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 or not.
 Classification of gauges
 According to Type
 Standard gauges
 Limit Gauges
 According to their purposes
 Workshop Gauge: To Check Dimension after manufacture
 Inspection Gauge: To check part before final acceptance
 Purchase Inspection Gauge: To check part of other factory
 Reference or master gauges: To check the dimension of Gauge
 According to the form of the tested surface
 Plug gauges
 Snap and ring gauges
 According to their design
 Single limit and double limit gauges
 Single ended and double ended gauges
 Fixed and adjustable gauges.
 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.
 made as an exact copy of opposed(mating) part
 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. A limit gauge is not a
measuring gauge. Just they are used as inspecting
gauges. Limit gauge are mainly used for checking for
cylindrical holes of identical components with a large
numbers in mass production.

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 Purpose of Limit Gauges
 Components are manufactured as per the specified
tolerance limits, upper limit and lower limit. The
dimension of each component should be within this
upper and lower limit.
 If the dimensions are outside these limits, the
components will be rejected.
 If we use any measuring instruments to check these
dimensions, the process will consume more time. Still
we are not interested in knowing the amount of error in
dimensions.
 It is just enough whether the size of the component is
within the prescribed limits or not. For this purpose, we
can make use of gauges known as limit gauges.
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 Design of Limit Gauge

• Allocation of Tolerance
– Manufacturing Tolerance
– Wear Allowance
• Taylor’s Principle of gauge Design

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 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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Allocation of Mfg Tolerance

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Allocation of Mfg Tolerance

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 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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Allocation of Wear Allowance

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 Taylor’s Principle

• Go Gauge should always be so designed

that it will cover the Maximum 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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 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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 Types of Limit Gauges

 PLUG GAUGES

 RING GAUGES

 SNAP GAUGES

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 PLUG GAUGES
 The ends are hardened and accurately finished by
grinding. One end is the GO end and the other end is
NOGO end.
 Usually, the GO end will be equal to the lower limit size
of the hole and the NOGO end will be equal to the
upper limit size of the hole.
 If the size of the hole is within the limits, the GO end
should go inside the hole and NOGO end should not go.
 If the GO end and does not go, the hole is under size
and also if NOGO end goes, the hole is over size.
Hence, the components are rejected in both the cases.

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PLUG GAUGE
 TAPER PLUG GAUGES
 Taper plug gauges are used to check tapered holes. It
has two check lines. One is a GO line and another is a
NOGO line.
 During the checking of work, NOGO line remains
outside the hole and GO line remains inside the hole.
 They are various types taper plug gauges are
 1) Taper plug gauge — plain
 2) Taper plug gauge — tanged.
 3) Taper ring gauge plain
 4) Taper ring gauge — tanged.

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Taper Plug and Ring Gauges

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Taper Plug Gauge

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Cylindrical Plug Gauges

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Cylindrical Plug gauge

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 Plain Ring Gauges
 Used to check outside diameter of work
pieces.

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 Thread Plug Gauges
 Used for checking internal threads of the "go" and
"no-go" variety
 Based on same principle as cylindrical plug gauges
 "go" end (longer end)
– Should be turned in flush to bottom of hole
 "no-go" end
– Should just start into hole and become snug
before third thread enters

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Thread Plug Gauges

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Thread Ring Gauges

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 Snap Gauges
 One of most common types of comparative
measuring instruments
 Used to check diameters within certain limits by
comparing part size to preset dimension of snap
gauge
 Have C-shaped frame with adjustable gauging
anvils or rolls set to "go" and
"no-go“ limits of the part
 Several styles

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 DOUBLE ENDED SNAP GAUGE:
 This gauge is having two ends in the form of
anvils.
 Here also, the GO anvil is made to lower limit
and NOGO anvil is made to upper limit of the
shaft.
 It is also known as solid snap gauges.
 PROGRESSIVE SNAP GAUGE:
 This type of snap gauge is also called caliper
gauge.
 It is mainly used for checking large diameters up
to 100mm. Both GO and NOGO anvils at the
same end. The GO anvil should be at the front
and NOGO anvil at the rear.
 So, the diameter of the shaft is checked
progressively by these two ends.
 FEELER GAUGE
 A feeler gauge (also known as a thickness
gauge) is an accurately manufactured strip of
metal that is used to determine the gap or
clearance between two components.
 FEELER GAUGE
 A feeler gauge can be used to check the
following:
– Piston ring gap
– Piston ring side clearance
– Connecting rod side clearance
 Radius Gauge

 A radius gauge is a tool used to measure

the radius of an object.

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 Thread Pitch Gauge

 It used to quickly determine the pitch of

various threads by matching the teeth on
the leaves with teeth on the work.

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 Material for gauges:
 The material for gauges should fulfill most of the
following requirements:
 Hardness to resist wearing.
 Stability to preserve size of form.
 Corrosion resistance.
 Merchantability for obtaining the required degree of
accuracy
 Low co-efficient of linear expansion to avoid temperature
effect.
 Ex. High carbon steel, case hardened mild steel, invar
steel.