GOVT.

TOOL ROOM & TRAINING CENTRE

SUBJECT: ENGINEERING METROLOGY SUBJECT CODE:DTDM/DPM-111S 303

Fill in the blanks with appropriate words: (1 Mark Each)

1. In Shaft & Hole basis system _____of a dimension or part is the size in relation to which
all limits of variation are determined.(Basic size)
2. _____ is to define the position of tolerance zone in relation to the zero
line.(Fundamental deviation)
3. If interchangeability is not achieved, _____ will be required that is each part must be
selected to fit its mating part.(Selective Assembly)
4. Algebraic difference between size and the corresponding the basic size is
called_____(Deviation)
5. _____ is the permissible variation in the dimension of a part.(Tolerance)
6. Two mating surfaces or parts, one which enters into the other is known
as_____.(Enveloped surface or Male part)
7. Example for clearance fit_________.(Guide pillar & Guide bush)
8. The value of the tolerance grade IT6 is ______.(10i)
9. In plug gauges, plug made to the upper limit of the hole is known as______ gauge.(NO
GO)
10. Ring gauges are used to check______.(Shaft)

Multiple choice questions: (1 Mark Each)

1. The _______ of a component is the size by which it is referred to as a matter of

convenience.
a. Basic size
b. Nominal size
c. Actual size
d. None of these.

2. _____is the algebraic difference between the minimum limit of size and the
corresponding basic size.
a. Lower deviation
b. Upper deviation
c. Fundamental deviation
 d. Mean deviation.

3. Plug gauges are used to check_____.

a. Shaft
b. Hole
c. Angle
d. Surface roughness.

4. _____is the algebraic difference between the two maximum limit of size and the
corresponding basic size.
a. Lower deviation
b. Upper deviation
c. Fundamental deviation
d. Mean deviation.

5. 10 microns is equal to,

a. 1mm
b. 0.001mm
c. 0.01mm
d. 0.1mm.

6. The value of tolerance is a function of the basic size & is designated by a number
symbol, called the____
a. Grade
b. Fit
c. Precision
d. Accuracy.

7. In ISO system, allows for _____ types of fit.

a. 27
b. 23
c. 18
d. 26

8. In tolerance grade, formula for standard tolerance unit i=_______.

3
a. 0.45 √𝑑 + 0.001D
b. 0.45 3√𝐷 + 0.01D
c. 0.45 𝟑√𝑫 + 0.001D
 3
d. 0.45 √𝐷 + 0.001d

9. Snap gauges are used check _____

a. Shaft
b. Hole
c. Angle
d. Cylindrical & Non cylindrical.

10. In ISO system, allows for_____ grades of tolerances.

a. 27
b. 18
c. 8
d. 17

Answer the following questions: (2 Marks Each)

1. Define fit?
The relationship between two parts where one is inserted into the other with a certain
degree of tightness or looseness is known as a fit.
2. Define allowances?
An intentional difference between the hole dimension and shaft dimension for any type
of fit is called the allowance.
3. Define clearance?
Tolerance is the permissible variation in the dimensions of a part as it is not possible to
produce a part to exact specified dimension.
4. What is maximum interference?
The maximum interference is the negative difference between the maximum limit size
of the shaft and the minimum limit size of the hole.
5. What is interference fit?
It is defined as the fit established when a negative clearance exists between the size of
the holes and shafts.
6. Define gauges?
Gauges are inspection tools without a scale which serves to check the dimensions of the
manufactured part.
7. Define precision?
Precision is defined as the extent to which the instrument repeats its results while
making repeat measurement on the same unit of product.
 8. Define accuracy?
Accuracy is defined as the extent to which the average of a long series of repeat
measurement made on the same unit of product.
9. Name the 3 main types of fits?
Depending upon the actual limits of hole or shaft, the fit may be,
 Clearance fit
 Transition fit
 Interference fit
10. Name the 3 main types of gauges?
The 3 main types of gauges are,
 Plug gauges
 Ring gauges
 Snap gauges or gap gauges.

Answer the following questions: (3 Marks Each)

1. Explain interchangeability?
Interchangeability occurs when one part in an assembly can be substituted for a similar
part which has been made to the same drawing. Manufacturers of machine tools,
automobiles, aircrafts etc requires thousands of components which are identical, in such
large scale production each made component should built with corresponding female
component without interchanging the parts present in a lot of identical items, if this
condition exists it is called interchangeability.

2. What is selective assembly?

In selective assembly the parts are graded according to the size and only matched
grades of mating parts are assembled, this technique is most suitable where close fit of
two components assembles are required. It result in complete protection against non-
conforming assemblies and reduces machining cost since close tolerances can be
maintained.

3. Explain clearance fit and transition fit?

In a clearance fit there is a positive allowance between the largest possible shaft and the
smallest possible hole. With such fits the minimum clearance is greater than zero.
In a transition fit the diameter of the largest allowable hole is greater than that of the
smallest shaft, but the smallest hole is smaller than the largest shaft, so that a small
positive or negative clearance exist between the shaft and the hole.
 4. What is maximum & minimum metal condition?
Maximum metal condition in which a feature contains the maximum amount of material
within the stated limits.
Minimum metal condition in which a feature contains the least amount of material
within the stated limits.

5. How clearance fits are classified?

Clearance fits may be subdivided as,
 Slide fit
 Easy slide fit
 Running fit
 Slack running fit
 Loose running fit.

Answer the following questions: (5 Marks Each)

1. With help of sketch explain types of tolerances?

Type of a tolerance on a dimension may be either Unilateral or Bilateral.
A toleranced dimension is bilateral if the limit dimensions are given above and below
the nominal size as shown in figure.
 When the two limit dimensions are only above the nominal size (fig a) or only below the
nominal size (fig b) then the tolerances are said to be unilateral.

2. Why we need tolerances in job production?

In the field of machine soul technology it is not possible to make any part preciously to a
given dimensions due to,
 Tool wear
 Deflection
 Vibration of machine tool
 Change of temperature
 Human error etc.

3. Explain system of fit with sketch?

There are two distinct systems for varying the size of parts known as: Hole basis system
and Shaft basis system.
In hole basis system, when the hole is constant member and different fit are obtained
by varying the size of the shaft. In this hole system the high and low limits are constant
for all fits of the same accuracy grade and for the same basic size.
In shaft basis system, when the shaft is the constant member and different fits are
obtained by varying the size of the hole. In this shaft system the high and low limits are
constant for all fits of the same accuracy and grade and for the same basic size.
4. How plain gauges are classified?
Plain gauges are used for checking plain holes and shafts. They are classified as,
a. According to their type
 Standard gauges
 Limit gauges
b. According to their purpose
 Workshop gauges
 Inspection gauges
 Reference or master gauges
c. According to the form of the tested surface
 Plug gauges for checking holes
 Snap and ring gauges for checking shafts.
d. According to their design
 Single limit and double limit gauges
 Single ended and double ended gauges
 Fixed and adjustable gauges.
Answer the following questions: (8 Marks Each)

1. Explain plug gauge with sketch?

Plug gauges are the limit gauges for a hole and consists of two cylindrical wear resisting
steel plugs whose sizes are made to the limiting values of the hole dimension. The plug
made to the lower limit of the hole is known as “GO” gauge, and this will obviously
enter any hole which is not smaller than the lower limit allowed. The plug made to the
upper limit is known as “NO-GO” gauge, and will not enter any hole which is smaller
than the upper limit allowed. GO and NO-GO plugs are arranged at either end of a
common handle.
The handles of heavy plug gauges are made of any light metal alloys. While the handles
of small plug gauges can be made of some non-metallic materials.
The plug gauges are normally double ended for size upto 63mm and for sizes above
63mm they are single ended type.
For smaller through holes, a progressive form of plug gauges are used.
2. With help of sketch, explain Taylor’s principle in the design of gauge?

According to Taylors principle “GO” and “NOGO” limit gauges should be designed to
determine the maximum and minimum metal limits.
Go limit gauge: A “GO” gauge corresponds to maximum metal condition. For example
upper limit of a shaft or lower limit of a hole as shown in figures (a) & (b).
The GO snap gauge corresponds to upper limit of the shaft, while the “GO” plug gauges
corresponds to lower limit of the hole. The “GO” gauges should check all the possible
elements of dimensions at a time. A GO plug gauge must be of corresponding mating
section and preferably to the full length of the hole so that straightness of the hole can
be checked.
NO GO limit gauge : a “NO-GO” gauge corresponds to minimum metal condition. For
example, lower limit of a shaft and the upper limit of a hole. It should check only one
features of the component at a time. The NOGO snap gauge corresponds to lower limit
while the NOGO plug gauge corresponds to upper limit.
3. Explain snap gauge with neat sketch?

A snap gauge usually consists of a plate or frame with a parallel faced gap of the
required dimension as shown in figure. In these gauges the gauging anvils can be
adjusted endwise to suit any particular limit dimension required. Snap gauges are used
for both cylindrical as non cylindrical work as compared to ring gauges which are
conventionally used only for cylindrical work. Double ended snap gauges as shown in fig
can be used for sizes ranging from 3 to 100 mm. for the sizes above 100 upto 250 mm a
single ended progressive type snap gauge as shown in the fig is used.