Description
A gauge block is a block of metal or ceramic with two opposing faces ground precisely flat and parallel, a precise distance apart. Standard grade blocks are made of a hardened steel alloy, while calibration grade blocks are often made of tungsten carbide or chromium carbide because it is harder and wears less. Gauge blocks come in sets of blocks of various lengths, along with two wear blocks, to allow a wide variety of standard lengths to be made up by stacking them. The length of each block is actually slightly shorter than the nominal length stamped on it, because the stamped length includes the length of one wring film, a film of lubricant which separates adjacent block faces in normal use. This nominal length is known as the interferometric length.
In use, the blocks are removed from the set, cleaned of their protective coating (petroleum jelly or oil) and wrung together to form a stack of the required dimension, with the minimum number of blocks. Gauge blocks are calibrated to be accurate at 68 °F (20 °C) and should be kept at this temperature when taking measurements. This mitigates the effects of thermal expansion. The wear blocks, made of a harder substance like tungsten carbide, are included at each end of the stack, whenever possible, to protect the gauge blocks from being damaged in use.
As a general principle, machinists and toolmakers try to use a stack with the fewest number of blocks possible, because avoiding stacking the blocks avoids stacking their size errors cumulatively. Thus a stack totaling .638 that is composed of 2 blocks (a .500 block wrung to a .138 block) is preferable to a stack also totaling .638 that is composed of 4 blocks (such as a .200, .149, .151, and .138 all wrung together). However, the stacked error is still small enough that it is often negligible in all but the most demanding contexts of use; so "violations" of this principle are usually not a problem when necessary. In a busy shop, some of the blocks will be in use elsewhere, so one creates a stack from the blocks available at the time. Typically the few millionths of an inch difference will not be detectable, or matter, in the context. Contexts demanding ultimate precision are rarer and more expensive.
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