A STUDY ON PLAIN PLUG GAUGE

INDEX
• Introduction

• Interchangeability

• Limits, Fits and Tolerances

• Tolerances

• Fits

• Terminology and definitions used

• Fits system

• Limit gauging

• Taylor's principle

• Gauge tolerance

• Plain plug gauges

• Material for gauges

• Properties of materials
• OHNS steel

• Mechanical properties of OHNS steel

• Applications of OHNS steel

• Oil hardening

• Design of plain plug gauge for 36H7 hole

• Conclusion

• References
INTRODUCTION:
While manufacturing any parts it is nearly impossible to manufacture them according to their
exact dimensions due to the inherent inaccuracy of manufacturing methods therefore the need for
limits and fits was introduced.

In any production process regardless of how carefully it is maintained and designed a certain
amount of variation exist .Therefore it is impossible to produce a part to an exact size or basic
size .Therefore some variation known as tolerance must be allowed, this tolerance is made to lie
between two limits, upper and lower.

This difference between upper and lower limit is termed as permissible tolerance.

INTERCHANGEABILITY:
In this manufacturing of large number of components, it is not economical to produce both the
mating parts using same operator, therefore the concept of interchangeability comes into lay and
various components are manufactured in one or more batches by different persons on different
machines at different locations and then assembled at one place. To achieve this it is essential
that the mating parts are manufactured in bulk adhere to the limits of accuracy specified.

LIMITS, FITS AND TOLERANCES:

TOLERANCES:
As we know it is not possible to manufacture components to a given dimension because of
inaccuracies of the manufacturing process .The components all manufactured with some limits ,
these limits of various dimensions have to be specified considering this functional
requirements.Therefore tolerance can be defined as the magnitude of permissible variation of a
dimension , it is the algebraic difference between the upper and lower acceptable
dimension.Tolerance can be classified into: unilateral , bilateral and geometric tolerance.

• Unilateral tolerance:
If the tolerance is distributed only one-one side of the basic size , that is when limits lie wholly
on only one side of basic size then it is known as unilateral tolerance . It is used when precision
fits are required and also in drilling process where in dimensions of the hole are not likely to
deviate in one direction only.

• Bilateral tolerance:
When the dimension of the part is allowed to vary on both sides of the basic size it is called as
bilateral tolerance. Example: 15±0.03,20±0.01.
 Fig.1

• Geometric tolerance:

The geometric dimension such as roundness and straightness of a shaft have to be considered to
manufacture components more accurately.

Fig.2

FITS:
It is defined as "the relation resulting from the difference before assembly between the sizes of
two features i.e shaft and hole" as in IS919 (part-1).There are different types of fits:clearance fit ,
interference fit and transition fit.

• Clearance fit:
In this type of fit, the maximum size of the hole is always greater than that of the maximum size
of the shaft.

• Interference fit:
 In this type of fit, the maximum size of the hole is less than the minimum size of the
shaft, it provides an interference between the hole and shaft when assembled.

• Transition fit:
In this type of fit, a fit may be either be a clearance fit or interference fit depending on the actual
size of hole and shaft.

Fig.3

Fig.4

TERMINOLOGY AND DEFINITIONSUSED:

• SHAFT:
A term used, according to convention, to describe an external feature of a work piece, including
features which are not cylindrical.
• HOLE:
A term used, according to convention, to describe an internal feature of a work piece, including
features which are not cylindrical.
 • BASIC SIZE,NOMINAL SIZE:
The size from which the limits of size are derived by the application of the upper and lower
dimension.

• LIMITS OF SIZE:
The two extreme permissible sizes of a feature between which the actual size should lie.

• MAXIMUM LIMIT OF SIZE:

The greatest permissible size of a feature.

• MINIMUM LIMIT OF SIZE:

The smallest permissible size of a feature.

• ZERO LINE:
In a graphical representation of limits and fits, the straight line, representing the basic size, to
which the deviations and tolerances are referred. According to convention, the zero line is drawn
horizontally, with positive deviations shown above and negative deviations below.

• UPPER DEVIATION:
The algebraic difference between the maximum limit of size and the corresponding basic size

• LOWER DEVIATION:
The algebraic difference between the minimum limit of size and the corresponding basic size.

• SIZE TOLERANCE:
The difference between the maximum limit of size and the minimum limit of size, i.e. the
difference between the upper deviation and the lower deviation.
 Fig.5

FIT SYSTEM:
1. HOLE BASIS SYSTEM:
A system of fits in which the required clearance or interference is obtained by associating the
shafts of various tolerances with holes of single tolerance class.

Fig.6

2. SHAFT BASIS SYSTEM:

A system of fits in which the required clearance and interference is obtained by associating holes
of various tolerance classes with shaft of a single tolerance class.
 Fig.7

MAXIMUM MATERIAL LIMIT(MML):

The designation applied to that of the two limits of size which corresponds to the maximum
material size for the feature, i.e.
- the maximum (upper) limit of size for an external feature (shaft).
- the minimum (lower) limit of size for an internal feature (hole).

MINIMUM MATERIAL LIMIT(LML):

The designation applied to that of the two limits of size which corresponds to material size for
the feature, i.e. the minimum
- the minimum (lower) limit of size for an external feature (shaft).
- the maximum (upper) limit of size for an internal feature (hole).

STANDARD TOLERANCES:
The standard tolerance grades are designated by the letters IT followed by a number.The position
of the tolerance 30N with respect to zero line is designated by upper case letter(A to Zc) and for
lower case letters(a to zc).For holes and shafts respectively,the letter i,l,o,q,w,I,L,O,Q,W are
avoided.
-The upper deviations by letter 'ES' for holes and letter'es' for shafts.
-The lower deviation is indicated by letter 'EI' for holes and 'ei' for shafts.
 Fig.8

Fig.9

The ISO system of limits and fits provides 20 standard tolerance grades.IT01, IT0, IT1.......IT18,
in size range of 0 to 500 mm.Standard tolerances grades IT5 to IT18 the values for standard
tolerance in grades IT5 to IT18 for basic sizes up to and including 500mm are determined as a
function of 'i'.
i = 0.453 3√D + 0.001D microns
D is geometric mean of the basic size steps.

LIMIT GAUGING:
-In mass production where components are manufactured in accordance with the permissive
tolerance limits, it is essential to check whether the dimensions of the manufactured components
are in accordance with the specifications
-Therefore gauges are used to check for the limits of the parts instead of measuring the actual
dimension.
-Limit gauge ensures that the components lie within permissible limits but they do not determine
the actual size of dimensions.
-The gauges are required to check the dimensions of the components correspond to two signs
conforming to the maximum and minimum limits of the components. They are called GO gauge
and NO GO gauge.
-The GO gauge is manufactured to the maximum limit will assembles the mating part whereas
NO GO gauge will not assemble which is manufactured for minimum limit.
-Therefore, every gauge is a replica of the part that mates with the part for which the gauge has
been designed.

TAYLOR'S PRINCIPLE:
• The taylor’s principle states that the GO gauge is designed to check maximum metal
conditions that is lower limit of hole and higher limit of shaft .It should also check as
many as dimensions in one GO.
• The NO GO gauge is designed to check the minimum metal conditions that is higher
limit of hole and lower limit of shaft .It should check only one dimensions at a time
,therefore a separate NO GO gauge is determined for each and every dimension.
• The GO gauge should go through the hole or just pass over the shaft without any undue
force .The NO GO gauge should not pass.
• The nominal size of GO gauge corresponds to the lower limit of hole and higher limit of
shaft ,in contrast the NO GO gauge the nominal size confers to the higher limit of hole
and lower limit of shaft.

Fig.10
GAUGE TOLERANCE:
• As even gauges cannot be manufactured to the exact dimensions ,some tolerances are
given to the gauges ,this gauge tolerance should be kept as minimum as possible.
• Normally gauge tolerances is taken as 10% of work tolerance
• In the NO GO gauge , the gauge does not fully engage with the work and therefore goes
with minimum wear.
• Where as the GO gauge which passes through the component has wear as they measuring
surfaces often gets constantly rubbed against the surface of the workpiece .Therefore
wear allowance is provided opposite to wear.
• The wear allowance is taken as 10% of gauge tolerance and it is added for plug gauge
and subracted for ring gauge.
• The wear allowance is added in the direction opposite to the wear.

PLAIN PLUG GAUGES:

• These gauges are used for gauging holes and are commonly made up of hardened wear
resistant stee l,gauging surface .whereas the handles are made up of light metal alloy
steel.
• They can be either double ended or single ended depending on the standards.
• The gauge is coated with an anti-corrosive coating to protect it against climate change.
• Specifications that are designated:
-Nominal size.
-"GO" and "NO GO" on GO and NO GO sides respectively.
-Class of tolerance of the workpiece to be gauges.
-red colour band on NO GO gauge side to distinguish from GO gauge.
 Fig.11

MATERIAL FOR GAUGES:

• The material used to manufacture the gauges should be hard and wear resistant and
should maintain dimensional stability.
• The material should be corrosion resistant , easily machinable to obtain a required degree
of accuracy and surface finish.
• It should have low coefficient of thermal expansion to avoid temperature effects.
• High-carbon steel is the most suitable and inexpensive material for manufacturing
gauges.
• Mild steel gauges are suitable for larger gauges.
• Chromium-plated guages are extensively used as chromium makes the surface very hard ,
resistant to abrasion and corrosion.

SOME MATERIALS AND PROPERTIES:

• High carbon alloy steel is the commonly used gauge material because of their relatively
high hardness and wear resistance.
• Croine plated alloy steel is used for mass production runs. The durability of these gauges
is’ 10 to 12 times than that of without crome plated high carbon alloy steel gauges. One
advantage of crome plated gauging members is that when excessive wear had taken place
the cost of replacement of worn out part is small.
• For economy, only the parts subjected to wear are made of hardened alloy steel and
handles are made of cheaper mild steel.
 • For high degree of accuracy, mass production, excessive wear condition, in bigger size
gauges, the whole body is made of mild steel and contact surface are deposited with a
layer of hard materials like, cemented carbides, tungsten carbide Stellite etc.

OHNS STEEL:
OHNS steel is a general purpose tool
steel that is typically used in applications where alloy steels cannot provide sufficient hardness,
strength and wear resistance. Chemical composition of OHNS is Carbon 0.94%, Manganese
1.2%, Silicon 0.30%, Chromium 0.50% and Vanadium 0.15%. The hardening
temperature of OHNS steel is between 790 C and 820 C.
OHNS steel is a non - shrinkage steel. This term refers to steels which show little change in
volume from the annealed state when hardened and tempered at low temperatures.
Such steels are required for master tools, gauges and dies which must not change size when
hardened after machining in the annealed condition.

MECHANICAL PROPERTIES OF OHNS STEEL:

STRENGTH AND HARDNESS:

Generally the strength increases as the carbon and manganese content increases. Given the high
percentage of both of those, OHNS becomes strong .OHNS has 58 RC to 64 RC hardness.

TOUGHNESS AND BRITTLENESS:

Toughness of a material determines whether it can be subjected to shock conditions, and the
extent to which it may undergo deformity in shape but still not snap. OHNS steel tends to be
very tough. As opposed to toughness , brittleness measures whether a material will snap instead
of getting deformed, when load is applied. OHNS steels are less brittle than cast or pig iron
because of the presence of magnesium.

DUCTILITY AND MALLEABILITY:

Ductility is a material’s ability to be drawn into wires without breaking. Ductility decreases with
increasing carbon, and because OHNS steel has very high carbon content, it is not very ductile.
On the other hand, malleability determines a material’s ability to be rolled into sheets without
getting ruptured. OHNS steel is quite malleable and can be worked upon even at low room
temperatures.

APPLICATIONS OF OHNS STEEL:

It is to be considered as die steel. It is used for manufacturing of blanking and stamping dies,
rotary shear blades, thread outing tools, milling cutters, measuring tools, gauging tools, wood
working tools, reamers, etc.
OIL HARDENING:
Oil quench hardening is a common method for hardening alloy steel forgings. It’s ideal for
achieving the required strength and hardness properties on many alloys with less risk of cracking
than water or polymer quench processes.
The process of oil quench hardening for forgings is performed by first fully austenitizing the
steel in the temperature range of 1500°F – 1650°F depending on the steel grade. It is held at this
temperature for a time proportionate with the part cross-section.
The entire austenitizing process is typically carried out under a protective carbon-controlled
atmosphere that prevents excessive scale formation on the forged surface. Once soaked at the
austenitizing temperature for the appropriate amount of time, the load is quenched in agitated oil
to produce a fully hardened martensitic microstructure, the depth of which is dependent on the
alloy grade and section thickness. From this point, the parts are tempered down to the specified
hardness range to improve toughness.
In cases where parts are especially distortion sensitive or crack-prone. A custom-tailor oil quench
process id performed to minimize or eliminate these problems completely while still achieving
the required material properties.

DESIGN OF PLAIN PLUG GAUGE FOR 36H7 HOLE:

1.Fundamental Tolerance:
For H7 the fundamental tolerance is 16i from the standard tolerance grade from ISI919 part 1
We know that I = 0.453 3√D + 0.001D
Here,36 lies between the range 30 to 50 ,therefore
D = √30×50 = 38.7298mm.
Now i= 0.453√(38.7298) + 0.001(38.7298)
i= 1.571µm.
16i= 16(1.571µm) =0.02512mµ≈0.025mm.

2.Limits of hole:
The fundamental deviation for the hole if zero as the H lies on the basic line.
The tolerance is 0.025mm.
Hence , the lower limit is 36mm and the upper limit id 36.025mm.

3.For plug gauge of 36H7 hole:

The gauge tolerance is taken as 10% of work tolerance ,therefore
Gauge tolerance = 10% of 0.025
= 0.0025mm.
The wear tolerance is taken as 10% of gauge tolerance , therefore
Wear tolerance = 10%of 0.0025
= 0.00025mm.

4.For GO plug gauge side:

Lower limit= basic size + wear tolerance
=36+0.00025
=36.00025mm.
Higher limit=basic size +wear tolerance +gauge tolerance
=36+0.00025+0.0025
= 36.00275mm.
Therefore for the GO gauge side the limits are 36.00025mm and 36.00275mm.

5.Limits for NO GO gauge side :

Lower limit= basic size + fundamental tolerance
=36+0.025
=36.025mm.
Higher limit = basic size + fundamental tolerance + gauge tolerance
= 36+0.025+ 0.0025
=36+0.0275
=36.0275mm.

Therefore the NO GO gauge side limits are 36.025mm and 36.0275mm.

CONCLUSION:
This report on the design of a double sided plain plug gauge deals with the basic concepts of
limits and fits,IS standard system,paramaters regarding the designing of a guage,material
requirements and about OHNS(oil hardened non shrinkage steel) steel used to design the plain
plug gauge fo 36H7.

REFERENCES:
1.Engineering metrology and measurements text book by N.V.Raghavendra,L.Krishnamurthy.
2.A text book of metrology by M.Mahajan.
3.IS 919-part1
4.IS 919-part2
5.https://en.wikipedia.org/wiki/Metrology
6.https://en.wikipedia.org/wiki/Limits_and_fits
7.http://shodhganga.inflibnet.ac.in/bitstream/10603/76202/14/14_chapter%204.pdf
8.https://en.wikipedia.org/wiki/Tool_steel