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.

Plate Gauge Wire Gauge