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    Inspection and Gaging

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    Ramji Rao
    This document discusses inspection and gaging tools. It covers basic principles of measurement and gaging, standard gage tolerances, allocation of gage tolerances including bilateral, unilateral and commercial systems. It also discusses gage materials, surface plates, templates, plug gages, ring gages, snap gages and techniques for checking flatness, profiles, parallelism, perpendicularity and runout.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Inspection and Gaging

    Uploaded by

    Ramji Rao
    226 views38 pages
    This document discusses inspection and gaging tools. It covers basic principles of measurement and gaging, standard gage tolerances, allocation of gage tolerances including bilateral, unilateral and commercial systems. It also discusses gage materials, surface plates, templates, plug gages, ring gages, snap gages and techniques for checking flatness, profiles, parallelism, perpendicularity and runout.

    Original Description:

    Brief presentation about Inspection and gaging for precision engineering application

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    This document discusses inspection and gaging tools. It covers basic principles of measurement and gaging, standard gage tolerances, allocation of gage tolerances including bilateral, unilateral and commercial systems. It also discusses gage materials, surface plates, templates, plug gages, ring gages, snap gages and techniques for checking flatness, profiles, parallelism, perpendicularity and runout.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    226 views38 pages

    Inspection and Gaging

    Uploaded by

    Ramji Rao
    This document discusses inspection and gaging tools. It covers basic principles of measurement and gaging, standard gage tolerances, allocation of gage tolerances including bilateral, unilateral and commercial systems. It also discusses gage materials, surface plates, templates, plug gages, ring gages, snap gages and techniques for checking flatness, profiles, parallelism, perpendicularity and runout.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 38
    At a glance
    Powered by AI
    The document discusses inspection and gaging tools used to measure dimensions and ensure they are within specified tolerances. It covers topics such as gage classes and their tolerances, allocation of gage tolerances, and various methods for checking dimensions.

    There are four classes of gages - Class XX with the closest tolerances for master gages, Class X for master and inspection gages, Class Y for inspection and working gages, and Class Z with the lowest tolerances for working gages. The document provides a table showing standard gage maker's tolerances for each class.

    In the bilateral system, the GO and NOGO gage tolerance zones are divided by the high and low limits of the workpiece tolerance zone. In the unilateral system, the work tolerance zone entirely includes the gage tolerance zone and the work tolerance is smaller than the sum of the gage tolerances.

    9.

    Inspection and Gaging Tools


    Nageswara Rao Posinasetti

    1 October 11, 2020


    Inspection
     Nominal dimension
     Tolerance
     Use
     Appearance

     Cost

     Datum or Reference

    2 October 11, 2020


    Basic principles of gaging
     Measurement
     Measuring can be defined as the determination of
    a dimension.
     Gaging
     Gauging is defined as the acceptability of a given
    dimension whether it lies in its specified or
    allowable limits or not.
     Gage tolerance
     10% work tolerance
    3 October 11, 2020
    Gage maker tolerances
     Class XX – closest tolerances – master gages
     Class X – next best – master and inspection
    gages
     Class Y – next best – inspection and working
    gages
     Class Z - lowest – working gages with coarse
    tolerances

    4 October 11, 2020


    Table 9-1 Standard Gage Maker’s Tolerances

    Above To and Class (in)


    (in) including (in) XX X Y Z
    0.010 0.825 0.00002 0.00004 0.00007 0.00010

    0.825 1.510 0.00003 0.00006 0.00009 0.00012

    1.510 2.510 0.00004 0.00008 0.00012 0.00016

    2.510 4.510 0.00005 0.00010 0.00015 0.00020

    4.510 6.510 0.000065 0.00013 0.00019 0.00025

    5 October 11, 2020


    Gage tolerances
     Plug gage for 1  0.0006 inches
     Gage tolerance = 0.00012 inch

     From table Z class

     If Plug gage for 1  0.0006 inches

     Gage tolerance = 0.00006 inch

     From table X class

    6 October 11, 2020


    Gage tolerances
     Plug gage for 1  0.0075 inches
     Gage tolerance = 0.0015 inch

     From table Z class

     Smaller degree of gage tolerance means more


    expensive
     Gage tolerances should be realistically applied.

    7 October 11, 2020


    Allocation of gage tolerances
     Bilateral system
     The GO and NOGO gage tolerance zones are
    divided into two parts by the high and low limits
    of the workpiece tolerance zone

    8 October 11, 2020


    Maximum
    Work
    Tolerance
    limit

    Work tolerance zone

    Bilateral

    Minimum
    Work
    Tolerance
    9
    limit October 11, 2020
    Allocation of gage tolerances
     Hole to be gaged 1.2500  0.0006 inch
     Work tolerance = 0.0012 inch

     Hole size from 1.2506 to 1.2494 inch

     Gage tolerance (10%) = 0.00012 inch

     Z-class tolerance zone

     GO gage size 1.2494  0.00006 inch

     NOGO gage size 1.2506  0.00006 inch

    10 October 11, 2020


    Table 9-1 Standard Gage Maker’s Tolerances

    Above To and Class (in)


    (in) including (in) XX X Y Z
    0.010 0.825 0.00002 0.00004 0.00007 0.00010

    0.825 1.510 0.00003 0.00006 0.00009 0.00012

    1.510 2.510 0.00004 0.00008 0.00012 0.00016

    2.510 4.510 0.00005 0.00010 0.00015 0.00020

    4.510 6.510 0.000065 0.00013 0.00019 0.00025

    11 October 11, 2020


    Allocation of Gage Tolerances
     Unilateral system
     The work tolerance zone entirely includes the
    gage tolerance zone
     Work tolerance smaller by the sum of the gage

    tolerance

    12 October 11, 2020


    Maximum
    Work
    Tolerance
    limit

    Work tolerance zone

    Unilateral
    Bilateral

    Minimum
    Work
    Tolerance
    13
    limit October 11, 2020
    Allocation of gage tolerances
     Hole to be gaged 1.2500  0.0006 inch
     Work tolerance = 0.0012 inch

     Hole size from 1.2506 to 1.2494 inch

     Gage tolerance (10%) = 0.00012 inch

     Z-class tolerance zone

     GO gage size 1.24940 + 0.00012 inch

     NOGO gage size 1.25060 - 0.00012 inch

    14 October 11, 2020


    Allocation of gage tolerances
     Commercial gages
     Allocate gage tolerance negatively with reference
    to both the maximum and minimum limits of the
    workpiece tolerance (C)
     NOGO gage tolerance is divided by the maximum

    limit of the workpiece tolerance and the GO gage


    tolerance is held within the minimum limit of the
    workpiece tolerance.

    15 October 11, 2020


    Maximum
    Work
    Tolerance
    limit

    Work tolerance zone

    Commercial
    Plain plug
    Commercial
    Plain ring

    Minimum
    Work
    Tolerance
    16
    limit October 11, 2020
    Allocation of gage tolerances
     The objectives in choosing an allowance
    system should be the economic production of
    as near 100% usable parts as possible, and the
    acceptance of the good pieces and rejection of
    the bad.

    17 October 11, 2020


    Gage Wear Allowance
     Wear allowance is an amount added to the
    nominal diameter of a GO-plug and
    subtracted from that of a GO-ring gage.
     It is used up during the gage life by wearing
    away of the gage metal.

    18 October 11, 2020


    Gage Wear Allowance (5%)
     Hole diameter 1.5000  0.0006 inch
     Work tolerance = 0.0012 inch
     Gage tolerance (10%) = 0.00012 inch
     GO gage size 1.49940 + 0.00006 = 1.49946
    inch
     Add gage maker tolerance as shown
    previously, 1.49946 +0.00012 and –0.00000 as
    limits

    20 October 11, 2020


    Gage Materials
     Chrome plated
     Tungsten carbide tipped

    21 October 11, 2020


    Surface Plate
     Main horizontal reference plane
     Rigid block of granite or cast iron
     Generally have three-point suspension to
    prevent rocking when mounted on uneven
    surface
     Two types
     Cast-iron plates
     Granite surface plates

    22 October 11, 2020


    Surface Plate
     Cast-iron plates
     Well ribbed and high strength
     Good wear-resistance qualities

     After machined, surface scraped by hand to flat

     Operation long and cost high

     Granite surface plates


     Manufactured from gray, pink, or black granite
     Several degrees of accuracy

     Extremely flat finishes produced by lapping

    23 October 11, 2020


    Advantages of Granite Plates
     Not appreciably affected by temperature
    change
     Will not burr, therefore, accuracy not impaired
     Nonmagnetic
     Rustproof
     Abrasives will not embed themselves as easily
    in the surface

    24 October 11, 2020


    25 October 11, 2020
    Template
     Specified profile
     Guide to the location of workpiece features
    with reference to a single plane.
     A straight edge is a template for checking
    straightness.
     Radius gages

     Screw pitch gages

    26 October 11, 2020


    Plug Gages
     A plug gage is a fixed gage usually made up of
    two members
     One member is called the GO end and the
    other the NO-GO or NOT-GO end
     AGD – American Gage Design standards

    27 October 11, 2020


    Ring gages
     Ring gages are usually used in pairs, consisting
    of go member and no-go member.

    28 October 11, 2020


    Snap Gages
     For measuring length, diameter, thickness or
    width

    29 October 11, 2020


    Amplification and Magnification of Error

     As the measurable error becomes small, it is


    difficult for direct reading and hence some
    means of magnification is required.
     Dial indicators

     Optical

     Pneumatic gauging

    30 October 11, 2020


    Geometric Dimensioning and
    Tolerancing
     ASME Y14.5-1994 (Rev. 2009)
     ISO 1101, 129, 3040

    31 October 11, 2020


    Modifiers
     Maximum Material Condition (MMC) -
     Minimum diameter of a hole and maximum
    diameter of a shaft
     Least Material Condition (LMC)
     Maximum diameter of a hole and minimum
    diameter of a shaft

    32 October 11, 2020


    Flatness checking
     Checking process depends upon the accuracy
    required
     Using a dial indicator

     After the surface is leveled, the indicator


    explores the entire area and the full indicator
    movement is a measure of flatness.

    33 October 11, 2020


    Checking a Profile
     Follow a master part as shown in Fig 9-42.
     Number of dial indicators set in a plane
    confirming the contour as shown in Fig 9-43.

    34 October 11, 2020


    Checking for
    Parallelism/Perpendicularity
     Parallelism can be checked by placing a part on
    a surface plate and searching for out of parallel
    condition with an indicator.
     Some times a special fixture may be required
    as shown in Fig 9-49.
     Perpendicularity of a cylindrical feature and it
    MMC can be checked with a functional gage as
    shown in Fig 9-51.

    35 October 11, 2020


    Checking a Runout
     Total runout consists, by definition, of two
    concentric cylinders that encompass a feature
    about a defined axis.
     Generally, total runout is measured by taking
    single runout at intervals along an entire
    cylinder.
     The extremes of needle deflection for the
    entire set of intervals yields total runout.

    36 October 11, 2020


    Checking a Position
     Shown is a hole relation gage to check hole-
    to-hole relationship.
     If RFS (Regardless of Feature Size) is used in
    place of MMC, gaging will become difficult.
     To maintain the positional tolerance of 0.10 in
    eleven gage pins will be required for all sizes
    between MMC and LMC.

    37 October 11, 2020


    Positional Tolerance Rules
     For parts with internal features, the nominal
    gage feature size is directly determined by
    subtracting the total positional tolerance
    specified at MMC from the specified MMC
    size of the feature to be gaged for location.
     For parts with external features, the nominal
    gage feature size is directly determined by
    adding the total positional tolerance specified
    at MMC size of the feature to be gaged for
    location.
    38 October 11, 2020

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