METROLOGY AND

INSTRUMENTATION
Unit- II
Design of Limit Gauges
 What are Gauges ?
 Gauges are the scale-less inspection tool used
to check the dimension of the parts.
 It doesn’t determine the actual size or
dimension of part.
 Used to check whether the inspected part
within the specified limit.
 Need for Limit Gauging
 No need of actual size of the part in mass
production
 Inspection to check whether part is within
prescribed limit.
 Speedy inspection with simple tool
 Reduction in production cost
 Classification of Gauges
1. Plain gauges
(a) According to their type:
(i) Standard gauges
(ii) Limit gauges
(b) According to their purpose:
(i) Workshop
(ii) Inspection
(iii) Reference, or master, or control gauges
(c) According to the form of the tested surface:
(i) Plug gauges for checking holes
(ii) Snap and ring gauges for checking shafts
 Classification of Gauges
(d) According to their design:
(i) Single- and double-limit gauges
(ii) Single- and double-ended gauges
(iii) Fixed and adjustable gauges
2. Adjustable-type gap gauges
3. Miscellaneous gauges
(a) Combined-limit gauges
(b) Taper gauges
(c) Position gauges
(d) Receiver gauges
 Gauge Materials
Consideration of selection of material
• Wear resistance
• Dimensional Stability stability and form
• Corrosion resistance
• Easily machinable to get required accuracy and
surface finish
• Low coefficient of expansion
 Gauge Materials
Materials
• High carbon steel
• Mild steel
• Case hardened steel
• Oil hardened steel
• Cast iron
• Glass and ceramic
• Invar
Taylor’s Principle for plan limit gauges

1. GO Gauge is designed to check the maximum metal

limit while NO-GO gauge should be designed to
check minimum metal limit.
2. GO gauges should check all related dimension
(roundness, size etc)
3. NO-Go gauge should check only one dimension of
the work piece at a time, for the minimum metal
conditions (indicating the presence of the least
amount of material permitted at a prescribed
surface) size
Taylor’s Principle for plan limit gauges

For Hole
Taylor’s Principle for plan limit gauges

For Shaft
 Description of some commonly used
gauges
1. Snap Gauges:
 A Snap gauge is used for the inspection of external
dimensions.
 It consist of a U-shaped frame having jaws equipped
with suitable gauging surfaces.
 A plan gauge has two parallel jaws or anvils which
are made to some standard size & cannot be
adjusted
 They may be either single-or double -ended
Snap Or Gap Gauge
 Description of some commonly used
gauges
Double Ended Snap Gauge:
 Description of some commonly used
gauges

Progressive Snap Gauge:

Adjustable-type Snap gauge

lec# 7 & 8
2. Plug Gauges:
 A plain plug gauge is an accurate cylinder used as
an internal gauge for size control of holes
 These gauges may be either single or double ended
Plug Gauge
 Plug Gauge
Single ended GO and NOT- GO Plug Gauges
 Plug Gauge
Double ended Plug Gauges:
Double ended plain gauges have “GO” and “NOT GO”
members assembled on opposite ends
 Plug Gauge
Progressive Plug Gauges:
Progressive gauges have both gauging sections
combined on one side
3. Ring Gauges:
 Used to gauge outside diameters
 Used in Pairs as “Go” & “Not Go”
4. Taper Gauges:
 Taper gauges are not dimensional gauges but
rather a means of checking in terms of degrees
 Their use is a matter more of fitting rather than
measuring
5. Thickness or Feeler Gauge:
 It consist of a number of thin blades & is used in
checking clearances & for gauging in narrow
places
Standard Gauges : These are made to the nominal size of the
parts to be tested.
Limit Gauges : These are „go‟ and „no go‟ gauges.
Plug Gauges : These are used for checking holes of many
different shapes and sizes.
Ring Gauges : External diameter measuring gauges.
Taper Gauges : Taper testing gauges.
Snap Gauges : These are used for checking shafts.
Thread Gauges : These are used for pitch diameter of the
thread.
Form Gauges : These are used to check the contour of a
profile.
Feeler Gauges : For checking the clearance between the
mating surfaces.
 Gauges designation

Plug gauges
40 H7

Basic size 7 indicates

H indicates “IT7 Tolerance”
“Gauging a bore”
 Gauges designation
Ring gauges

40 f7
Basic size

f indicates
“Gauging a Shaft”
7 indicates
“IT7 Tolerance”
 Manufacturing Tolerance
• It is economically impractical to attempt to
make “Go” and “Not Go” gauges exactly to the
two limits of work tolerance.

• Limit gauges are made 10 times more accurate

than the tolerances they are going to control
 Wear Allowance
• The surface of “Go” gauge is constantly rub
against the surface of the part in inspection and
loose their initial size.

• The size of plug gauge is reduced but size of

snap gauge is increased.

• 10% wear allowance is provided only for the

“GO” gauge if working tolerance is greater than
0.09 mm.
 Disposition of tolerance and Allowance
.
 Disposition of tolerance and Allowance
.
Q. GO and NO GO plug gauges are to be designed for a
hole .Gauge tolerance can be taken as 10% the hole
tolerance . Find the size of GO and NO GO design of the
plug gauge.

Sol:
 Comparators?
A comparator is a precision instrument
employed to compare the dimension of a given
component with a working standard.

It does not measure the actual dimension but

indicate how much it differs from the basic
dimension.
However, it can be used for direct
measurement , within its range of operation.
Comparators?
 Basic Features of comparators

1. A Sensing device which faithfully senses the

input signal.
2. A magnifying system to amplify the signal to
suitable level
3. A display system (commonly a scale and a
pointer)
 Desirable Features of comparators
1. Wide range for comparison
2. No backlash, friction
3. Should be precise and accurate
4. Clear indicator
5. Easy to operate
6. No pointer oscillations
7. Compensation for temperature effets
 Classification of Comparators
1. Mechanical Comparator: It works on gears pinions,
linkages, levers, springs etc.
2. Pneumatic Comparator: Pneumatic comparator works
by using high pressure air, valves , back pressure etc.
3. Optical Comparator: Optical comparator works by
using lens, mirrors, light source etc.
4. Electrical Comparator: Works by using step up, step
down transformers.
5. Electronic Comparator: It works by using amplifier,
digital signal etc.
6. Combined Comparator: The combination of any two of
the above types can give the best result.
 Mechanical Comparators

Some of the comparator which belong to this class

are:
1.Dial indicator
2.Reed type comparator
3.Sigma Comparator
4. Johnson Mikrokrator
 Dial Indicator
Amplifies the length or displacement and translate
it into rotational motion of pointer over circular
scale

Applications:
1. To compare two heights or distance between
narrow limits
2. For determining errors in geometrical forms
3. For testing alignment, roundness and
parallelism of work piece
4. For quality control and inspection work
Dial Indicator

Bezel clamp

Contact point
 Least Count of Dial Indicator

Linear movement of Plunger , 1 mm = 1 revolution (100 divisions)

Least Count =

L.C= 0.01 mm
Least Count of Dial Indicator

?
 Sigma Mechanical Comparator

L
 Magnification of Sigma Mechanical
Comparator
In the first stage,
Magnification is L/x.

The second stage ,

magnification : R/r.

Therefore, overall magnification : (L/x) × (R/r).

Sigma Mechanical Comparator
Back pressure type Pneumatic comparator
Back pressure type Pneumatic comparator
Back pressure type Pneumatic comparator

Advantages:-
1. Very high magnification
2. Less friction, wear and inertia
3. Determines ovality and taperness of circular
bores
Disadvantages:-
1. Requires compressor and accurate pressure
regulator
2. Non portable
 Optical (profile) Projector
• Profile projector is also
commonly known as optical
Projector

• It is an instrument which
projects the large shadow of the
profile of the workpiece on a
screen

• From the projection of the

workpiece, measurement can
be made directly or indirectly
Optical (profile) Projector
 Optical (profile) Projector
Uses of Profile projector

• Profile projector is widely used for complex

shape stampings, gears, cams and threads
• Used in the automotive industry to inspecting
surface deformities.
• In glass Producing industries to inspecting
minute flaws in glassware.
• Used to inspect the components with
irregular shapes and sizes.
STUDY AND APPLICATIONS OF
TOOL MAKER’S MICROSCOPE
 Tool maker’s microscope
• The toolmaker's microscope is an optical measuring
machine equipped for linear and angular measurement.
 Applications of T M M
• The determination of the relative position
of various Points on work (Linear
measurement)
• Measurement of angles by using a
protractor eye-piece.(Angular
measurement)
• Comparison of thread forms and
measurement of pitch and effective
diameter.(Screw thread measurement)
 Interferometry

• Interferometry is a techniques in which waves,

usually electromagnetic waves, are
superimposed causing the phenomenon of
interference in order to extract information.

• An interferometer is an optical device which

utilizes the effect of interference.
Interference of wave
• If two rays are in same
phase, then resulting
intensity will be the
sum of two intensity.

• If two rays are out of

phase, then resulting
intensity will be the
difference of two
intensity.
 Interferometry

• If two rays having same amplitude are in same

phase, then resultant will be twice & result will
be Bright spot. i.e Even number of half
wavelength
• If two rays having same amplitude are out of
phase, then resultant will be zero & result will
be Dark spot. i.e Odd number of half
wavelength (2n+1)(λ/2)
Interferometry
 Optical Flat
• An optical flat is a disk of
high-quality glass or quartz.

• The surface of the disk is

ground and lapped to a
high degree of flatness.

• Sizes of optical flats vary

from 25 to 300 mm in
diameter, with a thickness
ranging from 25 to 50 mm
Optical Flat
Interference Bands by Optical Flat
 Effect of angle on fringe spacing

• If angle θ increases, fringes are brought closer

to each other, and if θ is reduced fringe spacing
increases
Different Fringe patterns
Checking of heights and Parallelism of Slip
gauge

Δh
Optical flat as comparator

h
Δh

G
N.P.L Flatness interferometer
Q. An optical flat is used to check the height of the
slip gauge against a standard gauge of 20 mm height.
The wavelength of a cadmium light source is 0.509
μm. If the number of fringes on a gauge width of 15
mm is 10 and the distance between the two blocks is
30 mm, calculate the true height of the gauge being
inspected.

Sol:
The difference in height h is given by the following
equation: