of pin or bar. Should check the upper limit of the hole.
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To Check Circular Shaft

Ring Gauge Should be used as Go Gauge Length should be equal to the length of the shaft
To Check Circular Shaft

Snap Gauge Should be used as Not Go Gauge Should check the low limit of shaft For non circular shaft, Snap gauge will not pass through
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Fixing with Handles

Taper Lock Design
Used for diameter upto 63.5 mm. Used for smaller size plain and screw gauges.
Trilock Design
Used for diameter from 63.5 mm to 203mm. Gauge is attached with handle with three lock nuts.
Provision of Pilot
For closely toleranced parts Plug gauge doesnt easily enter the hole so piloting is used
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Thread or Screw Gauge

Nuts and internal threads are checked with Plug thread gauge and screws with Ring thread gauge. Three types of Fit
Close Fit Medium Fit Free Fit
Designing a Gauge
A 25mm H8-f7 fit is to be checked. The limit of size for H8 Hole are: High Limit - 25.033mm. Low Limit - 25.000mm. The limits for the f7 shaft are: High limit - 24.980mm. Low limit - 24.959mm. Taking the gauge makers tolerance to be 10% of the work tolerance, design plug gauge and gap gauge to check the fit.
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Designing a Gauge
Find tolerance for hole an shaft Find gauge tolerance Basic Size for Go Plug Gauge is LL of Hole Basic Size for Go Plug Gauge is HL of Hole For plug gauge: High limit of Go Plug gauge Low limit of Go Plug gauge High limit of Not Go Plug gauge Low limit of Not Go Plug gauge Repeat for Snap gauge Draw the Diagram of Go, Not Go Plug gauge and Go, Not Go Snap gauge
Self Study
10.7 10.8 10.9 10.10 Advantage of Limit Gauge Disadvantage of Limit Gauge Care of Gauges Other types of Gauge
Thank You
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5/7/2011

IPE 381 Chapter:10 Gauges and Gauge Design

Classification of Plain Gauge

Classification of Plain Gauge

(b) Snap and ring gauges for checking shafts.

Classification of Plain Gauge

Design of Limit Gauge

Taylors Principle of gauge Design Fixing of Gauge elements with handles

Allocation of Mfg Tolerance

Allocation of Mfg Tolerance

Allocation of Wear Allowance

To Check Circular Holes

To Check Circular Holes

To Check Circular Shaft

To Check Circular Shaft

Fixing with Handles

Thread or Screw Gauge

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