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What is Nominal size?
The Nominal size of a dimension is the size by which it is referred to as a matter of
convenience.

Define Actual size?

The Actual size of a dimension is its actual measured size.

What do you meant by Basic size?

The Basic size of a dimension is the size in relation to which all limits of variation
are made.

Define Fits?
The relation between two mating parts with reference to ease the assembly is called
Fit.
What is Limits?
Two extreme permissible sizes of a dimension are called Limits. The high limit for a
dimension is the highest permissible size and the low limit is the lowest permissible
size.

Define Tolerance?
The difference between the high and low limit of a size is called tolerance.

Define Allowance?
The intentional difference in the sizes of mating parts is called the Allowance.

What is the difference unilateral and bilateral system of tolerance?. Discuss the least
count of a vernier caliper?
A smallest measurement that can be obtained on a vernier caliper is called the least
count of a vernier caliper. Generally vernier calipers are available with 0.02mm least
count in metric system and 0.001" in inch system.
 Find out the least count of a vernier caliper when its main scale graduation is 49 mm and
the vernier scale is divided in to 50 equal parts?
What are the reasons behind false reading on vernier caliper while taking
measurements?

 Vernier caliper may have defects.

 Tidy job piece or measuring faces of vernier caliper.
 Wrong way of holding the vernier caliper and unawareness of reading
measurements.
 Taking measurements when the job on motion.
 Pressure variation of holding fingers.
 Temperature difference between the job and the vernier caliper.
11. What are the main merits of a vernier caliper over a micrometer?
 Vernier caliper is a multi purpose instrument, can be used to measure inside,
outside, and depth as well, where a micrometer is not considered as
multipurpose.
 The different size of a job can be measured with a single vernier caliper but
numbers of micrometers are needed for different sizes of job.
 Vernier caliper is easy for taking measurements and simple working, where as a
micrometer works with a principle of nut and bolt and quiet sensitive.
 The measurements can be taken easily by a vernier caliper than by a micrometer.
Range of Vernier Calipers:
What are the purposes of Vernier Height Gauge?

Vernier height gauge is a special type of vernier instruments which is used to measure
heights of different engineering objects
What is the function of a Vernier Depth Gauge

A vernier depth gauge is used to measure and check the depth of blind holes, steps etc.
to the accuracy of 0.02 mm 0.001".
What is the use of of vernier Bevel Protractor?
Vernier Bevel Protractor is used to measure and check the angles of a job to the accuracy of 5' (5
minutes).

The least count of bevel protractor is 5'.

Mention the features of a Universal Bevel Protractor?
 Minimum reading is 5 minutes.
 Main scale and Vernier scale are on the same plane to eliminate the reading parallax.
Fine adjustment of the blade insures the precision measuring and laying out of angle.
 Main parts are of hardened stainless steel to prevent rust.
 Combined with an attachment or Height gauge, a wide range of measurements is
available
Why Micrometer carries a ratchet stop?
Ratchet stop supports to measure accurate reading applying uniform pressure on the measuring
faces irrespective of operator's skill and strength.
What is meant by zero error on a screw gauge?
Case (a): No zero-error

Case (b): Positive zero-error of 2 circular scale division. Positive zero-error correction is done

by subtracting the positive zero-error from the actual reading.

Case (c): Negative zero-error of 4 circular scale division. Negative zero-error correction is

done by adding the negative zero-error from the actual reading.

Why Micrometer carries a ratchet stop?
Ratchet stop supports to measure accurate reading applying uniform pressure on the measuring
faces irrespective of operator's skill and strength.

What are the reasons behind false reading on Micrometer while taking measurements?
 There is zero error in Micrometer.
 Dirty work piece or measuring faces of micrometer.
 Unengaged Ratchet stop.
 Taking measurement when the job on motion.
 Wrong way of holding Micrometer.

 Temperature variation between the work piece and the Micro meter.
Define Zero reading of a Micrometer?
Zero reading of a micrometer is the initial reading which may vary according to the size of the
micrometer.
Zero reading of 0-25 mm micrometer is 0
Zero reading of 25-30 mm micrometer is 25 mm
Zero reading of 50-75 mm micrometer is 50 mm etc

Specify the term Backlash of a micrometer?

Backlash is the lack of motion or lost motion of the spindle when the rotation of the thimble is

changed the direction.

What is backlash error ? Why is it caused ? How is it avoided ?
If by reversing the direction of rotation of the thimble, the tip of the screw does not start
moving in the opposite direction immediately but remains stationary for a part of rotation; it
is called backlash error.

Reason: It happens due to wear and tear of the screw threads.

To avoid the backlash error, while taking the measurements the screw should be rotated in
one direction only. If the direction of rotation of the screw needs to be changed, then it
should be stopped for a while and then rotated in the reverse direction.
What is a Gear tooth Vernier caliper?

 A vernier gear tooth caliper consists of two vernier perpendicular to each other.
 It is used for measuring the chordal thickness of a gear tooth at the pitch circle of
the gear.
 The horizontal vernier caliper is used for measuring the tooth thickness of a gear.
 Its working is similar to an outside vernier caliper.
 The vertical vernier caliper is used for measuring the distance from the top of a
tooth (addendum circle) to the pitch circle of the gear.
What is dial indicator
Dial indicators are measuring devices designed expressly to measure relative position. The
primary parts of a dial indicator are the face or dial, the case, and the plunger.

The plunger is a spring loaded part that can be depressed into the case causing the dial to
move
Lever Dial Gauge
State the uses of a Dial test indicator?
To check the parallelism of machined or ground surfaces.
To check the true rotation of round jobs.
To compare the dimensions of finished components.
 What is a surface table used for?

Surface plates are flat and plane surface used as a horizontal reference space for
dimensional measurement,
What is a gauge?
A Gauge is a checking instrument which is commonly used in tool room and machine shop for
checking the finished components.

A gauge is an important measuring device in the field of design engineering. It is a device used
to provide certain dimensional information, according to a specified standard or system.

Some gauges are meant to measure the size of the object. But, most gauges are mainly used to
specify if the dimensions of the measuring object are less or greater than defined standards that
are within the tolerance range.

Point on the advantages of Gauges?

It increases the production.
It saves the time.
It makes the parts interchangeable. It reduces the supervision charges.
It minimizes the production cost.
The various gauges used in different sectors are listed below.
1.Plug Gauge
2.Ring Gauge
3.Snap Gauges
4.Feeler Gauge
5.Screw Pitch Gauges
6.Radius or Fillet Gauge
7.Calliper Gauge
8.Dial Gauge
9.Height gauge
Limit gauges
Types of limit plug gauges
1. Solid type
2. Renewable type – taper inserted type
3. Fastened type – single, double ended
4. Flat type
5. Progressive type
6. Pilot plug gauge
7. Combined dual purpose type
RING GAUGE
RADIUS AND FILLET GAUGE
The function of these gauges is to check the radius of curvature of convex and
concave surfaces over a range from 1 to 25 mm.
The gauges are made in sets of thin plates curved to different radius at the ends.
Each set consists of 16 convex and 16 concave blades.
RADIUS
FEELER GAUGE
Feeler 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.
Each blade has an indication of its thickness.
To find the size of the clearance, one or two blades are inserted and tried for a fit
between the contacting surfaces until blades of suitable thickness are found.
FEELER
INDICATING GAUGES
Indicating gauges employ a means to magnify how much a dimension deviates, plus
or minus, from a given standard to which the gauge has been set.
They are intended for measuring errors in geometrical form and size, and for testing
surfaces for their true position with respect to one another.
Indicating gauges can be of a dial or lever type.
Materials which are used for making gauges are high carbon
and alloy steels, cemented carbides, etc.
 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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Design of Limit Gauge
• Allocation of Tolerance
– Manufacturing Tolerance
– Wear Allowance
• Taylor’s Principle of gauge Design
• Fixing of Gauge elements with handles
– Taper lock design
– Trilock Design
• Provision of Guards
• Provision of Pilot Correct Centering
• Materials
• Hardness and Surface finish
• Rigidity
• Alignment of Gauge faces

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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 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.

• 10% wear allowance is provided only for the “GO”

gauge if working tolerance is greater than 0.09 mm.
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Allocation of Wear Allowance

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