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Chapter 10
Gauge Design
Intro
The word gauge has been used to describe the several types of measuring instruments such as a
caliper gauge, depth gauge, telescoping gauge and electronic gauge. Both instruments and gauge
have traditionally been used interchangeably. Figs. below show the fixed type gauge which is the
replica of the shapes of the parts to be measured.
Figure (a) Plug gage for holes, with GO-NOT GO on opposite ends. (b) Plug gage with GONOT GO on one end. (c) Plain ring gages for gaging round rods. Note the difference in knurled
surfaces to identify the two gages. (d) Snap gage with adjustable anvils.
Limit Gauges
Adoption of a system of limits and fits logically leads to the use of limit gauges, with which no
attempt is made to determine the size of a work piece they are simply used to find whether the
component is within the specified limits of size or not. The simplest forms of limit gauges are
those used for inspecting holes or shafts.
Consider first a hole on which the limits on diameter are specified. It would appear that quite
simply the GO gauge is a cylinder whose diameter is equal to the minimum hole size, and that
the NOT GO gauge is a similar cylinder equal in diameter to the maximum hole size.
Unfortunately it is not as simple as this, for the same reason that limits of size are required for
the work; nothing can be made to an exact size and this includes gauges. Thus the gauge maker
requires a tolerance to which he may work, and the positioning of this gauge tolerance relative to
the nominal gauge size requires a policy decision. For instance, if the gauge tolerance increases
the size of a GO plug gauge, and decreases the size of the: NOT GO end, the gauge will tend
to reject good work which is near the upper or lower size limits.
Similarly if the gauge tolerance increases the size of the NOT GO plug gauge and decreases
the size of the GO end then the gauge will tend to accept work which is just outside the
specified limits.
It follows that a number of questions must be answered in designing a simple limit gauge:
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Gauge Tolerances
It is a general rule in measurement that the precision of the measuring equipment should be at
least ten times as good as that of the workpiece to be measured. Thus, if a workpiece has a
tolerance of 0.08 mm the measuring equipment should be capable of detecting differences of
0.008 mm or less. While it is true of gauging that the gauge tolerance must be less than the work
tolerance. B.S 969 : 1982 recognizes that a hard and fast rule cannot be applied to limit gauges.
The gauge tolerances in B.S. 969: 1982 are therefore arranged to be a reducing percentage of the
work tolerances as the work tolerance increases. They are set out in a table below, along with the
wear allowances. This is a modified form of that in B.S. 969 : 1982 and, for interest, the gauge
tolerance is also shown expressed as a percentage of the mean work tolerance.
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Wear Allowance
An allowance for wear is normally applied only to the GO gauge. A NOT GO gauge should
rarely be fully engaged with the work and should therefore suffer little wear. The allowance for
wear on new GO gauges is therefore made by setting the tolerance zone for the gauge in from
the maximum material limit for the work by an amount equal to the wear allowance. A new
gauge is then made to within the limits specified by the tolerance zone for the gauge in this
position. If the gauge then wears with use it can be allowed to wear until its size coincides with
the maximum material limit for the work.
When the gauge is in use it must be checked regularly and if wear is detected on the GO
gauge then it can still be used as long as its size does not exceed from the nominal size.
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The GO gauge checks the maximum metal condition and should check as many dimensions as
possible. The NOT GO gauge checks the minimum metal condition and should only check one
dimension. Thus a separate NOT GO gauge is required for each individual dimension.
Consider a system of limit gauges for a rectangular hole, as shown above.
The GO gauge is used to ensure that the maximum metal condition is not exceeded and that
metal does not encroach into the minimum allowable hole space. It should therefore be made to
the maximum allowable metal condition dimensions, due allowance being made for wear and the
gauge tolerance. The Fig. below shows the design size of the gauge is associated with one of the
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coupled with stability, and at the same time it can be readily machined and brought to a high
degree of surface finish.
REFERENCES:
1. S. Kalpakjian and S R. Schmid, Manufacturing Engineering & Technology, 4th Edn.,
Prentice Hall, 2001.
2. CV Collett & AD Hope, Engineering Measurements, 2nd edition, Pitman Pubr., 1987.
3. FET ONLINE Archive, 2002/2003.