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    4 Gage Design

    Uploaded by

    Abhay Sharma
    Gaging is used to check that a product's dimensions are within prescribed tolerances to ensure proper functioning. There are fixed gages that simply check if a part passes or fails, and indicating gages that measure deviation from nominal sizes. Common fixed gages include plug, ring, snap and thread gages. Indicating gages amplify small movements and include mechanical, pneumatic, optical and electrical comparators. Proper gage design considers material selection, tolerances, and wear allowance.

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    4 Gage Design

    Uploaded by

    Abhay Sharma
    129 views30 pages
    Gaging is used to check that a product's dimensions are within prescribed tolerances to ensure proper functioning. There are fixed gages that simply check if a part passes or fails, and indicating gages that measure deviation from nominal sizes. Common fixed gages include plug, ring, snap and thread gages. Indicating gages amplify small movements and include mechanical, pneumatic, optical and electrical comparators. Proper gage design considers material selection, tolerances, and wear allowance.

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    Gaging is used to check that a product's dimensions are within prescribed tolerances to ensure proper functioning. There are fixed gages that simply check if a part passes or fails, and indicating gages that measure deviation from nominal sizes. Common fixed gages include plug, ring, snap and thread gages. Indicating gages amplify small movements and include mechanical, pneumatic, optical and electrical comparators. Proper gage design considers material selection, tolerances, and wear allowance.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    129 views30 pages

    4 Gage Design

    Uploaded by

    Abhay Sharma
    Gaging is used to check that a product's dimensions are within prescribed tolerances to ensure proper functioning. There are fixed gages that simply check if a part passes or fails, and indicating gages that measure deviation from nominal sizes. Common fixed gages include plug, ring, snap and thread gages. Indicating gages amplify small movements and include mechanical, pneumatic, optical and electrical comparators. Proper gage design considers material selection, tolerances, and wear allowance.

    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    of 30

     “A device for investigating the dimensional fitness

    of a part for a specified function”: Definition given


    by Sheffield Corporation.
     Definition given by ANSI: “A process of measuring
    manufactured materials to assure the specified
    uniformity of size and contour required by
    industries.”
    Gaging accomplishes two things:
    1. It controls the dimensions of a product within the
    prescribed limitations.
    2. It segregates or rejects products that are outside these
    limitations.

    2
    Gages are designed to check one of the seven basic
    elements of workpiece geometry:
    1. Distance
    2. Flatness
    3. Parallelism
    4. Perpendicularity(Squareness)
    5. Angularity Gages are designed to check the
    6. Concentricity acceptable variations(tolerances)
    for the product to function properly.
    7. Surface texture

    3
    Types of gages:
    Fixed gages are used to ensure that a product is
    within the prescribed limits of size.
    Indicating gages measure the extent of deviation
    from a normal or basic size and provide a means of
    evaluating the size of each part.
    Combination gages are special devices designed to
    measure or check more than one dimension of a
    workpiece at a given set up.

    4
    Advantages of fixed-limit gauges:
     They are free from errors such as drift, backlash, non-
    linear response, power fluctuations
     Give a positive yes or no decision regarding acceptability
     No power supply required, can be used anywhere
     Quite rugged
     Less susceptible to inaccuracy caused by dirty conditions
     Relatively inexpensive
    Disadvantages:
     Requires greater skill on the part of the inspector
     Do not give the amount of deviation from a nominal
    dimension

    5
     Taylor’s principle:
    It states that the ‘GO’ gauge should check all the
    possible elements of dimensions at a time
    (roundness, size, location, etc.) and the ‘NO GO’
    gauge should check only one element of the
    dimension at a time.
     ‘GO’ limit is for the maximum material limit
     ‘NO GO’ is for least material limit

    6
    Fixed gages

    RING GAGES

    7
    Fixed gages

    RECEIVING GAGES

    8
    Fixed gages

    PLUG GAGES

    9
    TAPER PLUG
    GAGE

    10
    PIN GAGE

    Snap Gage
    11
    PLUG AND RING
    THREAD GAGES

    12
    13
    Important Thread parameters
     Lead
     Angle
     Roundness
     Thread form
     Diameter
    A single full-form plug or ring screw gage cannot
    check all the thread elements.
    At least three sets of plug or ring screw gages are
    required to check a thread completely. One set will
    check pitch diameter, the second the major diameter
    and the third the minor diameter.

    14
    Indicating gages/Comparators
    The majority of indicating gages compare the actual
    dimension of the workpiece with the dimension of
    a master setting gage.

    The amplification of indicating-gage movement


    may be mechanical, pneumatic, optical, electric
    and electronic comparators.
    Also, a combination of these magnifying principles,
    such as mechanical-optical comparators, electro-
    mechanical comparators, electro-pneumatic
    comparators, multi-check comparators etc..

    15
    Desirable Characteristics of Comparators:
    1. Record variations in microns.
    2. Scale should be linear and have wide range of
    acceptability.
    3. No backlash and lag between the plunger movement
    and recording mechanism.
    4. Must be precise and accurate.
    5. Indication must be clear, must return to zero and pointer
    should be free from oscillations.
    6. Design and construction must be robust.
    7. Suitable and uniform measuring pressure.
    8. Must possess maximum compensation for temperature
    effects.

    16
    Mechanical comparators
    These instruments utilize the mechanical means of
    magnifying the small movement of the measuring
    stylus/contact plunger, which may consist of gear trains,
    levers, cams, torsion strips, reeds and/or a combination
    of these systems.
    The magnification range is about 250 to 1000 times.
    A mechanical comparator uses pointers as an indicator
    pivoted around a suspended axis and moving against a
    circular dial scale.
    Ex.: Dial indicator, Johansson Mikrokator, Sigma Mechanical
    comparator

    17
    18
    Depth gage
    19
    REED MAGNIFIER

    20
    Twisted-strip mechanical indicator
    A: Spindle
    B: Spring Knee
    C: Twisted strip
    D: Pointer
    E: Graduated Scale

    21
    Pneumatic Gage

    The restrictive effect produced as the surface approaches the nozzle


    has a well defined relation to the clearance between the two. This
    effect can be amplified and transmitted to a scale for measuring
    purposes.
    22
    Differential Back Pressure Pneumatic Gage
    Two master
    gages are
    required to set
    the
    amplification

    23
    Solex Air Gauge
    24
    Commercially available Pneumatic Comparator

    25
    Advantages of pneumatic gages:
    1. Simplicity
    2. Deep bores or holes can be gaged.
    3. Can be used without danger in an explosive
    atmosphere.
    4. Does not mar surface finish or distort fragile
    workpieces.
    5. Excellent for gaging rough surfaces.
    6. Extremely fast and accurate.
    7. Has a cleaning effect which reduces possibility
    of false readings due to oil, dirt or contact on the
    workpiece.

    26
    Three wire thread measurement

    Measurement of effective diameter of thread profile

    27
    Optical Profile
    projector

    28
    Gage Design
     Material selection
    High degree of wear resistance is required.
    Chromium plating, Flame plated tungsten carbide,
    Tungsten carbide, Ceramic etc. can be used.
     Gauge tolerance
    This is required for gauge manufacturing, also known as
    gaugemaker’s tolerance.
    For normal limit gauges, it is 10% of work tolerance
    For inspection gauges, it is 5% of work tolerance
    For reference gauges, it is 10% of gauge tolerance

    29
    Gage Design
     Wear Allowance
    Wear allowance is given to prevent the gauge to pass
    those parts which are not within its design tolerance
    zone.
    Wear allowance is applied to a ‘Go’ gauge only.
    Wear allowance is usually taken as 10% of gauge
    tolerance.
     Allocation of Gauge tolerance and wear allowance

    30

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