Measurement devices. Kalevi Aaltonen, Aalto University

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1 Measurement devices Kalevi Aaltonen, Aalto University

2 Production engineering measurements, measuring uncertainty, measurement accuracy = statistical mathematical methods

3 The pyramid of accuracy Material standards Gauge blocks Reference spheres Ring gauges A c c u r a c y descending Micrometers, CMM, Pin gauges Calipers, Height gauges Steel rules Gauges

4 History of measurements Hand held measuring devices caliper micrometers gauge blocks dial indicators Measuring machines contour tracers roundness testers vision measuring systems coordinate measuring machine

5 History of measurements MANUFACTURING METHODS AND MEASURING METHODS WERE DEVELOPED SIDE BY SIDE LEONARDO DA VINCI S ENGINEERING LATHE SKETCH FROM 1500-CENTURY.

6 History of measurements MACHINETOOLS DEVELOPED MORE ACCURATE MORE PRECISE MEASURING EQUIPMENT WERE PRODUCED THE CHICKEN OR THE EGG CAUSALITY DILEMMA ELI WHITNEY S MILLING MACHINE DECADE

7 History of measurements CONSEPT OF INTERCHANGEABLE COMPONENTS AND PARTS WAS INVENTED ARMS INDUSTRY WAS THE FORERUNNER IN USA COLT REVOLVER; SPARE PARTS IN THE COUNTRYWIDE SERVICE SYSTEM

8 History of measurements FIRST UNIVERSAL BORING MILL PRECISE AXIS MOVEMENT BELT DRIVE FROM LINE SAFT 1896

9 History of measurements MICROMETERS WERE THE FIRST HAND HELD PRECISION MEASUREMENT EQUIPMENT JAMES WATT (1772) INVENTED THE PEDESTAL MICROMETER JEAN LAURENT DEVELOPED PALMER S MICROMETER (1848)

10 History of measurements W. SMITH S MICROMETER (1876) BROWN & SHARP S MICROMETERS (1877) MODERN MICROMETER

11 History of measurements YEAR 1848 PROPRIETARY (PATENT PENDING) SYSTEM PALMER MICROMETER

12 History of measurements SVEDES DEVELOPED GAUGE BLOCKS AND MEASURING GAUGES C E JOHANSSON 1890 GAUGE BLOCKS ARE THE FOUNDATION OF ALL PRECISION MEASUREMENTS!

13 History of measurements Eskilstuna Tekniska Söndags- ochaftonskola, 1885

14 History of measurements IN HIS WORLD WIDE ROADSHOW CARL EDVARD JOHANSSON GAVE LECTURES HOW TO USE THE GAUGE BLOCKS AND HOW TO ENSURE CALIBRATION OF MEASURING EQUIPMENT

15 History of measurements DURING THE FIRST WORLD WAR MEASURING MASTER PIECES WERE ESSENTIAL NBS (NATIONAL BUREAU OF STANDARDS, NOW NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)) MANUFACTURED THE STANDARD MASTER PIECES

16 History of measurements NUMERICALLY CONTROLLED MACHINE TOOLS MADE POSSIBLE TO MACHINE MORE ACCURATE AND PRECISE PARTS AND COMPONENTS

17 Hand-held measuring equipment VERNIER, DIGITAL, AND DIAL CALIPERS AND MICROMETERS ARE THE MOST IMPORTANT HAND-HELD MEASURING EQUIPMENT ACCURACY: 0,01 0,2 mm CALIBRATION IS IMPORTANT!

18 Caliper

19 Caliper

20 Caliper

21 Caliper

22 Caliper JAWS FOR INSIDE MEASUREMENT BODY SCALE DEPTH ROD (PROBE; BLADE) JAWS FOR OUTSIDE MEASUREMENT LOCK SCREW AND THUMB VERNIER SCALE LEVER

23 Digital Caliper

24 Caliper DIGITAL CALIPER AND DEEPNESS CALIPER

25 Caliper

26 Caliper

27 Caliper

28 Caliper

29 Caliper ABBE S PRINCIPLE: - CALIPER???? - MICROMETER, OK

30 Micrometer MEASURING FACES ANVIL SPINDEL SLEEVE SPINDLE LOCK MEASUREMENT STRIPE FRICTION THIMBLE FRAME ISOLATION PLATES THIMBLE SCALE TRIGGER DISPLAY

31 Micrometer EXTENSION ADAPTOR LOCKING LOCKING SPRING MEASURING FACE MEASUREMENT STRIPE FRAME BUSHING SCALE THIMBLE ROD TYPE INSIDE MICROMETER

32 Micrometer THREE-POINT BORE MICROMETER SUITS WELL TO MEASURE HOLE DIAMETERS AND GEOMETRICAL SHAPE ERRORS LIKE ROUDNESS ERROR

33 Micrometer DIGITAL MICROMETER

34 Micrometer THREAD- DISC- AND DEPTH MICROMETER

35 Micrometer MICROMETER HANDLE WITH TRIGGER HELPS AND SPEEDS UP HOLE MEASUREMENTS

36 Micrometer MICROMETER CALIBRATION RINGS, CONES, DISCS AND GAUGE BLOCK HOLDER

37 Micrometer MICROMETER CALIBRATION SET (GAUGE BLOCKS AND OPTICAL PARALLES)

38 Go and no go gauges HOLE AND SAFT GO AND NO GO GAUGES RATIONALIZE MEASUREMENT IN MASS PRODUCTION

39 Go and no go gauges WITH THREAD GAUGES YOU CAN ENSURE BOTH THE MEASURES, TOLERANCES AND FUNCTIONALITY OF THE THREAD

40 Go and no go gauges SHAFT GAUGE HAS GO AND NO GO MEASURING FACES

41 Go and no go gauges GAUGES MAKE MEASUREMENTS MORE PRODUCTIVE AND EASY TO PERFORM

42 Gauge blocks GAUGE BLOCKS ARE THE FOUNDATION OF THE MODERN CALIBRATION AND PRECISION MEASUREMENTS. THE INVENTOR OF THE GAUGE BLOCKS WAS C. E. JOHANSSON.

43 Gauge blocks GOOD OLD TIMES WHEN EVERYTING WAS BETTER!

44 Gauge blocks GAUGE BLOCKS IN ESKILS- TUNA GUN FACTORY 1890

45 Gauge blocks

46 Gauge blocks CALIBRATION OF GAUGE BLOCKS AND CHECKING THE PARALLELISM OF MEASURING SURFACES

47 Gauge blocks GAUGE BLOCK TOLERANCES ACCORDING TO STARDARD ISO 3650

48 Gauge blocks ACCESSORIES AND ATTACHMENTS TO GAUGE BLOCK MEASURING DEVICE

49 Gauge blocks GAUGE BLOCKS AND STONE MEASURING DEVICES MUST BE HANDELED WITH CARE; SERVICE AND MAINTENANCE CAREFULLY

50 Gauge blocks SINE BAR TO MEASURE ANGLES WITH GAUGE BLOCKS

51 Dial indicators DIAL INDICATORS, LEVER INDICATORS AND DIAL COMPARATORS ARE MOST COMMON HAND-HELD MEASURING DEVICES.

52 Dial indicators DIAL INDICATORS WITH DIFFERENT KIND OF AUXILIARY DEVICES ENABLES HOLE MEASUREMENT

53 Dial indicators PRECISION LEVER INDICATOR IS EASY TO USE. NOTE THE COSINE ERROR OF THE STYLUS.

54 Dial indicators

55 Dial indicators BASE OF THE DIAL INDICATOR MUST BE RIGID AND SOLID. MAGNETIC BASES ARE EASY TO USE

56 Dial indicators CALIBRATION OF THE DIAL INDICATOR WITH GAUGE BLOCK

57 Dial indicators MOST ACCURATE DIAL INDICATORS ARE CALLED DIAL COMPARATORS. BECAUSE OF SHORT MEASURING RANGE AND HIGH PRECISSION THEY ARE SUITABLE FOR HIGH ACCURACY MEASUREMENTS.

58 Dial indicators ELECTRICAL AND DIGITAL DIAL INDICATORS COMPLETE TRADITIONAL MECHANICAL DIAL INDICATOR MARKET

59 Dial indicators CONVENTIONAL DIAL INDICATOR, INDICATOR WITH EXTRA LONG STYLUS AND WATERPROOF DIAL INDICATOR

60 Dial indicators

61 Dial indicators MEASURING GROOVES AND THICKNESS REQUIRES SPECIAL DIAL INDICATORS

62 Dial indicators MEASURING THE RUNOUT OF A CAR BRAKEDISC WITH DIAL INDICATOR

63 Dial indicators MEASURING THE RUNOUT OF THE STEEL SAFT WITH DIGITAL DIAL INDICATORS

64 Dial indicators DIAL INDICATOR WITH TWO POINT MEASURING HEAD ENABLES MEASUREMENT OF DIAMETERS IN DEEP HOLES

65 Dial indicators THE STRUCTURE OF THE MEASURING DEVICE ASSIGNS THE ACCURACY NOT THE NUMBER OF DECIMALS IN READ-OUT

66 Dial indicators DIAL COMPARATOR SET UP MUST BE RIGID. DEVICE IS A MASTER PIECE OF PRECISION ENGINEERING.

67 Dial indicators PRECISION LEVER INDICATOR

68 Dial indicators COSINE ERROR OF THE PRECISION LEVER INDICATOR

69 Measuring devices Precision engineers square frame levels for high accuracy levelling

70 Gauge blocks CERAMIC GAUGE BLOCKS FOR HIGHEST ACCURACY. DESIGNED SPECIALLY FOR LABORATORIES, TEST ROOMS, CHECK MEASURING DEPARTMENTS, WHERE THE GAUGE BLOCKS AND OTHER VERY ACCURATE GAUGES ARE CALIBRATED EXPENSIVE, WEAR RESISTANT

71 Gauge blocks

72 Gauge blocks CERAMIC GAUGE BLOCK SET FOR CALIBRATING MICROMETERS PRICE:

73 Measuring devices MEASURING DEVICES MUST HAVE PROPER STORAGE BOXES AND GREASING WITH PROTECTION VASELINE IS IMPORTANT TO PREVENT RUSTING

74 Measuring devices ADJUSTABLE ANGLE BLOCK SET

75 Granite datum surface MEASURING PARALLELISM AND FLATNESS ON GRANITE SURFACE PLATE

76 Gauge blocks GEOMETRICAL FLATNESS MEASUREMENT RESULTS; GRAPHICAL ILLUSTRATION; UPPER AND LOWER TOLERANCE LIMITS INCLUDED

77 LESSONS TO LEARN: History of measuring is a long and interesting story Hightec products require hightec measuring devices and machines Calibers, micrometers, gauge blocks, dial indicators are commonly used hand held measuring equipment Wireless data transfer of hand held measuring devices gives new opportunities to create measurement protocols Measurement devices are expensive and sensitive; they require good care and maintenance Vita, si scias uti, longa est, Seneca (Life, if well lived, is long enough)

78 Acta est fabula. Plaudite! (Play is over. Applaud!) (emperor Augustus) Professor Kalevi Aaltonen Aalto University 78

2 - Machining Fundamentals Measurement. Manufacturing Processes - 2, IE-352 Ahmed M El-Sherbeeny, PhD Spring-2015

2 - Machining Fundamentals Measurement Manufacturing Processes - 2, IE-352 Ahmed M El-Sherbeeny, PhD Spring-2015 Learning Objectives Measure to 1/64 (.5 mm) with a steel rule Reading an Inch-based Vernier