Module 5 Gauges Royal Commission for Jubail and Yanbu Yanbu Industrial College Mechanical Engineering Department
Course Instructor: Dr. Abdulrahman Sait Engr. Saad Zamakhshari Table of Content
• Types of Gauges
• Gage Blocks
• Gage Blocks Buildup
• Care of Gauge Blocks
Telescope Gauges • Telescope Gauges, or snap gauges are non- graduated precision measurement tools, used to measure inside diameters and distance between parallel surfaces.
• Telescope gauges are easier to use than
inside micrometers because of their design.
• Another design of gauges for bore or hole
measurement has three measuring points. Precision Gauges • When it come to angular and V-grooves measurement, precision gauges with the help of balls and rollers when can calculate the angles of the complex shapes and lengths.
• The selection of the known diameter ball or rollers and
simple calculation we will be able to find the desired parameters Feeler Gauges • Thickness or Feeler gauges, are precision measurement tools composed of number of blades, each machined to an exact thickness.
• The blades could be used alone or in
combination to measure gaps and narrow spaces between surfaces. And they are available in English and Metric Feeler Gauges The Following precautions in connection with using feeler gauges should be observed:
1. The leaves of feeler gauges become rather readily burred, bent, or warped, or constant use shaves off a few ten-thousandths of thickness. The leaves of a thickness gauge should be checked regularly, and damaged blades replaced.
2. The retaining screw should exert only light pressure of the blades.
3. Apply a thin film oil to the blades to prevent rust.
4. Use the minimum number of the blades to make a certain thickness.
Sheet & Wire Gauges • Sheet Gauge is used to determine the thickness of the sheet metal. • Wire Gauges is used to determine the wires diameter. • Sheet Metal thickness and wire diameter are specified either by gauges numbers or by their thickness in inches or millimeters. Sheet metal and wire gauges have slots that correspond to the different gauge's sizes. • There is a table to provide the user with the names if different gauges and what they measure, and the decimal equivalent of the gauge numbers. Sheet & Wire Gauges • Standards used: • U.S. Standard Gauge • American Standard Wire • American Steel & Wire Company Gauge • etc.… Gage Blocks Interchangeable manufacturing system (IMS) requires an accurate standard of measurement to function efficiently. Gage blocks have provided industries with the means of maintaining sizes to specific standards and tolerances.
• Inch Gage Blocks:
• Commonly used is the 83-piece • Metric Gage Blocks: • Commonly used is 88-piece Uses of Gage Blocks 1. To check the dimensional accuracy of fixed gages to determine the extent of wear, growth, or shrinkage. 2. To calibrate adjustable gages, such as micrometers and vernier calipers, imparting accuracy to these instruments. 3. To set comparators, dail indicators and height gages to exact dimensions. 4. To set sine bars and sine plates when extreme accuracy is required in angular setups. 5. For precision layout with the use of attachment. 6. To make machine tool setup. 7. To measure and inspect the accuracy of finished parts in inspection rooms. Gage Blocks Accuracy Classification 1. Class AA set: commonly called laboratory or master set, is accurate to ± 0.000 002” (0.000 05 mm). These gage blocks are used in temperature-controlled laboratories as references to compare or check the accuracy of working gages.
2. Class A set: is used for inspection purposes and is accurate to ± 0.000 004” and (+ 0.000 15mm, - 0.000 05mm)
3. Class B set: commonly called the working set, is accurate to + 0.000 008” and (+0.0002.5mm, -0.00015mm). These blocks are used in the shop for machine tool setup, layout work, and measurement. Gage Blocks Temperature Effect Temperature doesn’t affect the ordinary measuring tools significantly, while working with very accurate measuring tools the small amount of heat may change the accuracy negatively. The following suggestions are offered to eliminate as much error as possible. 1. Handle gage block only when they must be removed. 2. Hold them by hand for as little time as possible. 3. Hold the between tips of the fingers so that the area of contact is small. 4. Have the work and gage blocks at the same temperature. If a temperature-controlled room is not available, both the work and gage blocks may be placed in kerosene until both are at the same temperature. 5. Where extreme accuracy is necessary, use insulating gloves and tweezers to prevent temperature change during handling. Gage Blocks Buildups When the blocks are required to make up a dimension are being calculated, the following procedures should be followed to save time, reduce the change of error and use as few blocks as possible. For example, if a measurement of 1.6428” is required: 1. Write the dimension required on the paper 1.6428 2. Deduct the size of two wear blocks: 2 x 0.05” - 0.100 = 1.5428 3. Use a block which will eliminate the right-hand digit - 0.1008 = 1.4420 4. Use a block which will eliminate the right-hand digit - 0.142 = 1.300 5. Continue to eliminate the digits from the right-hand - 0.300 = 1.000 6. Use a 1.000” block - 1.000 = 0.000 Gage Blocks Buildups Calculate the block buildup for 3.8716”:
Steps Block Value Procedure Result
Two wear blocks 2 x 0.05” 0.100” 3.8716 – 0.100 3.7716”
Use 0.1006” 0.1006” 3.7716 – 0.1006 3.6710”
Use 0.121” 0.121” 3.6710 – 0.121 3.550”
Use 0.550” 0.550” 3.550 – 0.550 3.000”
Use 3.000” 3.000” 3.000 – 3.000 0.000”
Gage Blocks Buildups Calculate the block buildup for 57.150 mm:
Steps Block Value Procedure Result
Two wear blocks 2 x 2mm 4mm 57.150 – 4 53.150 mm
Use 1.050mm 1.050mm 53.150 – 1.050 52.100 mm
Use 1.100mm 1.100mm 52.100 – 1.100 51.000 mm
Use 1mm 1.000mm 51.000 – 1.000 50.000 mm
Use 50mm 50.000mm 50.000 – 50.000 0.000 mm
Gage Blocks Buildups Calculate the block buildup for 27.781 mm:
Steps Block Value Procedure Result
Two wear blocks 2 x 2mm 4mm 27.781 – 4 23.781 mm
Use 1.001mm 1.001mm 23.781 – 1.001 22.780 mm
Use 1.080mm 1.080mm 22.780 – 1.080 21.700 mm
Use 1.700mm 1.700mm 21.700 – 1.700 20.000 mm
Use 20mm 20.000mm 20.000 – 20.000 0.000 mm
Care of Gage Blocks 1. Gage clocks should always be protected from dust and dirt by being kept in a closed case when not in use. 2. Gages should not be handled unnecessarily since they absorb the heat of the hand. Should this occur, the gage blocks must be permitted to return to room temperature before use. 3. Fingering of lapped surfaces should be avoided to prevent tarnishing and rusting. 4. Care should be taken that gage blocks are not dropped, or their lapped surfaces scratched. 5. Immediately after use, each block should be cleaned, oiled, and replaced in the storage case. 6. Before gage blocks are wrung together, their faces must be free of oil and dust. 7. Gage blocks should never be left wrung together for ant length of time. The slight moisture between the blocks can cause rusting which will permanently damage the block.
