GAGES

&
GAGES DESIGN
 INTRODUCTION
 Gage is a device / equipment used for
investigating the dimensional fitness of a
part for a specified function
 Gaging is defined as a process of
measuring manufactured materials to
assure the specified uniformity of size and
contour required by the industries
 Gaging accomplishes two functions:
 Controls the dimensions of a product within the
prescribed limitations
 Segregates or rejects products that are outside these
limitations
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 INTRODUCTION

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 Basic Elements of Check
 Gages are designed to check one of
the seven basic elements of
workpiece geometry:
 Distance : Relative location of the
various
components and elements of the
workpiece. Measured by
comparison to a known
standard
 Flatness : To ensure that every element
of a surface is within a
specified
distance from a nominal surface
plane. Determines straightness
08/04/09 and alignment of a product4
CHAD / MKM

 Parallelism : To ensure parallelism of two

 Basic Elements of Check
 Gages are designed to check one of the
seven basic elements of workpiece
geometry:
 Squareness : To ensure two flat surface
are normal to each
other
 Angularity : To check angle between
two flat
surfaces (other than 90°)
 Concentricity : To ensure that points on a
cylinder surface are

Gages concentric tothe

determine whether a elements
common axis fall within the
of geometry
 Surfacespecified
Texture : To(Tolerance)
variation check irregularities of a
surface
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 Types of Gages
 Gages are classified in three broad
categories:

 Fixed Gages
 Indicating Gages
 Combination Gages

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 Fixed Gages
 Most common of all the Gages
 Used for both large and small
production
 Used to ensure that a product is
within the prescribed limit of sizes
 Standard gages built to different
specifications
 Also known as limit gages
 May further be classified as Fixed
maser gags or Fixed limit gages
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 Gages - Classification
Indicating Gages
 Comparatively complex
 Measure the extent of deviation from a normal or
basic size
 Provides a means of evaluating the size of each
part
 Establishes its relationship to limits of sizes
 Determines to what extent the limits of sizes are
exceeded by rejected parts
 Used by the inspection department
Combination Gages
 Special devices
 Designed to measure or check more than one
dimension
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of a workpiece at a given setup
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 Types of Fixed Gages
 Ring Gages
 Receiving Gages
 Plug Gages
 Pin Gages
 Snap Gages
 Length Gages
 Flush Pin Gages

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 Types of Fixed Gages
 Thread Gages
 Form Gages
 Template Gages
 Go – not – Go Gages
 Dovetail Gages
 Taper Gages
 Gage Blocks

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 FIXED GAGES - APPLICATIONS

Ring Gages  Circular inside measuring

surfaces
 To check cylindrical surfaces,
Receiving  tapers
Similar toon
ringshafts,
gages external
Gages threads
 Used to verify specified
uniformity of size and contour
of non circular holes like
Plug Gages  splined
To checkshafts
uniformity of holes
 May be straight, tapers and of
any cross section
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 FIXED GAGES - APPLICATIONS

Pin Gages  Used for checking larger diameter

holes
 Also used to measure the width of
slots or grooves
 Also known as Width Gage
Snap  Fixed gages with inside
Gages measuring surfaces
 Used for checking diameters,
length, thickness etc.
Length  Special gage replacing common
machinist’s scale
Gages
 Checks length of a workpiece
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 FIXED GAGES - APPLICATIONS
Flush Pin  Used for checking special shapes
Gages that may be difficult to check by
other means like depth of slots,
distance between surfaces that
are not opposite to each other
etc.
Used for checking Internal /
Thread 
External threads
Gages
 Can check any of the five
essential elements of a thread
only
 Used
To for low
Check accuracy
form work of a
or contour
Form 

Gages workpiece
 Not a standard gage
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 FIXED GAGES - APPLICATIONS
Template  Similar to form gages
Gages  Checks position and dimension of
two adjacent surfaces
 e.g.. checking of machine
sideway, shoulders of a shaft etc.
Go – not –  Twin gages measuring maximum
go Gages and minimum limits of a
workpiece
Dovetail  To Check V slides with the help of
Gages rollers / buttons

Taper  To check taper of the shaft and

Gages taper plug gages
 Sine Bar
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 Types of Fixed Gages

RING GAGES RECEIVING GAGES

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 Types of Fixed Gages

PLUG GAGES
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 Types of Fixed Gages

TAPER PLUG GAGE

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 Types of Fixed Gages

PIN GAGE

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 Types of Fixed Gages

SNAP GAGGES SNAP GAGGES

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 Types of Fixed Gages

FLUSH PIN GAGGES

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 Types of Fixed Gages

PLUG & RING THREAD GAGES

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 Types of Fixed Gages

CHECKING A SCREW THREAD

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 Types of Fixed Gages

RAILROAD WHEEL TREAD

TOOL FORM GAGE
FORM GAGE

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 Types of Fixed Gages

SHAFT TEMPLATE TEMPLATE GAGE FOR

GAGE MACHINE WAYS

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 Types of Fixed Gages

GO – NOT – GO GAGE

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 Types of Fixed Gages

ADJUSTMENT OF SNAP GAGE

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 Types of Fixed Gages

DOVETAIL GAGES
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 Types of Fixed Gages

SINE BAR VISE CHECKING A TAPER

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 Types of Fixed Gages

TYPICAL SET OF GAGE BLOCKS

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 GAGE BLOCKS
 One of the important Secondary
standards

 Can be classified as Master Fixed Gage

 Available in a set of 81, 49, 41, 35 & 25

pieces (inch unit)

 Available in a set of 112, 105, 87, 50, 33

& 27 pieces (metric unit)
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 GAGE BLOCKS
Calibration Gage Blocks

Master Gage Blocks AAA / Grade 00

Precision Gage AA / Grade 0

Blocks
Inspection Gage A+ / Grade 1
Blocks
Working Gage Blocks B / Grade 2

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 Typical Gage Block Set
Range (mm) Steps (mm) No. of
Pieces
1.001 – 1.009 0.001 09
1.010 – 1.490 0.010 49
0.50 – 24.50 0.050 49
25, 50, 75, 25 04
100
1.0005 --- 01
TOTAL 112
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 GAGE TOLERANCE

GAGE TOLERANCE
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 GAGE TOLERANCE
 It is a commercial practice to apply unilateral
tolerance to Go & No Go Gages

 If not specified the gage tolerance is kept at 10%

of the product total tolerance

 Known as Rule of 10 to 1

 The tolerance on Go Plain plug gage is applied

plus

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 Tolerance on No Go plug gage is applied minus
 GAGE TOLERANCE
 Go plug ring gage tolerance is
applied minus
 No go ring gage tolerance is applied
plus
 For master ring and plug Bilateral
tolerance is used
 Wear allowance is applied on the
negative side of wear taking place
and applied mainly on Go side of the
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 GAGE TOLERANCE
Gage Standardisation based on their
Tolerance
 XX - Precision lapped
(Plug / male master only)
 X - Precision – lapped
(Plug or Ring)
 Y - Lapped Plug or Ring
 Z - Ground and Polished
 ZZ - Ground Only
Standardisation by American Gage Design Committee
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 INDICATING GAGES
 Detects variation in a specific distance
and display them on a dial or graduated
scale
 Compares the actual dimension of the
workpiece with that of a master setting
gage
 Also known as comparative gaging
 Measures only the amount and direction
of any deviation which exists in relation to
the nominal size
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 Classified based on method of
 INDICATING GAGES

SIMPLE LEVER MAGNIFIER

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 INDICATING GAGES

SERIES LEVER MAGNIFIER

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 INDICATING GAGES

INDICATOR DEPTH GAGE

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 INDICATING GAGES

DIAL INDICATOR DAIL GAGE – MECHANISM

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 INDICATING GAGES

INDICATOR PLUG GAGE FOR HOLE INSPECTION

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 INDICATING GAGES

SQUARENESS INDICATING GAGE

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 INDICATING GAGES

INDICATING PARALLEL GAGE

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 INDICATING GAGES

VISUAL GAGE
REED MAGNIFIER USING REED MECHANISM
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 INDICATING GAGES

TWISTED STRIP
MECHANICAL
INDICATOR

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 PNEUMATIC GAGES
 Measures Dimension with the help of
air
 Nearness of the surface is detected
by a jet of air directed towards it
through a nozzle
 Clearance between the surface and
the nozzle produces restrictive effect
 The effect can be amplified and
transmitted to a scale for measuring
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 PNEUMATIC GAGES

PRINCIPLE OF PNEUMATIC GAGING

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 PNEUMATIC GAGES

FLOW TYPE AIR GAGE

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 Electric & Electronic
Indicator
 Works on the principle of Displacement of
a mechanical contact type sensing
mechanism
 Electro mechanical Transducer converts
the displacement to proportional changes
in electrical current
 The change is displayed on a meter
calibrated in length unit
 The indicating meter can indicate plus or
minus directional movement from the
center in addition to magnitude
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 ELECTRIC INDICATOR

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 OPTICAL PROJECTOR

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 OPTICAL PROJECTOR

OPTICAL SYSTEM

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 AUTOMATIC GAGING
 An Automatic gaging machine is a
device that performs one or more of
the following functions:
 Successive inspection of a number of
independent dimensions and
automatic passing of only those
workpiece within set tolerances
 separation of workpieces into a
number of classes according to their
actual dimensions
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 AUTOMATIC GAGING
 Automatic gaging machine can be
fed by hand, from a hopper or by a
magazine
 Workpieces on a multistation
machine are carried automatically
from one gaging station to another
 Workpieces with dimensions within
the tolerance are dropped into a
hopper at the end of the machine
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 AUTOMATIC GAGING

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 AUTOMATIC GAGING

Checking of cylinder bores for size,

out of roundness & classification as per size
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 GAGE MATERIAL
 Selection of material for gages
depends on
 Tolerance to be checked
 Number of items to be checked
 Composition & hardness of material to
be gaged
 Cost of gage material
 Complexity of the workpiece to be
gaged
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 GAGE MATERIAL
 Major properties of gage materials
are : Dimensional stability & Wear
resistance
 Wear resistance of the gage
depends on
 Surface hardness
 Composition of the material
 Quality of the surface finish
 The surface must be hard but not so
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 GAGE MATERIAL
 Common materials used for gages
are
 Carbon steel
 Alloy steel
 Tungsten carbide : Good stability,
wear resistance, relatively high price &
sensitive to chipping. Controlled
temperature environment required
when gaging tightly toleranced
dimensions due to different thermal
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expansion than steel

 GAGE MATERIAL
 Chromium plating gages increases
wear resistance and corrosion
resistance to some extent
 Useful for restoring worn gages to
the original size
 Gages with wear areas around sharp
corners or edges should not be
chromium plated as the plating may
flake away
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08/04/09 CHAD / MKM 62
 Product Thread Inspection
Attributes Gaging (Fixed Limit)
• Attributes Inspection is a non-quantitative
type of inspection whose only possible
outcome is either accept or reject.
• Attributes Inspection is gaging at the limits of
tolerance.
• In the world of Screw Threads, Go and No Go
Ring and Plug Gages are the most common
type of Attributes Inspection.
• Attributes Inspection cannot measure actual
Pitch Diameter.
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Thread Gages Are Used
To:
• Assures Assembly of
Mating Parts
•Inspect Pitch Diameter and
the
Functional Thread
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• Pass or Fail Product

Thread Gages Are Not:
• Thread Chasers, Taps,
Dies or Other CuttingTools
• Hammers
• Die or Tap Clean Out Tools
• Intended to Measure
“Actual Size”
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Thread Gages Types
• Taper-lock Work Plugs (Standard)
• Reversible Work Plugs (When
Specified)
• STI Taper-lock Work Plugs (When
Specified)
• Ring Gages
• Setting Plugs Gages
• Pipe Plug Gages
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08/04/09 CHAD / MKM 67
 Thread Nomenclature
• Pitch Diameter - “located equidistantly
between the sharp
major & minor cylinders.”
• Major Diameter - “is an imaginary cylinder
that would bound the crests of an external
thread or the roots of an internal thread.”
• Minor Diameter - “is an imaginary cylinder
that would bound the roots of an external
straight thread or the crests an internal
thread.”

Ref.: ANSI/ASME B1.7M

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 Thread Nomenclature
• Pitch Diameter - is the
halfway point between the
sharp thread crest & root.
• Major Diameter - is the
largest diameter of a thread.
• Minor Diameter - is the
smallest diameter of a thread.
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 Remember

• Set Plug Gages are Only

Intended to Inspect Ring
Gages. They are Not Used to
Inspect Product Threads!

• Set Plug Gages Have the

Same Pitch Diameters as
the Rings They Set, (Go
08/04/09 CHAD / MKM 76
 Attributes Gaging (Fixed Limit)
• Attributes Inspection is a non-quantitative
type of inspection whose only possible
outcome is either accept or reject.
• Attributes Inspection is gaging at the limits of
tolerance.
• In the world of Screw Threads, Go and No Go
Ring and Plug Gages are the most common
type of Attributes Inspection.
• Attributes Inspection cannot measure actual
Pitch Diameter.
08/04/09 CHAD / MKM 77
 Custom Thread Gages
• Acme, Buttress, Hole Location,
UNJ, & UNR...
• Built to Your Specifications or
Applicable
Standard.
• Developed from Your Part
Drawings
• Designed to Meet Your Specific
Needs
08/04/09 CHAD / MKM 78
08/04/09 CHAD / MKM 79
• Never force a Gage into or on a Part Being Check
• Handle gages as you would any precision tool,
misuse or mishandling can result in nicks or other
deformities which can
destroy the integrity of the gage.
• Store gages in a secure location, preferably in
individual
compartments or containers. Gages should be
dipped in an oilwax based seal or coated with a rust
preventive prior to storing
08/04/09 CHAD / MKM 80
• Ship gages packed separately, coated with rust
Thread Gages Complete mesh
Location:
Cabinet #5
Purpose:
Measures the pitch of bolts and screws Correct
Instrument: fit

Click slide to
Use: See demonstration

1) Select either metric or imperial thread gauge

2) Select the appropriate gage Collision
3) Test the fit (See pictures to the right for
demonstration)
4) Select another gage if necessary
5) Check the other standard to make sure the bolt was Incorrect
not measured in the wrong units fit
Supplier:
MSC International Supply Co.
www.mscdirect.com