BASIC OF GAUGE ,NECESSITY OF GAUGE,TYPES OF GAUGE,THEIR USE AND SAFETY

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BASIC OF GAUGE, NECESSITY OF GAUGE, TYPES OF GAUGE, THEIR USE AND SAFETY:

BASIC OF GAUGE, NECESSITY OF GAUGE, TYPES OF GAUGE, THEIR USE AND SAFETY By S.K. PANDA Thursday, February 14, 2013 1

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Thursday, February 14, 2013 2 Outline • Basics of Gauges • Classification of Gauges • Gauge Design • Screw Gauges • Adv & Disadv of Limit Gauges • Gauge Design problem

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Thursday, February 14, 2013 3 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.

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Thursday, February 14, 2013 4 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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Thursday, February 14, 2013 5 Classification of Plain Gauge According to the form of the tested surface : Plug gauges for checking holes. (b) Snap and ring gauges for checking shafts.

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Thursday, February 14, 2013 6 Classification of Plain Gauge • 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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Thursday, February 14, 2013 7 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.

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Thursday, February 14, 2013 8 Design of Limit Gauge • Allocation of Tolerance – Manufacturing Tolerance – Wear Allowance • Taylor’s Principle of gauge Design • Fixing of Gauge elements with handles – Taper lock design – Trilock Design • Provision of Guards • Provision of Pilot Correct Centering • Materials • Hardness and Surface finish • Rigidity • Alignment of Gauge faces

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Thursday, February 14, 2013 9 Allocation of Tolerance 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.

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Thursday, February 14, 2013 10 Allocation of Mfg Tolerance

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Thursday, February 14, 2013 11 Allocation of Mfg Tolerance

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Thursday, February 14, 2013 12 Allocation of 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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Thursday, February 14, 2013 13 Allocation of Wear Allowance

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Thursday, February 14, 2013 14 Taylor’s Principle • Go Gauge should always be so designed that it will cover the M aximum 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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Thursday, February 14, 2013 15 To Check Circular Holes Go Plug Gauge Should Have a Full Circular Section. Length should be equal to the length of the hole.

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Thursday, February 14, 2013 16 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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Thursday, February 14, 2013 17 To Check Circular Shaft Ring Gauge Should be used as Go Gauge Length should be equal to the length of the shaft

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Thursday, February 14, 2013 18 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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Thursday, February 14, 2013 19 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

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Thursday, February 14, 2013 20 SUMMARY Gauging is the method by which it is determined quickly whether or not the dimensions of the checking parts, in the production, are within their specified limits. The tools which are used for the same are called gauges. Materials which are used for making gauges are high carbon and alloy steels, cemented carbides, etc.

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Thursday, February 14, 2013 21 Gauges can be classified mainly as follows : (a) Based on the standard and limit ( i ) Standard gauge (ii) Limit gauge (b) Based on the consistency in manufacturing process and inspection ( i ) Working gauge (ii) Inspection gauge (iii) Reference gauge (c) According to the shape or purpose for which each is used ( i ) Plug (ii) Ring (iii) Snap (iv) Taper (v) Thread (vi) Form (vii) Indicating (viii) Feller

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Thursday, February 14, 2013 22 KEY WORDS Standard Gauges : These are made to the nominal size of the parts to be tested. Limit Gauges : These are „go‟ and „no go‟ gauges. Plug Gauges : These are used for checking holes of many different shapes and sizes. Ring Gauges : External diameter measuring gauges. Taper Gauges : Taper testing gauges. Snap Gauges : These are used for checking shafts. Thread Gauges : These are used for pitch diameter of the thread. Form Gauges : These are used to check the contour of a profile. Feller Gauges : For checking the clearance between the mating surfaces. Indicating Gauges : To measure the position of the surfaces.

THANKYOU:

THANKYOU Thursday, February 14, 2013 23

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