3455 1971 Reff2020

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Reaffirmed2016)
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Fifth Rqrint NOVEMBER 1996
UDC 621’753’2 : 531’718’1 ( Incorporating Amendments No. 1 to 4 1 IS : 3455 - 1971
4

Indian Standard (Reaffirmed 2015)


.
GAUGING PRACTICE FOR PLAIN (Reaffirmed 2020)
WORKPIECES
( Firsf Revision ) (Reaffirmed 2014)

1. Scope-Lays down the gauging practice for inspection of plain workpieces with dimensions fess than
500 mm. This standard also gives the manufacturing tolerances and the permissible wear limit of the
gauges.
(Reaffirmed 2013)
2. Inspection Gauging of Plain Workpieces

2.1 Unless specified to the contrary, inspection by limit gauges is recognized as the acceptable method
for dimensional conformity to the specification of plain workpieces. To avoid any dispute requiring
checking of the conformity of the gauges of the manufacturer, the following procedure(Reaffirmed 2012)
is recommended
in the use of gauges of the manufacturer and of the purchaser.

2.2 lnspecfion by fhe Manufactorer - Generally the inspection department that checks the workpieces
made in the workshop may use the same types of gauges as those used in the workshop. In order to
(Reaffirmed
avoid differences between the results obtained by the workshop and inspection department 2011)
it is recom-
mended that the workshop uses new or only slightly worn gauges whilst the inspection department uses
gauges having sizes nearer the permissible wear limit.

2.3 lnspecfion by the Purchaser- There are three possible procedures for inspection on behalf of the
purchaser by an inspector who does not belong to the manufacturing plant concerned:
(Reaffirmed 2010)
a) the inspector may gauge the workpieces with the manufacturer’s own gauges, providing he
first checks the accuracy of these gauges;’
b) the inspector may use his own gauges, made in accordance with this standard, for inspecting
workpieces. It is recommended that these gauges should have sizes near the wear limit in
(Reaffirmed
order to avoid differences between the results obtained by the manufacturer and 2009)
the inspector;
c) the inspector may use his own inspection gauges for checking the workpieces. The diS-
position of the tolerance zones for these gauges should besuch as to ensure that the inspector
does not reject workpieces the sizes of which are within the Specified limits.
(Reaffirmed 2008)
3. Reference Temperature

3.1 The standard reference temperaturefor all industrial length measurements shall be 20°C. This is also
the temperature at which dimensions specified for workpieces and the inspection instruments are defined
and at which the inspection should normally be carried out.
(Reaffirmed 2007)
3.2 If the workpieces and the gauges have the same coefficient of linear expansion ( for example,
steel workpieces and steel gauges ), the checking temperature may deviate from 20°C without
detriment to the result, provided that the temperatures of both gauges and workpieces are the
same.
(Reaffirmed 2006)
3.3 If the workpieces and gauges have different coefficients of linear expansion (for example, steel
workpieces and carbide gauges or brass workpieces and gauges of steel or carbide ), the temperatures of
both &hould be close to 20°C at the time of gauging.

4. Limits of Size for Gauging (Taylor Principle ) (Reaffirmed 2005)


4.1 In order to ensure, as far as is practicable, that the functional requirements of the limits of sizes as
given in IS : 919-I 963 ’ Recommendations for limits and fits for engineering ( revised ) ’ are attained, the
limits of size should be interpreted in the following way within the basic dimensions:

a) For holes, the diameter of the largest perfect imaginary cylinder which can be inscribed within
the hole so that it just contacts the highest points of the surface, should not be a diameter
smaller than the GO limit of size. In addition, the maximum diameter at any position in the
hole shall not exceed the NO GO limit of size.
b) For Shafts, the diameter of the smallest perfect imaginary cylinder which can be circumscribed
about the shaft so that it just contacts the highest points of the surface, should not be a
diameter larger than the GO limit of size. In addition, the minimum diameter at any position
on the Shaft shall not be less than the NO GO limit of size.

Adopted 20 September 1971 @ April 1993, BIS


I I_

BUREAU OF I.NDIAN STANDARDS


MANAK BHAVAN, 9 BAHADUR SHAH WAR MAFtG
NEW DEU-II 110002
.:., ,4
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IS:3455- 1971

4.1.1 The above interpretation means that if the size of the hole or shaft is everyzdhere at its GO limit
then the hole of shaft shall be perfectly round and straight.

4.2 Subject to the above requirements, departures from true roundness and straightness may reach the
full value of the diametral tolerance specified. Typical extreme errors of form permitted by this interpre-
tation are illustrated in Fig. 1 and 2. Such extreme errors are unlikely to arise in practice.
Note-The above interpretation of the size limits results from the so-called Taylor principle, called after the
name of the late W. Taylor who first laid it down in 1905. It is based on the use of a correct system of limit gauges
to inspect shafts and holes. According t-o this principle a hole should completely assemble with a GO cylindrical
plug gauge,made to the specified GO limit of the hole, having a length at least equal to the length of engagement of
the hole and shaft. In addition, the hole is measured or gauged to check that its maximum diameter is not larger
than the NO GO limit.

4.2.1 The shaft should assemble completely with a ring gauge made to the specified GO limit of the
shaft and of a length at least equal to that of the length of engagement of the shaft and hole. Finally
the shaft is measured or gauged to check that its minimum diameter is not smaller than the NO GO limit.

4.2.2 In special cases the maximum errors of form permitted by the above interpretation may be too
large to allow satisfactory functioning of the assembled parts; in such cases separate tolerances should
be given for the form, for example, separate tolerances on circularity or straightness.

INSCRIBED CYLINDER

FIG. 1 EXTREME ERRORS OF FORM OF HOLE ALLOWED BY THE RECOMMENDED


INTERPRETATION OF THE LIMITS OF SIZE

5. Application of the Taylor Principle - Except for allowable deviations (see 6 ) strict application
of the Taylor principle leads to using:

a) a plug gauge or a ring gauge having exactly the GO limit diameter and a length equal to
the workpiece length ( or the engagement length of the fit to be made) for checking the
GO limit of the workpiece; and
b) a gauge contacting the workpiece surface only in two diametrically opposite points and having
exactly the NO GO limit diameter for checking the NO GO limit.

5.1 The GO gauge should perfectly assemble with the workpiece to be inspected and the NO GO
gauge should not be able to pass over or in the workpiece in any consecutive position in the various
diametrical directions on the workpiece length. ( In order that the GO and NO GQ limits should not be
trespassed, manufacturing and wear tolerances should be taken within these limits. )

6. Allowable Deviation from the Taylor Principle - As the application of the Taylor principle is not
always strictly compulsory or comes up against difficulties in conveniently using gauges, certain deviations
may be allowed ( see 7.9 ).

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IS: 3455- 1971

-GO LIMIT G-1 GO LIMIT


NOT GO LIMIT I-- NOT GO LIMITS
CIRCUMSCRIBED

k-GO LIMIT-----i L GO LIMIT2

FIG. 2 EXTREME ERRORS QF FORM OF SHAFT ALLOWED BY THE RECOMMENDED


INTERPRETATION OF TH,E LIMITS OF SIZE

6.1 At the GO limit a full form gauge is not always necessary or used. For instance:

a) The length of a GO cylindrical plug or ring gauge may be less than the length of engagement
of the mating workpieces if it is known or assumed that with the manufacturing process used
the error of straightness of the hole or shaft is so small that it does not affect the character of
fit of the assembled workpieces. This deviation from the ideal facilitates the use of standard
gauge blanks.

b) For gauging a large hole a, GO cylindrical plug gauge may be too heavy for convenient use,
and it is permissible to use a segmental cylindrical bar or spherical gauge if it is known or
assumed that with the manufacturing process used the error of roundness of the hole is so
small that it does not affect the character of fit of the assembled workpieces.

c) A GO cylindrical ring gauge is often inconvenient for gauging shafts and may be replaced by
a gap gauge if it is known or assumed that with the manufacturing process used the errors of
roundness ( especially lobing ) and straightness of the shaft are so small that they do not
affect the character of fit of the assembled workpieces. The straightness of long shafts,
which have a small diameter, should be checked separately.

6.2 At the NO GO limit a two-point checking device is not always necessary or used. For instance:

a) Point contacts are subject to rapid wear, and in most casis may be replaced where appro-
priate by small plane, cylindrical or spherical surfaces.
b) For gauging very small holes a two-point checking device is difficult to design and manu-
facture. NO GO plug gauges of full cylindrical form have to be used but the user must be
aware that there is a possibility of accepting workpieces having diameters outside the NO GO
Limit.

c) Non-rigid workpieces may be deformed to an Oval by a two-point mechanical contact device


operating under a finite contact force. If it is not possible to reduce the contact force to
almost zero, for example, by using a direct jet pneumatic device, then it is necessary to.use
NO GO ring or plug gauges of full cylindrical form.

6.3 Some thin-wa!led_workpieces Fay be out of round ( $ue t? internal stresses or heat treatment ). ln
these cases the N3 GO limit has the meaning that the ClrCUmterenCe of the cylinder corresponding t6
that limit shall not be transgressed. Therefore NO GO gauges of full cylindrical form have to be applied
with a force that just suffices to convert the elastic deformation into circularity but does not expand
or compress the wall of the workpiece.

3
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IS:3455-1971

6.4 Lastly, it is not possible to make the gauges exactly to the appropriate workpiece limit; they require
to be made to specified tolerances.

7. Limit Gauges

7.0 Limit gauges are used to inspect the workpieces. For gauging internal diameters, they are of the
following types:

a) Full form cylindrical plug gauge,

b) Full form spherical plug or disk gauge,


cl Segmental cylindrical bar gauge,

d) Segmental spherical plug gauge,


e) Segmental cylindrical bar gauge with reduced measuring faces, and

f) Rod gauge with spherical ends.

7.0.1 For gauging external diameters, they are of the following types:

a) Full form cylindrical ring gauge, and

b) Gap gauge.

7.0.2 To inspect or adjust limit gauges, the following gauges may be’used:

a) Referencegauges are either reference disks intended for setting gap gauges, or cyfindri-
cal ring or plug gauges used for calibrating gauges or indicating measuring
instruments.

b) Block gauges are standards of length having parallel plane end surfaces which are used
for calibrating gauges of indicating measuring instruments.

7.1 A fu// form cylindrical plug gauge ( Fig. 3A ) has a gauging surface in the form of an external
cylinder. The method of attaching the gauge to the handle should not affect the size and form of the
gauge by producing an undesirable stress.

7.1.1 A small circumferential groove near the leading end of the gauge and a slight reduction in dia_
meter of the remaining short cylindrical surface at the end are recommended to serve as a pilot to facilitate
the insertion of the gauge into the workpiece hole.

7.2 A full form spherical plug or disk gauge ( Fig. 3B ) has a gauging surface in the form of a sphere
from which two equal segments are cut off by planes normal to the axis of the handle.

7.3 A segmental cylindrical bar gauge ( Fig. 3C 1 has a gauging surface in the form of an external
cylinder from which two axial segments are either received [ Fig. 3C (i) ] or removed [Fig. 3C (ii) 1.
This gauge may have reduced measuring faces ( Fig. 3E ).

7.4 A segmentalspherical plug gauge ( Fig. 3D ) is similar to Fig. 3B but has two equal segments
cutoff 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.

7.5 A segmental cylindrical bar gauge with reduced measuring faces ( Fig. 3E ) is similar to Fig. 3~ but
has reduced measuring faces in a plane parallel to the axis of the handle.

7.6 A r& gauge with spherical ends ( Fig. 3F ) has spherical end surfaces which form part of one single
sphere.

7.7 A full form cylindrical ring gauge ( Fig. 4A) has a gauging surface in the form of an internal
cylinder. The wall of the ring pauge shall be thick enough to avoid deformation under normal condi-
tions of use.

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IS: 3455 - 1971

7.8 A gap gauge ( Fig. 48) has for its working size flat and parallel gauging surfaces, or alternatively
and preferably has one flat and one cylindrical surface, or two cylindrical surfaces, the axes of these
cylindrical surfaces being parallel to the axis of the shaft being checked. The GO and NO GO gaps
may lie on the same side of the gap gauge. Tha gap gauge may be fixed or adjustable.

A D Fui_l FORM CYLINDRICAL PLUG GAUGE B


o- FULL FORM SPHERICAL PLUG OR
DISC GAUGE

a- SEGMENTAL CYLINDRICAL BAR GAIJGE

a- ~EG~ENl.&SPHERICAL E
o- SEGMENTAL CVLINORICAL BAR GAUGE
WITH REWCEO MEASURIN@FACES

F a_0 ~00 GAUGE WITH SPHERICAL ENDS

FIG. 3 RECOMMENDED TYPES OF GAUGES FOR HOLES AND THEIR


CORRESPONDING SYMBOLS FOR FIG. 5

FULL FORM CYLINDRICAL Bk9 GAP GAUGE


A@
RING GAUGE

FIG. 4 RECOMMENDED TYPES OF GAUGES FOR S’HAkTS AND THEIR


CORRESPONDING SYMBOLS FOR FIG. 6
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IS : 3455 - 1971

7.9 The various types of gauges explained above are illustrated in Fig. 3 and 4. The recommended types
of gauges for the different ranges of nominal size of the workpieces are shown in Fig. 5 and 6. The
keys to the symbols used in Fig. 5 and 6 are given in Fig. 3 and 4.

DIAMETER IN mm
IORKPIECE GAUGES p;yFE;RfCE ,, - 120 315 500
I I I I

1
t--=D
TAYLOR +m- q - -+- ++-

GO

2
-o-o-

1 TAYLOR ____ct)__ o- -+- (j+)-


+----x3
r
[r GO
a4 2
0 l-----c------i

P
:.
s NOT GO I

FIG. 5 TYPES OF GAUGES USED TO CHECK HOLES, IN ORDER OF PREFERENCE

ORDER OF DIAMETER IN mm
WORKPIECE GAUGES PREFERENCE o

I- 0 TAYLOR s-1

FIG. 6 TYPES OF GAUGES USED TO CHECK SHAFTS, IN ORDER OF PREFERENCE

8. Inspection of Gauge Sizes

8.1 Reference Gauges- The gauge diameter should be measured between a plane and a spheri-
cally-ended anvil having a minimum radius of IO mm. The value obtained should be corrected for
deformation of the surfaces in contact caused by the measuring force, that is, the diameter of the gauge
is the diameter when the measurjng force is zero. The diameter should be measured in at least four
positions selected to reveal form errors.

8.1.1 All the measured diameters of the gauge should be on or between the specified limits of size,
and the range, that is, the difference between the maximum and minimum values, should not exceed the
form tolerance of the gauge ( see 10.2.3 ), If the presence of lobing is suspected then it may be checked
by a three-point measurement or by a roundness measurement.

6
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IS : 34559 1971

8.2 Spherical Plug, Disk and Red Gauges -The diameter of the spherical part of the gauge should
be measured between two parallel planes; these planes need only have a small area, for example, the
diameter of the plane-ended surface of the anvil of a measuring instrument may only be 5 mm.

8.2.1 The value obtained should be corrected for deformation of the surfaces in contact caused by the
measuring force, that is, diameter of the gauge is the diameter when the measuring force is zero.,

8.2.2 The diameter should be measured in. at least four positions, selected to reveal form errors. All
ihe measured diameters of the gauge should be on or between the specified limits of size, and the range,
that is, the difference between the maximum and minimum values, should not exceed the form tolerance
of the gauge (see 10.2.3). If the presence of lobing is suspected then it may be checked by a three-
point measurement or by a roundness measurement.

8.3 Cylindrical Ring Gauges- The -diameter is measured by means of t,wo spherically-ended anvils
. positioned in a plane normal to the axis of the ring gauge. When moving the measuring instrument in
this plane the greatest distance apart of’the two anvils determines the diameter. The value obtained
should be corrected for deformation of the surfaces in contact caused by the measuring force, that is,
the diameter of the gauge is the diameter when the measuring force is zero.

8.3.1 The diameter should be measured in at least four positions, selected to reveal form errors. All
the measured diameters of the gauge should be on or between the specified limits of size, and the range,
that is, the difference between the maximum and minimum values, should not exceed the form tolerance
of the gauge (see 10.2.3 ‘). If the presence of lobing is suspected then it may be checked by a
three-point measurement or by a roundness measurement.

8.4 Gap Gauges

8.4.1 The actual size of a gap is defined as the perpendicular distance between the gauging surfaces,
when no force is exerted on the gauge.

8.4.2 The working size of a gap gauge is defined as the diameter of a reference disk over which the
gap gauge just passes in a vertical direction under the working load marked on it, ar, if this is not
indicated, under its own weight. Beforehand, the disk should be greased with a thin film of petroleum
jelly and then carefully wiped but not rubbed. The gauging surfaces of the gap gauge should be
cleaned. The gap gauge should slide over the disk after having been brought carefully to rest in
contact with the disk and then released: inertia forces are so avoided.

8.4.3 For heavier gap gauges it is recommended that the working load should be less than the weight
of the gauge, so that the working size may be determined more accurately. The positions of the places
where the forces counterbalancing part of the weight of the gauge are to be applied ( see Fig. 7 ) should
be marked on gauges of nominal sizes above 100 mm.

FIG. 7 LOCATION OF POINTS WHERE FORCES COUNTERBALANCING


PART OF WEIGHT OF GAUGE SHOULD BE APPLIED

8.4.4 The working size of a gap gauge is not defined with a zero measuring force, as for the other
definitions, because the size of a reference disk is defined with a zero measuring force and the gap
gauge may be regarded as a comparator which is intended to transfer ( on the particular limit ) the size
of the reference disk to the workpiece.

8.4.5 In practice a reference disk may be used directly to accept a gap gauge in the case where the
disk and the gap gauge are supplied together and the gap gauge has been adjusted to the disk. 10 other
cases the following two alternative procedures are recommended:

a) The successive loads under which the gap gauge will pass over twq reference disks of
different diameter are determined under the conditions specified in the definition of the
working size. The difference in these two loads is taken as a basis for calculating the
working size of the gap gauge at its working load.

7
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IS:3455- 1971

b) A reference disk is taken with a diameter smaller * than the smallest permissible size of the
gap gauge. Gauge blocks are wrung successively on the gauging surfaces of the gap
gauge, if possible equally distributed so that in one case the sum of the diameter of the
reference disk and the gauge blocks is equal to the lowest permissible working size and in
the other case to the highest permissible working size of the gap gauget.

In the first case the gap gauge should pass over the reference disk, and in the second
case it should not pass over the reference disk, under the conditions specified in the definition
of the working size.

Doubtful cases are decided according to method ( b) above.

8.4.8’When the gap gauge is used in a horizontal position, with the axis of the workpiece vertical, its
working size is defined as the largest size of a reference disk or gauge block combination over which it
can just be moved by band without excessive force.

8.4.7 The difference between the working size and the actual size of a gap gauge is equal to the
amount by which the gauge is deformed by the force applied when determining the working size. The
design of the gap gauge should be as rigid as possible in relation to the weight of the gauge so as to
keep this difference in size to a minimum.

9. Method of Use of Gauges -The following recommendations relate to the general use of the
gauges in the workshop as well as in inspection.

9.1 Gauges for Holes

GO Gauge -A GO gauge should assemble completely with the hole when applied by hand
without using excessive force, and the total length of the hole should be checked. When gauging
non-rigid workpieces, such as thin-walled parts, the application of too great a force will enlarge the
diameter of the hole. A GO segmental gauge should be applied to the hole in at least two axial planes
uniformly placed around the circumference.

NO GO Gauge - A cylindrical NO GO plug gauge should not enter the hole when applied by
hand without using excessive force. The hole should be checked from both ends, if possible.

A NO GO gauge with spherical measuring surfaces is entered into the hole by tilting it. When
it is erected in the hole, contacting the hole on a diameter, it should not be possible to pass it through
the hole by hand without using excessive force. This test should be performed at not less than four
positions around and along the cylindrical surface of the hole.

9.2 Gauges for Shafts

GO Gauge - The GO gap gauge should pasa over a shaft, the axis of which is horizontal, under
its own weight or the force marked on the gauge, under the conditions specified in 8.4.

The GO gap gauge should pass over a shaft, the axis of which is vertical, when applied by hand
without using excessive force. It is recommended that the corresponding reference disk should be used
to assess the measuring force.

The above test should be applied at not less than four positions around and long the shaft.

A cylindrical GO ring gauge should pass over the complete length of the shaft when applied by
hand without using excessive force.

NO GO Gauge-The NO GO gauge should not pass over a shaft, the axis of which is
horizontal, under its own weight or the force marked on the gauge, under the conditions specified
in 8.4.

The NO GO gap gauge should not pass over a shaft the axis of which is vertical, when applied
by hand without using excessive force.

The above test should be applied -at nor less than four positions around and atong the shaft.

*For gap gauges up to 100 mm it is advisable to make the diameter of the disk 5 mm smaller than the nominal size,
and for gap gauges over 100 mm, 10 mm smaller than the nominal size.
iReference disks made to the lowest and highest permissible sizes may also be used.

8
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IS: 345511971

10. Manufacturing Tolerances and Permissible Wear of Gauges

10.1 Symbols --- The following symbols are used in this standard:

D = nominal diameter of workpiece in millimetres;


H = tolerance on cylindrical plug or cylindrical bar gauges;
H, = tolerance on spherical gauges;
HI = tolerance on gauges for shafts;
H P = tolerance on reference disks for gap gauges;

Y = margin, outside the GO workpiece limit, of the wear limit of gauges for holes;

Yl = margin, outside the GO workpiece limit, of the wear limit of gauges for shafts;
z = distance between centre of tolerance zone of new GO gauges for holes and GO workpiece
i imit;
z, - distance between centre of tolerance zone of new GO gauges for shafts and GO work-
piece limit;
2 = safety zone provided for compensating measuring uncertainties of gauges for holes of
nominal diameter over 180 mm;

a1 = safety zone provided for compensating measuring uncertainties of gauges for shafts of
nominal diameter over 180 mm; and
y’ and Y’~ =.. difference in absolute value between y and a or y1 and al.

10.2 Limit Gauges

10.2.1 Positions of tolerance zones and wear limits in relation to workpiece limits ( shown diagram-
matically in Fig. 9 ).

NO GO limit of workpieces -- The tolerance zone of new NO GO gauges for nominal sizes up to
and including 160 mm is symmetrical to the NO GO limit. For sizes above 180 mm the tolerance zone
is symmetrical to a line lying inside the workpiece tolerance zone at a distance CCor a1 from the NO GO
limit.

GO limit of workpieces --- A reasonable life for GO gauges is provided in two ways:
a) the tolerance zone of a new GO gauge is moved inside the workpiece tolerance by an
amount 2 or z,;
b) the GO gauge is allowed to wear outside the GO limit of the workpiece by an amount y or y1
when this value is not zero.

In the range of sizes above 180 mm nominal diameter the values of y and y1 are reduced by the
amount of the safety zones a and a1 respectively so that in these cases, the actual wear of the GO
gauges is limited toy’ and yfl respectively outside the GO limit of the workpiece (or to a and a1 within
this limit if y and y’ are equal to zero).

The values of they or y1 margin have been taken as small as possible in order to reduce to a
minimum the risk that workpieces with sizes outside the prescribed GO limit be accepted. This margin
is therefore provided only in the case of smaller tolerances on workpieces, from IT6 to IT8, the deletion
of this margin being possibly contemplated in the future ( in connection with the development of low
cost low wear gauges ).

In the range of sizes above 180 mm nominal diameter the workpiece tolerance has been reduced,
at the GO ( with y or yr margin ) and NO GO limits, by the amount of the safety zones a and a,. Manu-
facturers and purchasers should not forget that due to errors of measurement the sizes of work-
pieces may fall outside the limits of the gauges by the amount of the safety zones u and a1 and that the
extreme workpiece limits, given by y and y,, may be reached.

10.2.2 Tolerances on size of working gauges -The tolerances on size of working gauges are based on
the fundamental tolerances of grades IT1 to IT7 and are shown in Table 1.

Values of a, y, z. etc, for the gauges are shown in Table 2.

Gauge size for component tolerance ’ T ‘, not included in Table 2 shall be calculated by using
the data for the next higher values of ‘ T ’ in the same range.

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lS:3455- 1971

10.2.3Tolerances on form of working gauges - The tolerances on form of working gauges are based
on the fundamental tolerances of grades IT0 to ITB.and are shown in Table 1,

10.3 Reference Disks for Gap Gauges

10.3.1Positions of tolerance zones with respect to the workpiece limits ( shown diagrammatically in
Fig. 9).

NO GO limit of workpiece - For nominal sizes up to and including 180 mm the tolerance zone
of ihe reference disk is symmetrical to the NO GO limit. For sizes above 180 mm the tolerance zone is
symmetrical to a line lying inside the workpiece tolerance zone at a distance a from the NO GO limit.

GO limit of workpiece -The tolerance zone of the reference disk for a new gap gauge is
symmetrical to the z, value.

The tolerance zone of the reference disk for checking wear is located in the following manner:
a) Workpieces of nominal sizes up to and itxluding 180 mm - For tolerance grades IT6 to IT8
the tolerence zone of the reference disk is symmetrical to they, value. For tolerence grades
IT9 to IT1 6, y1 is zero and hence the tolerance zone of the reference disk is symmetrical to
the GO limit of the workpiece.
b) Workpieces of nominal sizes above 180 mm - For tolerance grades IT6 to IT8 the tolerance
zone of the reference disk is symmetrical to the y’, value (u’~ =yl - LYE). For tolerance
grades IT9 to IT1 6 y1 is zero and hence the tolerance zone of the reference disk is symmetrical
to the value inside the GO limit of the workpiece.

10.3.2 Tolerances on size of reference disks - The tolerances on size of the reference disks are based
on the fundamental tolerances of grades IT1 to IT3 and are shown in Table 1.

Values of a1 y1 2,. etc, for the reference disks are given in Table 3.

Gauge size for component tolerance ‘ T ‘, not included in Table 3 shall be calculated by using
the data for the next higher values of ‘ T ’ in the same range.

10.3.3 Tolerances on form of reference disks- The tolerances on form of the reference disks are
based on the fundamental tolerences of grades IT1 to IT2 and are shown in Table 1.

10.3.4Relation between tolerances of gap gauges and their reference disks - The relation
between the tolerances HI of the gap gauge and the tolerance of its reference disk H, is as follows:
H1 determines the limits of size of the working size ( see clause 8.4 ) of a gap gauge. The
difference between the limits of size given by HI for the gap gauge and by H, for the reference disk
represents a safety zone on both sides of Hp to compensate for errors of measurement, in the same
way as ct and o(, do for workpieces of diameters over 180 mm, HI and H, are, therefore, symmetri-
cal ( see Fig. 8 ). Therefore, if according to the definition of working size, gap gauges lie outside
the zone HP but within the zone HI, they are still to be regarded as correct.

/+I = manufacturing tolerance of the gap-gauge


Hy = manufacturing tolerame of the reference disk
A = safety zone

FIG. 8 RELATION BETWEEN MANUFACTURING TOLERANCES OF


GAP GAUGES AND OF REFERENCE GAUGES

10
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IS : 3455 - 1971

‘IQ.4 Reference Ring and Plug Gauges for Setting Measuring Instruments- The gauges should ba
made to tolerances on size and form equal to those for reference disks. The tolerance on size is disposed
bilaterally with respect to the appropriate test limit of the workpiece. The size of each gauge should be
measured across a diameter halfway through the gauge, and the axial plane in which this diameter
occurs and the measured size of the gauge should be marked on the end face of t;le gauge.

11. Formulae for Calculation of Gauge Dimensions

11.1 From the position of the tolerance zones and wear limits in relation to workpiece limits illustrated
in Fig. 9, the formulae for calculation of gauge limits can be computed and these are given below. In
these formulae, in addition to the symbols given in 10.1, the following are used:

G = higher limit for workpiece, and

K = lower limit for workpiece.

FORMULAE FOR GAUGE DIMENSIONS

T Gauge
Size
Nominal Size

Up to 180 mm Above 180 mm


,
Gauges Reference Gauge Gauges 1 Reference Gauge
Basic Basic M’g / Basic Mfg
Size % Size Tol Z:F $7 ~ Size Tol
_- ~- ---___

Inside mea- No Go G *H G-a &Hs i


surements ? 1
or or
*Hs *H*
2 2

GO (New) K+z *H Not Not


2 Provided Provided

Wear K-Y
- K-y+a -
Limit
-_
Outside mea- Wear G+YI - / G+YI “HP G+yl-=I -
surements Limit 2-
-’ _-
Go (New) G-q *HI 1 G-q G-q *HP
2 1 -5
I--

No Go K K+~I * Hp

- I 2
‘H
2 should only be used when spherical gauges are not used
-

11.2 Sample Calculation - Illustrative examples for the calculation of gauge limits are given below:

Required Gauge Size for 25C9 Plug Gauge

The component tolerances will be + 0.162


According to IS : 919-l 963
+ 0.110 >
Corresponding work limits will be G = 25’000 + 0.162 = 25.162 mm
K = 25’000 + O-1 10 = 25-l 10 mm

11
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IS:3455- 1971

GAUGES FOR INSlOE MEASUREMENTS~M~E! GAUGES FOR OUTS406 MEASU+?EMENTS (SHAFTS


).
ILLUSTRATIONS FOR GRADES 6 TO 6, ILLUSTRATITIONS Fop GRADES 5 70 6,
ABOVE GRADE 9.Y IS ZERO ABOVE GRADE 9,Y, IS ZERO
HP
r-i- ,

MwlWL SIZE
UPTO OOmm

ra

SOMINAL SIZE
4BOVE 160mm

ANUFACTURING
y
TOLERANCES PERMlSSl91
si?FoR TOLERANCE ON WORK- PIECES ( T )
INSIDE
MEASUREMENTS
OUTSIDE
MEASUREMENTS
I

m m nunll
FIG. 9 TOLERANCE ZONES OF LIMIT GAUGES AND REFERENCE DISKS

For plug gauges size can be calculated as under:


*NO GO size = G f H/2 = 25.162 f OS002 mm
*GO size new = (K+2)*H/2=(25’110+0’009)*0*002
= 25.119 f 0’002 mm
*GO size wear limit = K - y = 25’110 - 0
= 25*110mm
Required Gauge Size for Snap Gauge 270 + d
- 0.05
The component tolerance will be:
.G = 270,000 mm
K = 270 - 0’05 = 269.950 mm
Snap gauge size can be calculated as under:
tGO size wear limit = G + yl - a1 = 270*000 + 0*007 - 0*0004
- 270003 mm
tG0 size new = (G-q)f~~ - ( 270*000 - 0.008 ) f 0wO06 ’
= 269,992 f 0.006 mm
TN0 GO size = (K -t- a1 ) rt I-$ = ( 269,950 + 0.004 ) f 0.006
269.954 f 0*006 mm
*For actual sizes of plug gauges for standard fits for 1 to 500 mm nomlnal sizes, refer IS :?959-1975 ‘Gauge
allowances and manufacturing tolerance for plaln gauges for Inside measurements for IS0 fit sizes (nominal size up to
500 mm)8.
*For actual sizes of snap gauges and ring gauqes for standard fits from l,to 500 mm nominal sizes, refer IS : 7875-1975
1Gauge allowances and manufacturing tolerance or plain gauges for outrlde measurements for IS0 fit sizes ( nominal
rlze up to M)Omm ) ‘. 12
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IS : 3455 - 1971
12. General Requirements

12.1 No recommendations are given in this standard for details of the design of gauges. The technical
supply conditions shall conform to IS : 7018-1973 ‘ Technical supply conditions for gauges
The marking and designation of the gauges shall also c&form
to the above Indian Standard.

TABLE 1 MANUFACTURING TOLERANCES FOR GAUGES


- -_._-L- ~.....--
i
Tolerance Grade for
Workpiece /
I-
IT4
-1
I
ITS IT8
-/_-
IT7
- -
I IT8 to
IT10
_- -_
IT11 to
IT12

Size -7Form Size Forn Size Form Srze I:orrr Size / Form Size Form Size :orm
(ITI j (ITI (ITI (IT) I (ITI
-- (ITI UT) (ITI (ITI (ITI
-,_
UT)
_I_ -
(ITI (IT) (IT)

Tolerance Grade for Cy- 0+ o* 1’ 1* 2 1; 3 2 5 5


lindrical Plug Gauges
!
Tolerance Grade for Cy- - - l- 2 2
1 3
lindrical Bar Gauges
/
Tolerance Grade for - - ! - 2 1 2 1
I
Spherical Plug or Disk
Gauges

Tolerance Grade for - - -


Spherically Ended Rod
Gauges

Tolerance Grade for Cy- - - -


lindrical Ring Gauges

Tc$;;ze Grade for Gap - - -

Tolerance Grade for Re- - - -


ference Disks for Gap
bauges
I
Tolerance Grade for Re- - - I -
ference Cylindrical Set-
ting Plug Gauges

Tolerance Grade for Refe- ; - - -

rence Cylindrical Setting


Ring Gauges ;_

- A- --

*‘Up to 6 mm diameter only.

13
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IS:3455-1971

TABLE 2 GAUGE TOLERANCES AND THEIR LOCATION FOR GAUGES


FOR INSIDE MEASUREMENTS ( HOLES )

( Clause 10.2.2 )

All values are in micrometer ( Cm)

Nominal Siid I Work Tolerance Grades as per I SO I

18

( Continued)

14
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IS : 3455 - 1971

TABLE 2 GAUGE TOLERANCES AND THEIR LOCATION FOR GAUGES


FOR INSIDE MEASUREMENTS ( HOLES) - Contd

All values are in micrometer ( pm )

Nomir Grades as per IS0


I

120

1 Hs.12 1 ,305 t 3.5 t 3-5 t t 14.5 I 14-s I


180
I z 151711: I 21 I 24 I 40 I 45 I 80 I loo I 170 I 210 t

al 2 3 4 4 7 10 16 25 45 70 110

T 32 52 1 81 130 1 210 320 1 520 810 1300 2100 3200


HI2 4 6 6 11.5 26 26
I
315 . W2 4 4 4 8 16 I6
250
Y 5 7 9 0 0 0 0

Z 6 6 14 24 27 45 50 90 110 190 240

a 3 4 6 6 19 15 I 20 35 I 55 90 I 140 .

1 T
H/2 1I 4.5
36 t 57
1 1
6*5 89 iI 140 1
6.5 230 iI 360 1 570
12.5 I1 890 26.5 1400 1I 2300 1 3600
23.5

4.5 9 18 16
315
0 0 0 0

Z 7 10 16 26 32 50 6c; 100 125 210 280

a 14 6 1 7 7 1 11 I5 1 30 45 70 110 180

T I 40 63 1 97 155 1 250 400 1 630 970 [ 1550 I2500 1 4000


H/2 1 j 7-5 7.5 13.5 31.5 31.5

500 ““: ; 5 5 10 20 20
400
9 11 0 0 0 0

2 6 11 ie 32 37 55 70 110 145 240 320

a 5 7 9 9 14 20 35 55 90 140 220 ,
Free Standard provided by BIS via BSB Edge Private Limited to Young Engg. & Calibration Services
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IS : 3455 - 1971

TABLE 3 GAUGE TOLERANCES AND THEIR LOCATIONB FOR GAUGES FOR


OUTSIDE MEASUREMENTS (SHAFTS )

( Clause fO.3.2 )

All values are in micrometer ( pm)

Somir
r

her

6
Yl 1 1.5 3 0 0 0 0

21 1 2 3 7. 11 28 56

T 8 l! 1 18 27 43 1 70 110 1 180 270 1 430 700 1 1100


HI/~ 1 1*5 2.5 24 I 9 9

10
18 Hp/2
VI 1 0.6
Il.51 1
I
2
Q6 IL
I
1 I
I
t
0 I
I
0
1 I
I
1.5
0 I
I
15
0 I
I
I 21 I 1.5 I 2.5 I 4 I 8 t 16 1 32 i 64 I

T 9 13 I 21 33 52 I 84 130 1 210 330 1 520 840 1 1300


Y/2 l-25 2 3 3 h.5 105 10.5

18 30 HP/~ 0.75 0.75 1.25 1.25 145 2 2

YI 2 3 L 0 0 0 0
-
I 21 1 l.5 I 3 I 5 1 9 r 19 t
I
36 I 72 I

T 11 16 1 25 39 62 1 100 160 1 250 390 1 620 1000 1 1600


_ Y/2 I.25 2 3.5 3.5 5.5 12.5 12.5

30 50 _ HP/~ 0.75 0.75 1.25 I.25 1.25 2 2

Yl 2 3 5 0 0 0 0

1 _.
.Ll 1 .
L 3.5 6 11 22 12 80

I T 117 ." 19 1 30 46 74 1 120 190 I 300 460 1 740 1200 I 1900


HI/~ 1 1.5 2.5 L L 6.5 15 15

50 80 ,-Hd2 1 1 1.5 .I.5 1.5 2.5 2.5

Yl 2 3 5 0 0 " 0 0

Zl 2 L * 7 13 25 48 \ 90

( Conm/ed)

16
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IS:3455- 1971

TABLE 3 GAUGE TOLERANCES AND THEIR LOCATIONS FOR GAUGES FOR


OUTSIDE MEASUREMENTS ( SHAFTS ) - Contd
All values are in micrometer ( pm )

lomrr Sizes I I Work Tolerance Grades as per IS0 I


r
UP to Symbols 5 6 7 8 9 10 11 12 13 14 15 16
Over 8 Incl.
T 15 22 35 54 87 140 510 a70 uoo 2200
b-l.12 2 3 5 5
80 120

T 25 1 40 1 63 1 100 1 160 I 250 I 400 I l

‘120 180

180

250

400

EXPLANATORY NOTE

This standard was originally issued in 1966 with a view to introducing a uniform gauging
practice in the country. The method of specifying the tolerance for gauges and also the calculation of
gauge limits was based on the proposals then under consideration at the level of Technical Committee
lSO/TC 3 Limits and Fits.
In this revision, the gauging practice for inspection of plain workpieces has been elaborated in
detail and it is based on Draft IS0 Recommendation No: 1938 IS0 system of limits and fits: Part II
Inspection of plain workpieces. In the present version, not only have the tolerances for the gauges
been indicated but also the gauging principles have been enumerated and recommendations on the use of
gauges for various size ranges have been elaborated, The numerical values given in this standard are
expressed in terms of the various grades of tolerances provided for in IS : 919-I 963. These are, therefore,
valid for the ISI system of tolerances only. However, all other requirements of a more general nature
given in this standard may still be applied as a rule to any system of limits for plain workpieces.
In the earlier version, not only the tolerances for the limit gauges were covered but also certain
requirements on the surface finish hardness, etc, of the gauges were incorporated. Since these
requirements are now being covered separately in Indian Standard Technical supply conditions for
gauges and measuring devices ( under preparafion ), these have been deleted in the present revision.

17
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