Lab no: 06

“To study Gauge Blocks and Dial indicator”

Objective:
 To learn about the Gauge Blocks and their use.
 To learn about the Dial indicator and its use.

Introduction:
Gauge Blocks:

Gauge blocks (also known as gage blocks, Johansson gauges, slip gauges, or Jo blocks) are a
system for producing precision lengths. The individual gauge block is a metal or ceramic block
that has been precision ground and lapped to a specific thickness. Gauge blocks come in sets of
blocks with a range of standard lengths. In use, the blocks are stacked to make up a desired
length.

Figure: 6.1

Wringing:
Wringing is the process of sliding two blocks together so that their faces lightly bond. Because of
their ultraflat surfaces, when wrung, gauge blocks adhere to each other tightly. Properly wrung
blocks may withstand a 75 lbf (330 N) pull. While the exact mechanism that causes wringing is
unknown, it is believed to be a combination of:

 Air pressure applies pressure between the blocks because the air is squeezed out of
the joint.
 Surface tension from oil and water vapor that is present between the blocks.
 Molecular attraction occurs when two very flat surfaces are brought into contact. This
force causes gauge blocks to adhere even without surface lubricants, and in a
vacuum.
It is believed that the last two sources are the most significant.
There is no magnetism involved, although to a user the clinging together of the blocks feels a bit
like weak refrigerator magnets sticking together. Unlike magnets, however, the cling only lasts
while the blocks are completely joined, the blocks do not attract each other across any visible
gap, as magnets would.

Procedure for wringing:

The process of wringing involves four steps:

1. Wiping a clean gauge block across an oiled pad.

2. Wiping any extra oil off the gauge block using a dry pad
3. The block is then slid perpendicularly across the other block while applying moderate
pressure until they form a cruciform.
4. Finally, the block is rotated until it is inline with the other block.

Figure6.2
Gauge Blocks Lengths:
 Largest Gauge Block length is 4mm
 The smallest gauge Block Length is 0.110 mm
Note: Force required to disconnect Gauge Blocks from each other is 330N.

(b) Dial Indicator:

A dial indicator is any of various instruments used to accurately measure
small distances and angles, and amplify them to make them more obvious.
Dial indicators have a dial display, in which a needle points to graduations in a circular array
around the dial.
 Figure:6.3
Parts of Dial Indicator:
1) Pointer
2) Cup
3) Linut hands
4) Contact point
5) Stem
6) Plangen/ spindle
Note:
Larger scale has 50 grades each equals 1mm.
Smaller scale on grade= 0.01mm
Applications:

1) In a quality environment to check for consistency and accuracy in the manufacturing

process.
2) On the workshop floor to initially set up or calibrate a machine, prior to a production run.
3) By toolmakers (such as moldmakers) in the process of manufacturing precision tooling.
4) In metal engineering workshops, where a typical application is the centering of a lathe's
workpiece in a four jaw chuck. The dial indicator is used to indicate the run out (the
misalignment between the workpiece's axis of rotational symmetry and the axis of
rotation of the spindle) of the workpiece, with the ultimate aim of reducing it to a suitably
small range using small chuck jaw adjustments.
 5) In areas other than manufacturing where accurate measurements need to be recorded
(e.g., physics).
6) Used to indicate fluctuations in the chuck of lathe.
7) Used to balance the wheels etc.
8) We can also use it to check the dimensions of the parts in QC

Procedure:

1. 1st set the Dial indicator at zero position.

2. Now place the work piece in the Dial indicator and note the reading on the larger scale
and smaller scale.
3. Now multiply least count (0.01) to the smaller scale reading.
4. Add large scale value to the product of the smaller scale value and 0.01mm this is your
final value.
5. Do the same procedure for other dimensions.

Reading and calculations:

One complete revolution of larger scale is 50mm, One grade of large scale is equal to 1mm.

One complete revolution is equal to 1mm , One grade of smaller scale is equal to 0.01mm (Least
count).

Table: 6.1 (reading through dial indicator)

S.No: Reading 1 Reading2 Average
(mm) (mm)
1.a 91.2 91.3 91.25
2.b 75.12 75.16 75.14
3.c 86.58 86.60 86.59
4.d 34.83 34.79 34.81
5.e 25.25 25.22 25.23

Observation and comments:

Here we see that there is small difference between the readings taken by different students it
shows personal error in readings

Conclusion:

After this lab you are able to know about the Gauge blocks and their use and application. We are
also able to know about the Dial indicator its use and applications.