Gauge Design
(Numerical Questions)
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Gauge Design – Workshop Gauge Vs Inspection Gauge Vs ISO
Inspection ISO Gauge
Workshop Gauge Gauge
NO GO X/10 X/10
X/10
Plug X
X/10 X/10
GO
X/10 X/100
Y/10
GO Y/100
Y/10 Y/100 Y/10
Ring Y
Y/10
NO GO Y/10 Y/10
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• Problem 1: Design a workshop standard plug and ring GO and NO GO
gauges for the hole-shaft assembly having 25H7f8 fit. It is given that the
upper deviation for shaft f =-5.5D0.41 and the 25 mm shaft diameter falls in
the step of 18 mm and 30 mm. Also determine the type of fit and
allowance. Assume IT7 = 16i and IT8 = 25i.
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NO GO
X/10
Plug Hole X
X/10
GO
X/100 (Wear allowance)
GO
Y/10 Y/100
Ring Shaft Y
Y/10
NO GO
εB
Hole
εb
Shaft 4
NO GO
X/10
Plug X
X/10
GO 25 mm
εf X/100 (Wear allowance)
GO
Y/10 Y/100
Ring Y
Y/10
NO GO
Fundamental deviation = -5.5D0.41 = -5.5x(23.23) 0.41 = -19.97 µm = -0.01997 mm
X = IT7 = 16i ; Y = 25i
D = (D1xD2)0.5 = (18x30) 0.5 = 23.23 mm
i = 0.45(D)1/3 + 0.001xD = 1.3066 microns = 0.001306 mm
Now X = 16i = 0.02089 mm and Y = 25i = 0.03265 mm 5
NO GO
X/10
Plug X
X/10
GO 25 mm
X/100 (Wear allowance)
GO
Y/10 Y/100
Ring Y
Y/10
NO GO
Hole dimension = 25+0.02089
+0.00 mm
Shaft dimension = 25−0.01997
−0.05262 mm
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NO GO
X/10
Plug X
X/10
GO 25 mm
X/100 (Wear allowance)
GO
Y/10 Y/100
Ring Y
Y/10
NO GO
Plug gauge tolerances = 0.02089/10 = 0.002089 mm
Wear allowance on GO plug gauge = 0.002089/10 = 0.0002089 mm
Ring gauge tolerances = 0.03265/10 = 0.003265 mm
Ring GO gauge wear allowance = 0.003265/10 = 0.0003265 mm
(+0.00208 +0.000208)
For Hole – Plug GO Gauge = 25+0.000208 mm = 25+0.00228
+0.000208 mm
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NO GO X/10
Plug X
X/10
GO 25 mm
X/100 (Wear allowance)
GO Y/100
Y/10
Ring Y
Y/10
NO GO
For Hole – Plug NO GO Gauge = 25+0.02089
+0.0188 mm
Fundamental deviation = -0.01997 mm
For Shaft – Ring GO Gauge = 25−0.01977−0.0003265 −0.02
−0.01977−0.0003265−0.003265 mm = 25−0.0233 mm
For Shaft – Ring NO GO Gauge = 25−0.01977−0.0325+0.00325
−0.01977−0.0325 mm = 25−0.0490
−0.0522 mm
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Problem 2 - Homework: Design a plug and ring GO and NO GO gauges (as per ISO
system of gauge design) for the hole-shaft assembly having 25H7f8 fit. It is given that
the upper deviation for shaft f =-5.5D0.41 and the 25 mm shaft diameter falls in the step
of 18 mm and 30 mm. Also determine the type of fit and allowance. Assume IT7 = 16i
and IT8 = 25i.
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• Problem 3 : A hole of nominal size 25 mm has a tolerance of ± 0.015
mm. Considering the gauge tolerance to be 10% of work tolerance,
design a GO gauge as per workshop standards (assume no wear
allowance). What would be the dimensions of the GO gauge in unilateral
tolerance system?
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• Problem 3 : A hole of nominal size 25 mm has a tolerance of ± 0.015 mm.
Considering the gauge tolerance to be 10% of work tolerance, design a GO
gauge as per workshop standards (assume no wear allowance). What
would be the dimensions of the GO gauge in unilateral tolerance system?
NO GO
0.015 mm
Hole
25 mm
0.015 mm
GO 0.003 mm
Work tolerance = 0.03 mm
Guage Tolerance = 0.1x Work tolerance = 0.003 mm
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• Problem 3 : A hole of nominal size 25 mm has a tolerance of ± 0.015 mm.
Considering the gauge tolerance to be 10% of work tolerance, design a GO
gauge as per workshop standards (assume no wear allowance). What
would be the dimensions of the GO gauge in unilateral tolerance system?
NO GO
0.015 mm
Hole
0.015 mm
GO 0.003 mm 24.985 mm
Shift in basic size for unilateral system – Basic size = 25 – 0.015 = 24.985
The size of the GO gauge in unilateral system will be = 𝟐𝟒. 𝟗𝟖𝟓+𝟎.𝟎𝟎𝟑
𝟎 mm 12
Problem 4 : GO and NO GO plug gauges are to be designed for a hole of dimensions
20+0.050
+0.010 𝑚𝑚. The gauge tolerance was taken as 10% of work tolerance and wear
allowance was neglected. If ISO system of gauge design was followed, what would be
the size of GO and NO GO gauge?
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Problem 4 : GO and NO GO plug gauges are to be designed for a hole of dimensions
20+0.050
+0.010 𝑚𝑚. The gauge tolerance was taken as 10% of work tolerance and wear
allowance was neglected. If ISO system of gauge design was followed, what would be
the size of GO and NO GO gauge?
NO GO
0.004 mm
Hole 0.050 mm
GO 0.004 mm
0.010 mm
20 mm
Work tolerance = 0.04 mm
Guage Tolerance = 0.1x Work tolerance = 0.004 mm
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Problem 4 : GO and NO GO plug gauges are to be designed for a hole of dimensions
20+0.050
+0.010 𝑚𝑚. The gauge tolerance was taken as 10% of work tolerance and wear
allowance was neglected. If ISO system of gauge design was followed, what would be
the size of GO and NO GO gauge?
NO GO 0.004 mm
Hole 0.050 mm
GO 0.004 mm
0.010 mm
20 mm
Size of GO Guage = 20+0.014
+0.010 𝑚𝑚
Size of NO GO Guage = 20+0.054
+0.050 𝑚𝑚 15
Thank you
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