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
and alignment of aproduct
Parallelism : To ensure parallelism of two flat
surfaces
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 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
concentric to a common axis
Surface Texture: To check irregularities of a
surface

Gages determine whether the elements of geometry fall within the

specified variation (Tolerance)

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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 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, tapers
on shafts, external threads
Receiving Similar to ring gages
Gages Used to verify specified uniformity
of size and contour of non circular
holes like splined shafts
Plug Gages To check 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 Gages Fixed gages with inside measuring
surfaces
Used for checking diameters, length,
thickness etc.
Length Special gage replacing common
machinists scale
Gages
Checks length of a workpiece quickly
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 FIXED GAGES - APPLICATIONS
Flush Pin Used for checking special shapes that
Gages may be difficult to check by other
means like depth of slots, distance
between surfaces that are not
opposite to each other etc.
Thread Used for checking Internal / External
threads
Gages
Can check any of the five essential
elements of a thread only
Used for low accuracy work
Form Gages To Check form or contour of a
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 and
go Gages minimum limits of a workpiece

Dovetail To Check V slides with the help of

Gages rollers / buttons

Taper Gages To check taper of the shaft and 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 Blocks AA / Grade 0

Inspection Gage Blocks A+ / Grade 1

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, 100 25 04
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

Tolerance on No Go plug gage is applied minus

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 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 gages
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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
Classified based on method of amplification :
Mechanical, Pneumatic, Optical , Electrical
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 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
purpose
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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
brittle
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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 expansion than steel
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 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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 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
Pass or Fail Product Threads
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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
Pipe Ring Gages
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 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
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They Set, (Go PD Larger

 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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 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
Drawings May Be Supplied, if
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Required. (All Created Drawings Require
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 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

Ship
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gages packed separately,
CHAD / MKM
coated with rust 80

preventive, with
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