MINI PROJECT:

STUDY OF PLAIN PLUG GAUGE

JNTUH COLLEGE OF ENGINEERING

SULTANPUR
DOMITILA DESAI
M SAI KOUSHIK
ABSTRACT:
Gauges are used in manufacturing process to check whether the
component can be accepted or rejected. In this process the
component while being manufactured is inspected with different
types of gauges depending on the type of the component.In this
report we deal with the types gauges, the principle behind the
designing of gauges , material used for manufacturing gauges and
studying of plain plug gauge for 36H7 hole.
What are gauges?
• Gauge is an inspection tool used to check product dimension
with reference to it’s maximum and minimum acceptable
limits.
• It is generally used to segregate acceptable and non
acceptable product in mass production.
• Their main function is to check whether or not the product
lies within the zone specified by the designer.
Types of gauges:
According to use :
• Standard gauge
• Limit gauge
• According to application :
• Workshop gauge
• Inspection gauge
• Master gauge
• According to form:
• Plug gauge for checking hole
• Snap and Ring gauge for checking shafts.
Gauges commonly used in
production work:
• Plug gauges
• Ring gauges
• Taper gauges
• Snap gauges
• Form gauges
• Feeler gauges.
Plug gauge Ring gauge Taper gauge
Form gauge Feeler gauge Snap gauge
Limit gauging:
• In this we use GO and NO GO gauges - which are made to the limit
sizes of the work to be measured.
• The main function of limit gauging is to determine whether the actual
dimensions of the work are within or outside the specified limits.
• There are two types of limit gauges : 1.double-ended
2.progressive
Taylor’s principle:
• For defining the conditions for GO gauge and NO-GO gauge we use
Taylor’s principle.
• According to Taylor’s principle GO gauge should satisfy maximum
material condition and NO-GO gauge should satisfy minimum material
condition.
Plain plug gauges:
These gauges are used for gauging holes and are commonly made
up of hardened wear resistant steel on gauging surface and the
handles are made up of light metal alloy steel.
Gauge Tolerance:
• Like any other component even gauges cannot be manufactured to
exact dimensions so some tolerances are given to the gauges to
accommodate the dimensional variations which arise due to
limitations of manufacturing.
• Normally gauge tolerance is taken as 10% of work tolerance.

Wear Allowance:
• In the NO GO gauge ,the gauge does not fully engage with the work
and therefore goes under minimum wear, where as in the GO gauge
the gauge passes through the component and the surface often gets
rubbed against the surface of the work piece thereby having wear.
• Therefore wear allowance is provided for GO gauge.
• The wear allowance is taken as 10% of gauge tolerance.
Material for gauges:
Requirements:
• Hard and wear resistant.
• Corrosion resistant.
• Easily machinable.
• Low coefficient of thermal expansion to avoid temperature effects.
OHNS steel :
• Is typically used in making gauges where alloy steels cannot provide
sufficient hardness, strength and wear resistance.
• It is general purpose tool steel that is used in making gauges.
• Chemical composition: 0.94% carbon, 1.2% manganese, 0.3% silicon,0.5%
chromium and 0.15% vanadium.
Design of Plain Plug Gauge for 36H7
hole:
1.Fundamental Tolerance:
For H7 the fundamental tolerance is 16i from the standard tolerance
grade of ISI919 part 1
We know that i = 0.453 3√D + 0.001D
Here,36 lies between the range 30 to 50 ,therefore
D = √30×50 = 38.7298mm.
Now i= 0.453√(38.7298) + 0.001(38.7298)
i= 1.571µm.
16i= 16(1.571µm) =0.02512mµ≈0.025mm.
2. Limits of hole:
The fundamental deviation for the hole if zero as the H lies on the basic
line.
The tolerance is 0.025mm.
Hence , the lower limit is 36mm and the upper limit is 36.025mm.
3. For plug gauge of 36H7 hole:
The gauge tolerance is taken as 10% of work tolerance , therefore
Gauge tolerance = 10% of 0.025
= 0.0025mm.
The wear tolerance is taken as 10% of gauge tolerance, therefore
Wear tolerance = 10%of 0.0025
= 0.00025mm.
4. GO plug gauge side:
Lower limit= basic size + wear tolerance
=36+0.00025
=36.00025mm.
Higher limit=basic size +wear tolerance +gauge tolerance
=36+0.00025+0.0025
= 36.00275mm.
Therefore for the GO gauge side the limits are 36.00025mm and
36.00275mm.
5. Limits for NO GO gauge side:
Lower limit= basic size + fundamental tolerance
=36+0.025
=36.025mm.
Higher limit = basic size + fundamental tolerance + gauge tolerance
= 36+0.025+ 0.0025
=36+0.0275
=36.0275mm.
Therefore the NO GO gauge side limits are 36.025mm and 36.0275mm.
Conclusion:
• The main function of gauges is to check whether a given component
lies in the permissible limits given by the designer or not.
• Limit gauges are designed on the basis of maximum and minimum
limits of the component needed to be checked.
• Taylor’s principle says that GO gauge should be designed for the
maximum material condition, whereas NO GO gauge should be
designed for the minimum material condition.
• Plain plug gauges are used to inspect the holes or hollow shaft.
• The material which is most widely used for making gauges is OHNS
steel.