Gauge in Measurement Instruments | Types, Examples, PDF

What is a Gauge in Measurement?

→ Gauge refers to a standard or device used to determine the dimensions.

→ It is either a measurement system or a tool that helps determine specific properties like size, pressure, or capacity.

→ A gauge is an important measuring device in the field of design engineering.

→ It provides dimensional information and it is also called inspection tools.

→ Most of the gauges are mainly used to measure the dimensions that are less or greater than defined standards.

→ In other words, we can say that they are used to check whether the dimensions are within the tolerance or out of the tolerance.

→ Gauges can be operated electrically or mechanically.

Table of Contents:

• What is a Gauge in Measurement?
• Classification of Gauges
• Types of Gauges in Measurement
• Why Gauges are needed?
• Guidelines For Using the Gauges
• Examples of Gauges
• Benefits
• Conclusion

Classification of Gauges:

→ Gauges are divided into two categories.

⏩Two categories of gauges are:

1. Standard
2. Non-Standard

01. Standard:

→ If the gauge is the exact copy of the mating part of the component and used to measure that mating part then it is known as Standard Gauge.

→ It is used to check the mating part dimensions.

→ They are widely used for checking the limit of the dimensions of the part such as lower limit or higher limit.

→ They are also known as "Go" and "No-Go"

→ Examples: Ring, Plug, Thread gauge, etc...

02. Non-Standard:

→ If it is difficult to measure some dimensions of the part.

→ Also, it is not possible to measure with the standard go and no-go gauge.

→ Then we need to use some relative reference to measure the product which is called a non-standard gauge.

→ Examples: Checking fixtures, Temples, etc...

➡️ Sample Presentation File

➡️ WhatsApp Us to Get this Presentation Bundle

➡️ Mail us to Get this Presentation Bundle

Types of Gauges in Measurement:

→ Gauges are used to check the manufacturing part's dimensions.

→ Sometimes they are used with scale and sometimes without scale.

→ They do not indicate the actual value of the inspected dimension on the parts.

→ A clear distinction between measuring instruments and parts is not always observed.

→ In this condition we can use gauges for measurement.

→ Gauges are an important part of the Measurement System Analysis Study.

⏩Gauges are used to measure different characteristics such as:

• Thickness
• Pressure
• Radius
• Size
• Diameter
• Distance between two point
• Wind Speed, etc.

→ Based on the application the types of gauges classified.

⏩Different Types of Gauges are:

• Pressure
• Temperature
• Speed
• Level
• Flow
• Electrical
• Force and Torque
• Specialty Gauges

Why Gauges are needed?

→ Gauges are essential tools used to measure and display various characteristics.

→ They are important in different fields such as manufacturing, automotive, healthcare, aviation, etc.

⏩Key Reasons why gauges are needed:

• Monitoring Conditions
• Ensuring Safety
• Accuracy and Control
• Performance Monitoring
• Preventing Equipment Damage
• Regulatory Compliance
• Inter-changeability of parts
• Smooth Assembly

Guidelines For Using the Gauges:

→ Ensure the selection of the correct gauge.

→ Do not use it as a hammer, this will cause deformation.

→ Do not tamper or modify the gauge unless performed by trained personnel.

→ Avoid any hard/sharp object coming in contact with the gauges, this will cause a dent/scratches on the surface.

→ Do not force it inside the hole to be measured, this will cause fast wear and damage.

→ Let the gauges enter the hole with their own weight.

→ After usage, grease/oil should be applied and kept in a proper place.

→ Use a gauge with defined guidelines.

→ Periodically calibrate or validate the gauge to maintain accuracy.

→ Before use, confirm that the gauge is free from physical damage, corrosion, dirt, dust, and leaks.

→ Never expose the gauge to pressures, temperatures, or loads beyond its rated capacity.

→ Adhere to the specific guidelines provided by the gauge manufacturer.

→ Keep logs of calibration, maintenance, and inspection for compliance and troubleshooting.

Examples of Gauges:

→ Different types of gauges are designed to measure different parameters.

→ Now we learn about the most commonly used different gauges with examples.

⏩Msot Commonly used Gauges are:

• Feeler
• Bore
• Depth
• Angle Plate
• Dial or Dial Indicator
• Thread Pitch

01. Feeler:

→ A feeler gauge is used to measure clearance between the mating surfaces.

→ They are manufactured in the form of a bunch of blades using steel.

→ They are made of 0.3 mm to 1 mm thickness and 10 mm long.

→ To measure the size of clearance, one or two blades are inserted in between the contacting surfaces, until an exact blade is found.

→ They are a bunch of fine thickened steel strips with a marked thickness which are used to measure gap width or clearance between the mating surface.

02. Bore:

→ Bore gauges are precision instruments used to measure the inside diameter (ID) of holes, cylinders, or bores.

→ They are essential tools in machining, manufacturing, and quality control.

→ They ensure that the components meet exact specifications.

→ A bore gauge is either analog or digital.

03. Depth:

→ A depth gauge is a precision measuring tool used to measure the depth of holes, slots, grooves, or other internal surfaces of an object.

→ It ensures that components meet specific dimensional requirements.

→ It is used in various industries, such as manufacturing, machining, and construction.

→ It can be of a scale, dial, or digital type.

04. Angle Plate:

→ It is a right-angle plate or tool used to measure the true right angle of two objects joined together.

→ An angle plate is a precision engineering tool used in machining, metalworking, and inspection tasks.

→ It serves as a fixture or reference surface to hold workpieces at precise angles.

→ Generally it is used to hold the workpiece at 90 degrees relative to a machine table or another surface.

05. Dial or Dial Indicator:

→ A dial indicator is a precision measuring instrument used to measure small linear distances, deflections, or variations in surfaces.

→ It is commonly used in machining, metalworking, and quality control to ensure accuracy and precision in components.

→ Analog and Digital dial indicators are available for measurement.

06. Thread Pitch:

→ It is used to measure the pitch and diameter of the thread.

→ Thread pitch is also known as screw pitch gauge or thread gauge.

→ It measures the internal threads of nuts and brushes.

→ Ring thread gauges check the external thread of bolts and screws.

07. Gauge Block:

→ It is also known as a slip gauge or Jo block and it is very precise.

→ They are precision tools used to calibrate and measure linear dimensions with extreme accuracy.

→ They are widely used in engineering, machining, and metrology.

→ It was Invented in 1896 by Swedish machinist Carl Edvard Johansson.

→ They are used as a reference for the calibration of measuring instruments such as micrometers, vernier calipers, sine bars, dial indicators, etc.

08. Ring:

→ A ring gauge is a fixed gauge that is used for measuring the external diameters of cylindrical objects.

→ They are made of thermally resistant steel for greater strength and stability.

→ It is used for "go" and "not go" purposes.

→ They are made with a variety of tolerance grades.

→ Its inside diameter is finished as per tolerance and is used for checking the external diameter of a cylindrical object.

→ They are used for comparative gauging as well as for checking, calibrating, etc.

09. Ruler and Scales:

→ Rulers and scales are used to measure lengths and other geometrical parameters.

→ They can be a single steel plate or a flexible tape type.

→ It is used for measuring straight lines, measuring distances, and drawing precise marks.

→ It is a fundamental tool in various fields, including education, engineering, drafting, and construction.

10. Vernier Caliper:

→ Vernier caliper is a precision instrument used to measure a small distance with high accuracy.

→ It has two different jaws to measure the outside and inside dimensions of an object.

→ It can be an analog or digital type of instrument.

→ Vernier is more accurate than the ruler or scale.

→ It can measure external dimensions, internal dimensions, and depths.

→ Vernier is a versatile instrument and is used in various applications such as for various engineering, machining, and quality control tasks.

11. Micrometer:

→ It is a fine precision tool that is used to measure small distances and is more accurate than the vernier caliper.

→ It is a precision measuring instrument used to measure small dimensions with extremely high accuracy.

→ It is commonly used in mechanical engineering, machining, and quality control to measure components such as shafts, wires, and thicknesses.

12. Plug Gauge:

→ A plug gauge is used for measuring the shape and size of a hole and it comes with different diameters.

→ They help measure the inside diameters of drilled holes or holes that are machined into a manufactured part, component, or assembly.

→ To check the lower limit of the hole, a No-go gauge is used and for the upper limit of the hole, a Go-plug is used.

13. Taper Gauge:

→ They are the measuring devices used to measure the width of gaps, grooves, hole diameter, and the inner diameter of the pipe.

→ A taper gauge is made of both plug and ring styles.

→ It has a polycarbonate or brass case or cap for easy carrying.

14. Snap Gauge:

→ These are mainly used for checking the shafts.

→ Snap gauges are also known as gap gauges.

→ It is a form of Go/no-go gauge used for both cylindrical and non-cylindrical parts.

→ The Go snap is used with a higher limit of the shaft and the No-go snap is used with a lower limit of the shaft.

15. Caliper Gauge:

→ It is similar to a snap gauge and is used to check the inside and outside dimensions of the product.

→ One end of the caliper gauge is used to check the internal dimensions.

→ And the other end is used to check the outer dimensions.

Benefits:

• High Precision and Accuracy
• Improved Quality Control
• Increased Efficiency
• Cost Savings by Defect Reduction
• Standardization and Versatility
• Enhanced Measurement Range
• Ease of Use as per Application
• Compliance with Industry Standards
• Increased Product Lifecycle

Conclusion:

→ The use of gauges provides significant benefits in manufacturing and quality control.

→ It helps us to improve precision, consistency, and efficiency.

→ They are used to reduce waste and errors.

→ They are essential for maintaining product quality, meeting tolerances, and enhancing the overall reliability of production processes across various industries.