Gauges are tools used to check dimensions like size, shape, and positions of parts in manufacturing. They are classified based on standards, consistency in production, elements checked, and shape/purpose. Common gauges include plug, ring, snap, taper, thread, and form gauges. Working gauges check parts during production while inspection gauges are used by quality inspectors. Reference gauges maintain dimensional standards for other gauges. Gauges help ensure parts meet specifications.
Gauges are tools used to check dimensions like size, shape, and positions of parts in manufacturing. They are classified based on standards, consistency in production, elements checked, and shape/purpose. Common gauges include plug, ring, snap, taper, thread, and form gauges. Working gauges check parts during production while inspection gauges are used by quality inspectors. Reference gauges maintain dimensional standards for other gauges. Gauges help ensure parts meet specifications.
Gauges are tools used to check dimensions like size, shape, and positions of parts in manufacturing. They are classified based on standards, consistency in production, elements checked, and shape/purpose. Common gauges include plug, ring, snap, taper, thread, and form gauges. Working gauges check parts during production while inspection gauges are used by quality inspectors. Reference gauges maintain dimensional standards for other gauges. Gauges help ensure parts meet specifications.
Gauges are tools used to check dimensions like size, shape, and positions of parts in manufacturing. They are classified based on standards, consistency in production, elements checked, and shape/purpose. Common gauges include plug, ring, snap, taper, thread, and form gauges. Working gauges check parts during production while inspection gauges are used by quality inspectors. Reference gauges maintain dimensional standards for other gauges. Gauges help ensure parts meet specifications.
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Gauging, done in manufacturing processes, refers to the method by which it is
determined quickly whether or not the dimensions of the checking parts in
production, are within their specified limits. It is done with the help of some tools called gauges. A gauge does not reveal the actual size of dimension. A clear distinction between measuring instruments and gauges is not always observed. Some tools that are called gauges are used largely for measuring or layout work. Even some are used principally for gauging give definite measurement.
GAUGES AND THEIR CLASSIFICATIONS
Gauges are the tools which are used for checking the size, shape and relative positions of various parts but not provided with graduated adjustable members. Gauges are, therefore, understood to be single-size fixed-type measuring tools.
Classifications of Gauges (a) Based on the standard and limit (i) Standard gauges (ii) Limit gauges or “go” and “not go” gauges
(b) Based on the consistency in manufacturing and inspection
(i) Working gauges (ii) Inspection gauges (iii) Reference or master gauges
(c) Depending on the elements to be checked
(i) Gauges for checking holes (ii) Gauges for checking shafts (iii) Gauges for checking tapers (iv) Gauges for checking threads (v) Gauges for checking forms
(d) According to the shape or purpose for which each is used
(i) Plug (ii) Ring (iii) Snap (iv) Taper (v) Thread (vi) Form (vii) Thickness (viii) Indicating (ix) Air-operated Standard Gauges Standard gauges are made to the nominal size of the part to be tested and have the measuring member equal in size to the mean permissible dimension of the part to be checked. A standard gauge should mate with some snugness.
Limit Gauges These are also called „go‟ and „no go‟ gauges. These are made to the limit sizes of the work to be measured. One of the sides or ends of the gauge is made to correspond to maximum and the other end to the minimum permissible size. The function of limit gauges is to determine whether the actual dimensions of the work are within or outside the specified limits. A limit gauge may be either double end or progressive. A double end gauge has the „go ‟ member at one end and „no go‟ member at the other end. The „go‟ member must pass into or over an acceptable piece but the „no go‟ member should not. The progressive gauge has „no go‟ members next to each other and is applied to a workpiece with one movement. Some gauges are fixed for only one set of limits and are said to be solid gauges. Others are adjustable for various ranges.
Gauge Design: Every gauge is a copy of the part which mates with the part for which the gauge is designed. For example, a bush is made which is to mate with a shaft; in this case, the shaft is the mating part. The bush is check by a plug gauge which in so far as the form of its surface and its size is concerned, is a copy of the mating part (shaft). Taylor‟s principle: According to Taylor, „Go‟ and „No Go‟ gauges should be designed to check maximum and minimum material limits which are checked as below: „Go‟ limit: This is applied to upper limit of a shaft and lower limit of a hole. „No Go‟ limit: This is applied to lower limit of a shaft and the upper limit of a hole. Taylor‟s principle states that the „Go‟ gauges should check all the possible elements of dimensions at a time (roundness, size, location, etc.) and the „No Go‟ gauge should check only one element of the dimension at a time. Based on Taylor‟s principle, „Go‟ gauge is designed for maximum material condition and „No Go‟ gauge is designed for minimum material condition.
Types of Limit Gauges:
The various types of limit gauges used for gauging internal diameters of holes are: 1) Full form cylindrical plug gauge: The gauging surface is in the form of an external cylinder. Generally a small circumferential groove is cut near the leading end of the gauge and the remaining short cylindrical surface is slightly reduced in order to act as a pilot. 2) Full form spherical plug or disc gauge: The gauging surface is in the form of a sphere from which two equal segments are cut off by planes normal to the axis of the handle. 3) Segmental cylindrical bar gauge: The gauging surface is in one of the two forms: one form; external cylindrical form from which two axial segments are made by lowering down surface at other places. the other form; external cylindrical form in which segments are formed by removing remaining material. 4) Segmental spherical plug gauge: It is similar to full form spherical plug gauge but has two equal segments cut off by planes parallel to the axis of the handle in addition to the segments cut off by planes normal to the axis of the handle. Other types of gauges includes;
WORKING GAUGES, INSPECTION GAUGES AND REFERENCE GAUGES
To promote consistency in manufacturing and inspection, gauges may be classified as working, inspection, and reference or master gauges : Working Gauges Working gauges are those used at the bench or machine in gauging the work as it being made. Inspection Gauges These gauges are used by the inspection personnel to inspect manufactured parts when finished. Reference Gauges These are also called master gauges. These are used only for checking the size or condition of other gauges and represent as exactly as possible the physical dimensions of the product.
GAUGES FOR CHECKING ELEMENTS
Hole Gauge It is used to check the dimensions of the hole present in the element. Shaft Gauge It is used to check the dimensions of the shaft. Taper Gauge It is used to check the dimensions of the tapers. Thread Gauge It is used to check the threading of the element. Form Gauge It is used to check the forms of the elements.
GAUGES COMMONLY USED IN PRODUCTION WORK
Some of the important gauges which are commonly used in production work have been discussed as follows :
Plug Gauges These gauges are used for checking holes of many different shapes and sizes. There are plug gauges for straight cylindrical holes, tapered, threaded square and splined holes.
Ring Gauges Ring gauges are used to test external diameters. They allow shafts to be checked more accurately since they embrace the whole of their surface. Ring gauges, however, are expressive manufacture and, therefore, find limited use. Moreover, ring gauges are not suitable for measuring journals in the middle sections of shafts.
Taper Gauges The most satisfactory method of testing a taper is to use taper gauges. They are also used to gauge the diameter of the taper at some point. Taper gauges are made in both the plug and ring styles and, in general, follow the same standard construction as plug and ring gauges.
Taper Plug and Ring Gauge
Snap Gauges These gauges are used for checking external dimensions. Shafts are mainly checked by snap gauges. They may be solid and progressive or adjustable or double-ended.
Snap Gauges Thread Gauges Thread gauges are used to check the pitch diameter of the thread. For checking internal threads (nut, bushes, etc.), plug thread gauges are used, while for checking external threads (screws, bolts, etc.), ring thread gauges are used. Single-piece thread gauges serve for measuring small diameters. For large diameters the gauges are made with removable plugs machined with a tang. Standard gauges are made single-piece.
Feller Gauges Feller gauges are used for checking clearances between mating surfaces. They are made in form of a set of steel, precision machined blade 0.03 to 1.0 mm thick and 100 mm long. The Indian standard establishes seven sets of feller gauges : Nos 1, 2, 3, 4, 5, 6, 7, which differ by the number of blades in them and by the range of thickness. Thin blades differ in thickness by 0.01 mm in the 0.03 to 1 mm set, and by 0.05 mm in the 0.1 to 1.0 mm set.
Plate and Wire Gauges
The thickness of a sheet metal is checked by means of plate gauges and wire diameters by wire gauges. It is used to check the thickness of plates from 0.25 to 5.0 mm, and the wire gauge, is used to check the diameters of wire from 0.1 to 10 mm.
High Performance Fasteners and Plumbing: A Guide to Nuts, Bolts, Fuel, Brake, Oil and Coolant Lines, Hoses, Clamps, Racing Hardware and Plumbing Techniques
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