Jordan University of Science and Technology

Faculty of Engineering Industrial Engineering Department

METROLOGY

IE 225
Fixed and Deviation Type Gauges
Eng. Nibal tawfiq
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Introduction
Some times it is not necessary to know the exact dimensions of a part, and it is enough to know if the dimensions are within the established limits. There are some attribute type instrument that are designed to check limits satisfaction called gauges. Gauges are designed to gauge only one dimension and indicate whether it is larger or smaller than a previously established standard. Gauges do not determine how much larger or smaller the measured dimension is than the standard. They are relatively inexpensive and easy to use.

Plug Gauges
o It is one of the most common type of gauges. o They are accurately ground cylinders, held in a handle. o It is used to gauge internal dimension such as holes. o The plug gauges that are used for cylindrical holes are two types: I. Plain plug gauge II. Step-type go, not go gauges o To control the minimum and maximum limits of a given hole, two plug gauges are required: I. The smaller, or go gauge: controls the minimum limit, because it must go (slide) into any hole that is large enough to meet the required dimension.
Using the plug gauge
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Plain plug gauge having go member on one end and not-to go member on the other

II. The larger, or not go gauge controls the maximum dimension, because it must not go into any hole that is not larger than the maximum permissible size.

How do we determine if the cylindrical hole meet the specification or not?

Max = B

Min = A

From the designer: The hole diameter must lie in the range (A-B) A: minimum allowable diameter B: maximum allowable diameter

How do we determine if the cylindrical hole meet the specification or not? This can be done using the plug gauge into two different steps: Step 1: to check for the minimum diameter Step 2: to check for the maximum diameter

Using plug gauge (GO)

Step 1: to check for the minimum allowable diameter This is performed using the GO gauge

Work piece d*

Plug gauge (GO)

d1

d1 is made to the desired minimum allowable diameter for the hole in the work piece

If d1 > d*: the plug gauge will not go inside the hole Then, the hole is smaller than what it should be. (The component is rejected) If d1 < d*: the plug gauge will go inside the hole Then, the hole is larger than its minimum allowable diameter. (GOOD)
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Using plug gauges (NOT GO)

Step 2: to check for the maximum allowable diameter This is performed using the NOT GO gauge

Work piece

d*

Plug gauge (NOT GO)

d2

d2 is made to the desired maximum allowable diameter for the hole in the work piece

If d2 > d*: the plug gauge will not go inside the hole Then, the hole is smaller than its maximum allowable diameter. (GOOD) If d2 < d*: the plug gauge will go inside the hole Then, the hole is larger than its maximum allowable diameter. (The component is rejected)
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Plug gauges
Go Not-Go

Plug gauge with stepped go and not-go member

In the plain type, the go and not-go plugs often are fastened into the two ends of a single handle for convenience in use.

In the step type, the go and not go diameter are on the a single plug, the go portion is the outer end. The not-go plug usually is much shorter than the go plug, it is subjected to little wear because it seldom slides into any holes. In using a plug or any other type of gauge, the gauge should never be forced into, or onto the part being measured.
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Plug gauges, types

The common type of plug gauges are: I. Cylindrical shape plug gauges
I. Plain plug gauge II. Step-type go, not go gauge

II. Taper plug gauges III. Flat plug gauges IV. Thread plug gauges

Taper plug gauges

There is a pair of marks etched at the proper pre-calibrated location. The tapered hole is too large if both marks on the gauge sink down out of sight. The tapered hole is too small if both marks are visible

Plug gauge to check a tapered hole

Tapered plug gauges

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Taper plug gauges

Method for checking a tapered hole with a plug gauge. If first gauge mark enters hole, but second not, taper is correct.

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Flat plug gauges

This gauge with go and not-go members designed to check the widths of slots, grooves, and channels.

(a) Flat plug gauge designed to check slots and channels

(b) Example of keys, slots that can be checked using flat plug gauge.

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Thickness or feeler gauge

It is used to measure the clearance between two parts. Feeler gauge sets contain a fan of blades or leaves differing from one another by one thousands or several thousands in thickness.
Typical feeler gauge set which has blades of various thicknesses

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Thickness or feeler gauge

Typical feeler gauge set which has blades of various thicknesses

To obtain the desired thickness, fold together the selection of leaves that will build up to a thickness, width, height or clearance between dimensions to be checked.
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Thickness or feeler gauge

(a)

(b)

Feeler gauge is used for valve clearance adjustment in the internal combustion engine

One of the most common application of feeler gauge is to establish the gap between the valve and its seat in the internal combustion engine of an automobile.
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Limitation on using the plug gauge

Gauge Wiggling*: If the gauge can be wiggled around in the hole, then there is a question about the real cause of the problem. There are a number of things that may cause gauge wiggling (**), including:
Tapered hole Out of round Bell-mouthed Non correct plug: discrepancy between the plug diameter and the hole size. Inspector skill: ability of the inspector to discover the defect.
(*) Wiggle: to move back and forth with quick irregular motion (**) These conditions may be difficult to distinguish with plug gauge

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Limitation on using the plug gauge

(a) (b)

(a) Various hole conditions which may be difficult to distinguish with plug gauge (b) Out of round hole

If the taper is slight, and if the plug and hole size are close to each other, there can be some doubt as to the inspector ability to discover the defects.
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Limitation on using the plug gauge: Bell mouth defect

A flared (expand or open outward) mouth on a pipe opening. It is a defect which occurs during metal drilling where a twist drill produces a hole that is not a perfect circle.
Bell mouth defect

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Ring gauges
(a) (b) (c)

(a) Go and no-go ring gauge

(b) Ring gauge

(c) Close-up shot of a diamond-pattern knurling on a cylindrical work piece.

Ring gauges are used to gauge shafts or other external round members. They are also made in go and not-go types. Go ring gauges have plain knurled exteriors. Not-go ring gauges have a circumferential (annular) groove in the knurling.
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Ring gauges

Ring gauges of a standard design

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Ring gauges (Go and not-go)

The ring gauges are used to check the over all outside diameter of a work-piece
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Ring gauges
The mating part principle was used traditionally to ensure the correct fitting of the machined shaft and its corresponding hole. Ring gauges used the same mating part principle, but they own advantages that make them more preferable. Advantages of using ring gauge: More accurate and reliable. Made to precise tested sizes. Have hardened surfaces, which decelerate the wear rate.
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Ring gauges - disadvantages

(a) Ovality in the shape of the work piece cannot be detected by a ring gauge. (b) Excessive taper in a work piece can be detected by a ring gauge.

They will accept out-of-round work without a qualm provided the largest diameter of the piece is within bounds, although such work may not help to make a satisfactory assembled product. The work must be taken out of the machine, and be deburred before an effective check can be made.
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Snap gauges
Snap gauges are the most common type of gauges for measuring external dimension. Various type of gauges are available in industry: o Single purpose snap gauge o Double end snap gauge o Progressive snap gauge These gauges offer two steps of measurement: o Go o Not-go
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Snap gauge

Various types of snap gauges (a) single purpose snap gauge, (b) double-end snap gauge, (c) progressive snap gauge

Single-purpose snap gauge: offer only a single size limit, go or not-go . Double end snap gauge: the go and not go may be two separate calipers at opposite ends of the gauge. Progressive or step-type snap gauge: offer
PROGRESSIVE SNAP GUAGE 25

progressive measurement of succeeding caliper in line with each other.

Snap gauges; progressive type gauge

If the work piece is of such size it can enter the go end of the gauge as at (a) in the figure, but not enter the not-go part of the gauge as at (b), then it is within the tolerances if the gauge has been properly set. When the work piece is too small, it will not enter the not-go caliper, position (c) in the figure, and is consequently reject.

An oversize diameter of the work piece, as in the position (o) of the figure, would not enter the go step of the gauge, and it will be rejected.

(d) position assumed by work-pieces of various diameters. Illustration the go and not-go principle of the progressive type gauge.

Work that is within specifications must go in go section of the gauge, but it must not go in the not-go section. 26

Checking the setting of the snap gauges

Tools required: Two sets of precision gauge blocks: I. First set for the prescribed not-go limit of the gauge. II. Second set section. for the go

If the gauge is properly set, the notgo gauge blocks should just enter between the not-go jaws. If the snap gauge anvils are not properly set (the gap between them may be too wide or too narrow, loosen the locking screws (c), and unscrew the adjusting screws a turn or so.

(b) Using gauge blocks to check the go and not-go settings of a snap gauge. (c) Adjusting a snap gauge to the required go and not-go settings
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Radius and template gauges

Stepped shaft

Most parts and products are designed with rounded edges and with corners filled in. WHY?

Some design for appearance. For technical reasons, i.e. in stepped shaft design it is always desirable to have fillets wherever change in diameter is needed. Sharp edges act as a stress concentrators and reduce the fatigue life of the rotating shaft.

Sharp edges become readily nicked and broken.

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Radius and template gauges

Rounded outer edges enable rough handling of the piece without getting nicked or burred. Another example in connection with fillets is the common fact that the sharp corners or edges of cutting tools and wheels wear off readily.
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Radius and template gauge

The tools that are used for checking the radii and fillets. Commercial radius gauges consists of a series of thin steel sheet or leaves, which are used to check the radius.
Radius gauge set for checking both internal and external radii

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Radius gauges
It is better to hold the gauge and work piece between a light and the eye of the observer. Proper light must be shined down on the junction of the radius gauge with the radius or fillet being compared.

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Radius gauge

Using the radius gauge

This set of six gauges can be used for reference while turning, checking the radius when youre rounding edges, measuring moldings you want to duplicate, or any other task that requires precisely radiused curves.

Radius and template gauge

Use of radius gauge to check various radii found on the work piece

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Template gauge
A pattern or gauge, such as a thin metal plate with a cut pattern, used as a guide in making something accurately, as in woodworking or the carving of architectural profiles. Template gauges are not confined to small sizes. Inspectors in aircraft work are familiar with the man-size sheets of metal with carefully calculated curvatures profiled in them to check the contours of wing surfaces, etc.

This profile or contour gauge can make life easier when cutting lines around difficult shapes

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Flush pin gauges

These are practically always single-purpose gauges designed for control of a particular dimension on a particular component. They are used for gauging work produced in continuing operations, mass production, or where patches of the same sort of part are made every so often. Flush-pin gauges have one moving part and are used to gauge the depth of shoulders .

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Flush pin gauge

Flush pin gauge

Step pin

Dimension to be gauged

Work piece A type of flush pin gauge being used to check the height of step

The main section is placed on the higher of the two surfaces with the movable pin resting on the lower surface. If the depth between the two surfaces is sufficient but not too great, the top of the pin, but not the lower step, will be slightly above the top surface of the gauge body. If the depth is too great, the top of the pin will be below the 36 surface.

Flush pin gauge

If the depth is not great enough, the lower step on the top of the pin will be above the surface of the gauge body. By running a finger, or a fingernail, across the top of the pin, its position with respect to the gauge body can be determined.

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Flush pin gauge

Step pin

c b a
Flush pin gauge Dimension to be gauged

d
Work piece

a Top surface of the gauge body b c Top (upper step) of the gauge pin Lower step of the gauge pin b >a &ac b<a c >a

Case (1): if d is within specification, sufficient but not too great, Case (2): if d is too large, Case (3): if d is not great enough,

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Fixed and deviation type gauges

The basic two type of gauges are:
Fixed gauges
All gauges studied in the first part of the chapter

Deviation type gauges

High amplification mechanical comparators Electrical comparator Pneumatic comparator

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Deviation type gauge

Those type of gauges determine the amount by which a measured part deviate, plus or minus, from a standard dimension to which instrument has been set. The comparators are often calibrated against standards such as gauge blocks. In most cases, the deviation is indicated directly in units of measurement. In some cases, the deviation is within a permissible (allowable) range.
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Deviation type gauges

These gauges employ mechanical, electrical, or fluid amplification techniques so that very small linear deviations can be detected. These instruments try to reduce the friction that is such a problem for the dial indicators. Deviation type gauges are available in a variety of amplifications and sizes.

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High amplification mechanical comparator

Mechanical comparators
It works on the same principle as dial indicator. It is used for taking accurate linear measurements by comparison with a standard. Components: Base Column Adjusting devices Gauging head
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Mechanical comparator

As the plunger is depressed, it causes the strip to stretch. As the twisted strip is stretched, it changes the angle of the pointer, and thus the indicated deflection.
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High amplification mechanical comparators

High amplification dial indicator (HADI):
The most commonly used dial indicator are graduated, for reading in 0.02 mm (0.001 ) and 0.002 mm (0.0001 ). HADI is graduated so that each divisions equals 0.0005mm (0.00002 ).
High amplification indicators (HADL) dial
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Mechanical comparator cont d

Any dimensional variations between the part being measured and the standard against which the instrument is set is shown on a magnified scale. The scale is graduated with a plus or minus inch or metric units of measurement.

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Electric comparator

Electrical Comparator operates on the Principal of the Change of Inductance of a coil by movement of a steel armature, which is moved by a plunger arrangement in contact with the surface to be checked.

Electrical comparator is a device in which movement results in a change in some electrical quantity, then amplified by electrical means.
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Electric comparator
(1) Spindle of dial indicator moves Pointer of the dial indicator moves Limit switches close, when the pointer reaches a prescribed tolerance Light the warning bull s eye lights in a power box

Undersize work Oversize work Continue shining as long as the work being measured is within specifications
(2) (3) (4)

Too large

Production work
Too small Within tolerance

Advantages of electric comparator: I. Fast II. Accurate to 0.003 mm (0.0001) III. Used in automatic inspection and control, example micro-switches comparator for die casting inspection.
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Pneumatic comparators
It is a technique of measuring lengths and diameters have been developed using controlled air pressure as an amplifying medium.

Schematic diagram for comparator in gauging an internal diameter of a hole 48

Pneumatic comparators
Correlate the flow of air between the faces of the jets in the gauging head and the work piece. The clearance between the gauging and the work piece controls both the velocity and the pressure of air. The larger the clearance (work piece is much larger than the gauging head), the greater the velocity and the lower the back pressure. The smaller the clearance, the slower the velocity and the greater the back pressure.
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Pneumatic comparators, types

Flow pneumatic gauges: indicate the velocity of the air. Pressure pneumatic gauges: indicate the air pressure. Both types are operated from either a portable or a plant supply of compressed air.

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Pneumatic comparators, How does it work?

Stage 1 (calibration):
Place a setting master gauge (1) over the gauging head. Employ compressed air. Adjust the pneumatic comparator pointer (needle) to read zero.

Stage 2 (measurement):
Any variation between the size of the master gauge and the part causes a change in the zero reading.
(1) A measuring device of a standard size that is used to calibrate other measuring instruments. 51

Pneumatic comparators advantages

Simple operation Relatively low cost Non-scratching, even of the finest or softest finish. Low gauge wear. Minimum skill required.

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