Agnel Charities’
Fr. C. Rodrigues Institute of Technology, Vashi.
Course Name: Mechanical Measurements and Controls (TE SEM V)
Subject Code: MEC501
Module 1 Introduction to Metrology
Lecture 05
Mr. Amar Murumkar
Assistant Professor, Mechanical Engineering Department,
FCRIT, Vashi, Navi Mumbai.
7/23/2024
Module No. 01 : Lecture 05
oIntroduction to Metrology
oNeed for inspection
oFundamental principles and definition
oStandards of measurements
oErrors in measurements
oInternational standardization
oLimits, fits and tolerances of interchangeable manufacture
oElements of interchangeable system
oHole based and shaft based systems
oTolerance grades
oTypes of fits
oGeneral requirements of Go & No go gauging
oTaylor’s principle
oDesign of Go & No go gauges
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Gauges
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Source: https://www.marposs.com/eng/application/technologies-hard-gauging-attribute-gauges
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Gauges
Scale less inspection tools are used to check the dimension of parts.
Not determine actual size or dimension of part.
Measurement by gauges is Easy and rapid. So they are suitable in mass
production.
Use to check whether the inspected part is within specified limits.
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Plug and Snap Gauges
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Maximum and Minimum Metal Condition
Maximum metal condition (MMC) corresponds to a condition in which a
feature contains the maximum amount of material within the stated limits.
For example maximum limit on shaft and minimum limit on the hole.
Least Material Condition (LMC) corresponds to a condition in which a
feature contains the least amount of material within the stated limits. e.g.
maximum hole diameter, minimum shaft diameter.
MMC is important with regard to geometrical tolerances since it critically
affects the interchangeability of manufactured parts.
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MMC vs LMC Taylor’s Principle
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Taylor’s Principle
In 1905, William Taylor developed a concept relating to the gauging.
Taylor’sprinciple states that the GO gauge is designed to check
maximum metal conditions, that is, LLH and HLS.
It should also simultaneously check as many related dimensions, such
as roundness, size, and location, as possible.
The NOT GO gauge is designed to check minimum metal conditions,
that is, HLH and LLS. It should check only one dimension at a time.
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Taylor’s Principle
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GO and NOT GO limits of plug gauge
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GO and NOT GO limits of snap gauge
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General Terminology
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General Terminology
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GO and NO GO Gauge
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System of Limits and Fits
The rapid growth of national and international trade necessitates the
developments of formal systems of limits and fits, at the national and
international levels.
• The International Organization for Standardization (ISO) specifies the
internationally accepted system of limits and fits.
• The ISO system of limits and fits comprises 18 grades of fundamental
tolerances to indicate the level of accuracy of the manufacture.
• The greater the number, the higher the tolerance limit.
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System of Limits and Fits
• These fundamental tolerances are designated by the letters IT followed by a
number.
• The ISO system provides tolerance grades from IT01, IT0, and IT1 to IT16
to realize the required accuracy.
• Tolerance values corresponding to grades IT5–IT16 are determined using
the standard tolerance unit (i, in μm), which is a function of basic size.
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Tolerance Grade
Tolerance unit,
• D = diameter of the part in mm.
• 0.001D = Linear factor counteracts the effect of measuring inaccuracies.
• Value of tolerance unit ‘i ’is obtained for sizes up to 500 mm.
• D is the geometric mean of the lower and upper diameters.
• D=
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Tolerance Grade
D=
The various steps specified for the diameter steps are as follows:
• 1–3, 3–6, 6–10, 10–18, 18–30, 30–50, 50–80, 80–120
• 120–180, 180–250, 250–315, 315–400, 400–500
• 500–630, 630–800, and 800–1000 mm.
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Tolerance Grade Standard tolerance units
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Tolerance Symbol
Used to specify the tolerance and fits for mating components.
Example: Consider the designation 40 H7/d9
• Basic size of the shaft and hole = 40 mm.
• Nature of fit for the hole basis system is designated by H
• Fundamental deviation of the hole is zero.
• Tolerance grade: IT7.
• The shaft has a d-type fit, the fundamental deviation has a negative value.
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Material for Gauges
Gauges should satisfy the following requirements:
1.The material used in the manufacture of gauges should be hard and wear resistant
for a prolonged life.
2. It should be capable of maintaining dimensional stability and form.
3. It should be corrosion resistant.
4.It should be easily machinable, in order to obtain the required degree of accuracy
and surface finish.
• High-carbon steel; Mild steel; Chromium-plated gauges; Glass
gauges etc.
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Gauge Tolerance
• Tolerance that is allowed in the manufacture of gauges is termed gauge
maker’s tolerance or simply gauge tolerance.
• Gauge tolerance should be kept as minimum as possible; however, this
increases the gauge manufacturing cost.
• The normal practice is to take gauge tolerance as 10% of the work
tolerance.
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WearAllowance
• According to Taylor’s principle, during inspection the NOT GO side should not
enter or pass. Hence, there is no need to provide an allowance for wear in case of
NOT GO gauges.
• Taylor’s principle also states that the GO side of the gauge should enter the hole or
just pass over the shaft under the weight of the gauge without using undue force.
• During inspection, the measuring surfaces of the gauge constantly rub against the
mating surfaces of the workpiece.
• Therefore, the GO gauges suffer wear on the measuring surfaces and thus lose
their initial dimension.
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WearAllowance
• Hence, wear allowance is provided for GO gauges to extend their service
life.
• As a consequence of this wear, the size of the GO plug gauge decreases
while that of the ring or gap gauge increases.
• A wear allowance of 10% of gauge tolerance is widely accepted in
industries.
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References
• Engineering Metrology and Measurement by N V Raghavendra and
Krishnamurthy, Oxford University Press.
• Metrology and Measurement by Anand, Bewoor and Vinay Kulkarni, McGraw
Hill.
• Mechanical Measurements and Metrology by R. K. Jain, Khanna Publishers.
• https://nptel.ac.in/courses/112/104/112104250/
• https://www.youtube.com/watch?v=V9NP5_TiU8U&t=92s
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Thank You.
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