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In today’s rapidly changing manufacturing landscape, the demand for efficiency and precision in measurement processes has led to the creation and use of model-based measurements. This shift has been driven by things like the increasing emphasis on quality control, the diversification of the parts and components being measured, the complexity of global supply chains, and shortened product lifecycles. As the industry moves from traditional 2D drawings to more advanced 3D annotated models, an important question arises: “Can model-based measurements truly revolutionize CMM (Coordinate Measuring Machine) programming processes and bring about substantial improvements?”

The Rise of Model-Based Measurements

Model-based measurements involve a novel approach that leverages 3D CAD (Computer-Aided Design) models and Product Manufacturing Information (PMI) to automate the generation of measurement programs. This transformation works by offering the following: 

• Simplifying programming complexities
• Reducing human error
• Significantly cutting down programming time

Unlike the conventional method – where manual programming could consume hours – the creation of automatic measurement program generation software has reduced these tasks down to mere minutes.

Industry Catalysts for Change

The aerospace and defense sectors have emerged as pioneers in adopting model-based measurements. Industry giants like Boeing, Lockheed, Raytheon, Ford, and Deere – alongside branches of the U.S. military – advocated for the integration of automatic measurement program generation software as part of their digital product definition strategies. This has prompted some original equipment manufacturers in the Department of Defense supply chain to embrace model-based definitions (MBDs). This further validates the potential of this approach.

Understanding Model-Based Definition (MBD)

Model-based definition involves employing 3D annotated models and associated data elements to define a product; clearly, a far cry from traditional drawings. While MBDs have been employed in product definition, they’re now being used for quality assurance purposes. This presents a more efficient way to compare CMM results with CAD models. This is particularly the case in industries like commercial aerospace, defense, and even the medical device market.

Benefits Involving Efficiency and Precision

The transition to MBD provides several tangible benefits to manufacturers seeking to simplify their measurement processes:

• Easier Processes: MBD eliminates the need for a convoluted 3D-to-2D-to-3D workflow. It simplifies the process to direct 3D CAD-to-3D CNC CMM programming. This leads to major reductions in programming time.
• Reduced Manufacturing Costs: The investment in automatic measurement program generation software is offset by the increase in productivity. The time savings can be as high as 95% (compared to traditional drawing-based methods).
• Improved Traceability: The direct read of metadata, features, and characteristics from the CAD model lessens the risk of misinterpretation (which could occur if relying on drawings).
• Optimization and Flexibility: MBD provides quick changes to plan parameters and CMM configurations. This facilitates adaptability to changing needs.
• Workflow Automation: Some projects have already achieved full automation. Machines communicate flawlessly, while human oversight assures optimal performance.
• Improved Productivity: Automation reduces the burden of low-level programming tasks on CMM planners. This allows them to focus on higher-value activities.

Mechanics of Automatic Measurement Program Generation Software

The core of automatic measurement program generation software is in its ability to sidestep traditional drawing-based methods. It directly generates and executes a model-based workflow. The process involves importing an MBD, applying rules that align with the configured CMM, and automatically generating a part program. Optimizations refine the program to minimize probe changes and path length. This helps to guarantee efficiency and precision.

Selecting the Right Metrology Software

When thinking about metrology software to support model-based quality control, several key considerations deserve your attention:

• Cost Efficiency: Despite the initial investment, the gains in programming productivity and just-in-time program generation can offset the costs.
• CAD Compatibility: Software should easily read, organize, and work with CAD models.
• Global Collaboration: The ability to work across various locations globally and share measurement plans and configurations is important.
• Training and Support: Look for software that provides effective training with a shorter learning curve for model-based measurements.
• Customizable Reporting: The software should allow customization to generate complete reports or focus on specific features.
• Versatility with CMM Systems: Compatibility with coordinate measurement systems provides flexibility and adaptability.

Embracing the Future of Measurement Programming

The integration of model-based measurements holds the potential to revolutionize CMM programming processes. This approach not only eases workflows, reduces costs, and improves traceability but also opens the door to a new era of automation and efficiency. As industries recognize these advantages, the adoption of model-based measurements is poised to become a cornerstone of modern manufacturing.

Discover Willrich Precision Instruments – A Tailored Precision Solution

Our Willrich Precision Instruments range encompasses personalized gaging answers, spanning functional fit gauges, meticulous design and construction, automated metrology cells, and seamless shop floor metrology fusion. Our adeptness extends from fundamental measurement requirements to intricate challenges. Trust us with your needs – whether conventional or intricate – and allow our dedicated team to explore and evaluate various product options, guaranteeing optimal resolutions for every scenario. Reach out to Willrich Precision Instruments now at 866-945-5742 or drop us an email at [email protected].

Ceramic ring gages are important measuring tools used in different industries. They are accurate, long-lasting, and can resist wear and corrosion. These gages are made of advanced ceramic materials, like zirconia or alumina. They work better than metal gages and are great for precise and reliable measurements. We’ll talk more about ceramic ring gages in this article, explain what they are, their unique properties, and which industries use them.

Understanding Ceramic Ring Gages

Ceramic ring gages are tools for measuring cylindrical parts like shafts or pins. They help ensure the dimensions of external features are correct. They check if measuring devices are correct and make sure parts meet exact standards. Ceramic materials in ring gages have benefits compared to metal gages. They resist wear more, and stay stable in size and temperature. Ceramic ring gauges work well in industries like automotive, aerospace, and manufacturing. They give precise and steady measurements that are important in keeping product quality and process efficiency.

• Calibration and Verification

Ceramic ring gages are mainly used to check and confirm measuring tools. These tools are used to check if devices like micrometers, calipers, and CMMs are accurate. Technicians and engineers use them as reference standards. Users can check if their measuring device is accurate and calibrated by comparing its measurements to the known dimensions of a ceramic ring gage.

Ceramic ring gages work great for calibration since they stay the same size and do not wear easily. They stay the same shape and size when temperatures and humidity change. This makes them good for calibration.

A ceramic ring gage size 0.8000 inch Class XX Ceramic Master ID Gage Ring, 5mm in length is often used to calibrate certain Keyence video measuring machines.  These rings can be purchased thru Willrich.com

• Dimensional Inspection

Ceramic ring gages are used to check the dimensions of manufactured parts. They help ensure the parts are the right size. This checks the size of round things like shafts, pins, and bushings. It makes sure they fit the right measurements for use in machines and other things.

Ceramic ring gages are great for this purpose because they are accurate and last a long time. This makes them a reliable option for consistent measurements. They can be used in different environments due to their resistance to corrosion. For example, they can be used in places with high humidity or corrosive materials.

• Quality Control and Process Monitoring

Ceramic ring gages are critical for quality control and process monitoring. They make sure that parts and components meet quality standards. Manufacturers can maintain product quality by checking part dimensions with ceramic ring gages, which help identify any deviations from specified tolerances. Then, necessary adjustments can be made to their processes regularly.

Ceramic ring gages are durable and reliable. They are great for quality control and process monitoring. They can withstand frequent use and tough conditions.

• Thread and Spline Inspection

Ceramic ring gages can check threaded and splined parts to make sure they meet the right size and can be used in assemblies. This application uses a ring gage that has internal threads or splines. They match the outer features of the part that needs to be checked. Users can check thread or spline tolerances by putting the component in the ring gauge. This ensures proper function when parts mate.

Ceramic ring gages are great for this job. They last a long time and stay accurate, even in tough environments.

Calibration is very important for many industries. It helps measuring instruments and devices be accurate and consistent. Gages are important tools used for measuring size, shape, and angles. They set a standard for calibration.

Technicians and engineers use them to check if measuring instruments are accurate. This helps maintain the quality and reliability of their measurements. Steel and ceramic gauges are often used for calibration. Each material has unique properties that can impact the gauges’ performance and lifespan. Each has its own advantages and disadvantages which make them popular options.

We will talk about the good and bad points of using steel and ceramic gages for calibration. You can make a smart choice based on what you need to measure and your working conditions.

Advantages of Steel Gages

Steel gages offer several benefits for calibration applications, including:

• Durability: Hardened steel gauges are tough and can handle heavy use in industrial settings. They are a good option for areas where the gages may face a lot of damage.
• Affordability: Steel gages are cheaper than ceramic ones. Businesses prefer them to minimize their costs. The cost advantage can be big when buying lots of gages or replacing old or broken ones.
• Versatility: Steel gages come in many sizes, shapes, and types, so they can be used for different calibration jobs. Users can choose the best gage for their measurements because of its versatility.

Disadvantages of Steel Gages

Despite their benefits, steel gages also have some drawbacks, such as:

• Susceptibility to Wear: Steel gauges are tough, but they may wear out if used often with rough materials or frequently. Wearing can cause the gage to change size, which affects calibration accuracy.
• Corrosion: Steel gages can be prone to corrosion, especially in humid or corrosive environments. Corrosion can cause problems with calibration by changing the size and surface. This can make it less accurate and reliable.
• Thermal Expansion: Steel gages may be affected by temperature changes. They can expand or contract, which changes their dimensions. The accuracy of calibration can be affected by sensitivity, especially in places where the temperature varies a lot.

Advantages of Ceramic Gages

Ceramic gages offer several benefits for calibration applications, including:

• Wear Resistance: Ceramic gauges are very durable, so they’re good for rough or frequent use. This can mean that the item lasts longer and gives more accurate results.
• Dimensional Stability: Ceramic materials keep their shape and size despite temperature and humidity changes. Ceramic gages are very stable, which makes them good for calibrating things even in places where conditions change.
• Corrosion Resistance: Ceramic gages don’t corrode easily. They are good for places that are humid or corrosive. Steel gages might rust in these places.
• Non-Magnetic and Non-Conductive: Ceramic gages are perfect for calibration in places where electrical or magnetic problems could be an issue. They are non-magnetic and non-conductive.

Disadvantages of Ceramic Gages

Despite their advantages, ceramic gages also have some drawbacks, such as:

• Cost: Ceramic gages cost more than steel gages. This may matter to companies who want to save money on equipment.
• Fragility: Ceramic materials are strong and wear-resistant. However, they are more likely to chip or crack than steel if mishandled or dropped due to being brittle.
• Limited Availability: Ceramic gages may be harder to find than steel gages, especially in unique sizes or styles. It can be harder to get new gages or find ones for specific jobs when they aren’t easy to come by.

Ring gages are important tools in many industries. They help ensure the accuracy and precision of manufactured items. Cylinder-shaped measuring tools are important for quality control, calibration, and inspection. They help check the size of parts and keep product quality high for technicians and engineers. This article will explain ring gages, the different types and how to use them in various applications.

What are Ring gages

Ring gages are tools used to measure the size of cylindrical parts like shafts and pins. Parts are checked to ensure they fit and work properly in assemblies and other uses. Ring gauges come in different materials like steel, ceramic, and tungsten carbide. Each material has its advantages and disadvantages depending on how it is used.

Gauges are important in many industries like cars, airplanes, and factories. They help keep things precise and efficient for good quality products. Understanding the various ring gauges and using them correctly can guarantee precise and reliable measurements, leading to consistent high-quality standards in all your operations.

Types of Ring Gages

Ring gages come in different types, each for a specific use in measuring. These include:

• Plain Ring Gages: Plain ring gages check the size of cylindrical parts. They’re also called cylindrical ring gages or go/no-go gages. These gages have a smooth, round hole and help determine if a part is within the allowed limits. A “go” gage checks the smallest size, while a “no-go” gage checks the biggest size. Technicians can use go and no-go gages to check if a part meets the required tolerances quickly.
• Threaded Ring Gages: Threaded ring gages are tools to check the threads on screws, bolts, and threaded rods. These gages have the same threads as the part being checked. This lets users check if the threads fit the requirements. Threaded ring gages come in go and no-go types. They let you measure the smallest and largest acceptable thread sizes.
• Spline Ring Gages: Spline ring gauges check the splines on gears, shafts, and couplings. These gages have splines that match the part being inspected. This helps check that the splines are within the required limits. Spline ring gages come in go and no-go options, like threaded ring gages. They let users check the smallest and largest possible spline dimensions.
• Adjustable Ring Gages: Adjustable ring gages are handy measuring tools. They can be adjusted to fit a variety of part sizes and tolerances. They are very versatile. These gages can be adjusted by turning the thread to fit the part being inspected. Adjustable ring gages are helpful when inspecting parts with different dimensions. They replace the need for many fixed-size gages.

How To Use Ring Gages

To use ring gages well, you need to know the right techniques and best practices. Here are some key steps to follow when using ring gages:

• Select the appropriate gage type and size: Choose the appropriate ring gage for your measurement task and the part being inspected. You may need to choose between a plain, threaded, spline, or adjustable gauge. Make sure the gage size is the same as part dimensions and tolerances specified.
• Clean the gage and part: Check that both the part and the gage are clean before using a ring gage. Dirt can mess up the measurements.
• Insert the part into the gage:  For plain ring gages, insert the part into the gage, ensuring that it is properly aligned with the bore. To use threaded or spline ring gages: 1. Place the gage on the part. 2. Make sure the threads or splines on the part and gage are aligned. 3. Rotate the part to ensure proper
• Check for proper fit:  For go gages, the part should fit smoothly and easily into the gage without excessive force. For no-go gages, the part should not fit or should only partially engage with the gage. If the part fits both go and no-go gages, it is considered out of tolerance and may need to be reworked or rejected.
• Record the results:  Record the inspection findings. Mention if the part meets the required standard or needs additional attention.

Ceramic pin gauges are important tools used in many industries. They are precise, long-lasting, and used for measuring the size of holes and the distances between them. These gauges are made from strong ceramic materials. They withstand wear, corrosion, and temperature changes. This makes them perfect for tough environments. We will talk about using a ceramic pin gauge. It is a useful measuring tool with many benefits. We will also share practical tips to ensure accurate measurements.

Ceramic pin gauges are precise measuring tools. They are used to measure the size of holes, slots, and other inside parts accurately. Industries like automotive, aerospace, and manufacturing often use them to make precise measurements. This is important for keeping product quality and process efficiency in check.

Using ceramic pin gauges improves measurement accuracy and reliability. They are more durable, and less affected by changes in temperature, deformation, and wear. They can be used in areas with electrical or magnetic issues because they don’t conduct electricity or magnetism. Using a ceramic pin gauge requires knowing how to handle, insert, and read it properly. Accuracy can be affected by other factors too. In fact, ceramic pin gages in below sizes are often used to calibrate a Keyence video measurement system.  Often customers buy .100” class xx ceramic master pins and .8000” class xx ceramic master pins from Willrich Precision to calibrate specific types of Keyence systems

Handling and Preparing the Ceramic Pin Gauge

To get accurate measurements, prepare and handle a ceramic pin gauge correctly. Follow these steps to prepare your ceramic pin gauge for use:

• Inspect the gauge: Make sure the gauge is not damaged before checking it. Look for chips or cracks because they can alter the measurements. If any damage is detected, do not use the gauge and replace it with a new one.
• Clean the gauge: Remove any dirt, grease, or debris from the gauge using a clean, lint-free cloth or compressed air. Contaminants on the gauge are bad. They can make measurements wrong and hurt the gauge or the thing being measured.
• Verify the gauge size: Ensure that the gauge is the correct size for the measurement you need to perform. Ceramic pin gauges come in different sizes, usually from 0.5mm to 20mm in diameter. The gauge size should be clearly marked on the gauge itself or on its storage case.

Inserting the Ceramic Pin Gauge

If you want to accurately measure a hole or feature, follow these guidelines when inserting the ceramic pin gauge.

• Align the gauge: To measure a hole or feature, make sure the gauge is straight and lined up with it. Misalignment can cause inaccurate measurements and may damage the gauge or the part.
• Insert the gauge gently: Insert the gauge slowly and gently into the hole or feature. Be careful not to damage the gauge or the part. Ceramic pin gauges fit tightly in the hole without needing too much force.
• Rotate the gauge: After fully inserting the gauge, gently wiggle it to make sure it’s in place. The gauge needs to touch the hole’s walls for an accurate measurement.

Reading the Ceramic Pin Gauge

To determine the size of the hole or feature being measured, follow these steps:

Carefully take out the gauge from the hole or feature, making sure that you don’t harm the gauge or the part.

• Measure the gauge: Measure the gauge’s largest point with a precise tool like a micrometer. Make sure to calibrate the measuring tool correctly and use the appropriate technique for that tool.
• Determine the size: To make it clearer, measure the diameter and then subtract the nominal size of the gauge, which is marked on either the gauge or its storage case. This will help you determine the size of the hole or feature. If you use a 10mm ceramic pin gauge and the diameter is 10.02mm, the hole or feature is 0.02mm bigger than 10mm.

Keyence’s IM Series Instant Measurement systems are devices that help industries improve inspection and measurement efficiency. They include the IM-6225, IM-7020, and IM-7030 models. Advanced optics, high-resolution cameras, and powerful software work together in these systems. They capture and analyze images of parts, giving quick and precise measurements of dimensions. To get the most accurate measurements from these systems, you need to use the right fixtures to hold the parts in place during inspections. Let’s talk about the top fixtures for Keyence IM-6225, IM-7020, and IM-7030. We’ll explain their features and benefits in various industrial uses.

Universal Fixturing Solutions

Fixturing solutions work for many part sizes and shapes. They are an excellent fit for Keyence IM Series systems in different industries. These tools have parts that can be changed easily to fit different inspection requirements. They include adjustable components like clamps, bases, and supports.

Modular Fixturing Systems

Modular fixtures are widely used with Keyence IM Series devices. They are versatile, customizable, and a popular choice. The systems have a base plate and different parts like clamps, supports, and locators. You can put them together fast to make a custom fixture for any part you need. The design is modular, so you can quickly change it for different parts or inspections. It’s easy to adapt. Some modular fixturing systems that work with Keyence IM-6225, IM-7020, and IM-7030 are popular.

• R&R Fixtures
• Renishaw QuickLoad™ Corner (QLC)
• Phillips Precision’s Inspection Arsenal®

Vacuum Fixturing Systems

Vacuum fixtures use suction to hold parts during inspection. They’re great for fragile or intricate parts that are hard to hold with typical clamps or supports. Vacuum systems have a base and vacuum cups. The cups can be changed to fit various shapes and sizes of parts. Vacuum fixturing systems compatible with Keyence IM-6225, IM-7020, and IM-7030 include:

• VacuGrip™ Vacuum Fixturing Systems
• Pierson Workholding’s SmartVac II™

Custom Fixturing Solutions

Custom fixturing solutions for Keyence IM-6225, IM-7020, and IM-7030 are important for precise and efficient inspections and measurements in multiple industrial uses. There are two ways to hold parts in place, 3D-printed fixtures, and machined fixtures. Each one has its advantages.

3D-Printed Fixtures

Additive manufacturing technology is used to create custom fixtures that match the size and shape of individual parts using 3D printing. This approach offers several advantages:

• Rapid prototyping:  3D printing makes it fast to create fixtures, so manufacturers can test and improve their designs quickly.
• Design flexibility: 3D-printed fixtures are easy to modify. Manufacturers can quickly change their designs to fit new part shapes or inspection needs.
• Cost-effectiveness: 3D printing can lower the cost of making custom fixtures by removing the need for costly tooling.
• Material versatility: 3D printing can use many different materials, like plastic and metal. This helps manufacturers choose the best material for their needs.

Machined Fixtures

Custom machined fixtures are made out of materials like aluminum or plastic. These fixtures offer several key benefits:

• Precision: Machining can make precise fixtures that hold parts well for inspection.
• Durability: Machined fixtures are stronger than 3D-printed ones and can be used for a long time in tough factories.
• Customizability:  Machined fixtures are made better by adding clamps, supports or locators. This makes them more useful and adaptable to different parts and inspections.

Scalability: Machining is good for making things in large amounts. It’s easy to make more when you need to.

Micrometers measure small dimensions with high accuracy and precision. They are used in industries like manufacturing, engineering, automotive, and aerospace. The measuring tool has two parts – a spindle and anvil. A screw mechanism adjusts them to measure object dimensions. There are different types of micrometers, each designed for specific purposes. To use them properly, it’s important to know their unique features and functions. This article gives an overview of micrometers and how they’re used in different industries.

• Outside Micrometers

The most popular type of micrometer is the outside micrometer. It is used to measure the size of things outside, like the thickness of plates or rods. It can also measure the width of flats. The measurement tool has three parts: a U-shaped frame, an anvil, and a spindle. You can adjust these parts using a screw to fit around what you want to measure. The micrometer’s design determines how to read the measurement. It can be from a scale, dial, or digital display.

Micrometers are commonly used in metalworking, machining, and manufacturing to measure the size of products accurately, which is essential for maintaining quality and efficiency.

• Inside Micrometers

Micrometer types for measuring internal dimensions are called inside micrometers. They can measure the diameter of holes, the width of slots, and the distance between two opposing surfaces. These devices have a rod or tube that includes a spindle and anvil. The screw mechanism adjusts them to fit the object being measured. The micrometer’s design will determine how the measurement is displayed. It may be shown on a graduated scale, dial, or digital display.

Inside Micrometersare often used in industries like machining, metalworking, and woodworking. They are necessary for maintaining product quality and process efficiency.

• Depth Micrometers

Depth micrometers are used to measure the depth of holes, slots, or recesses in objects. The tool has three parts: a flat base, a tube with a spindle, and a screw to move the spindle. The micrometer’s design determines how you see the measurement – on a scale, dial, or screen.

Many industries like machining, metalworking, and manufacturing use depth micrometers. These devices ensure accurate depth measurements, which are crucial for maintaining product quality and process efficiency.

• Tube Micrometers

Tube micrometers measure the thickness of tubes, pipes, and cylindrical objects. They’re made for this purpose. The tool has a U-shaped frame, an anvil, and a spindle. A screw mechanism is used to adjust them to the size of the object being measured. The anvil is round or cone-shaped to fit the tube or pipe.

Tube micrometers are often used in industries like automotive, aerospace, and manufacturing. They help measure wall thickness accurately, which is vital to maintain product quality and process efficiency.

• Screw Thread Micrometers

Screw thread micrometers are designed to measure the pitch diameter of screw threads. The measurement tools have special anvils and spindles with matching thread shapes. A screw mechanism adjusts them to fit the threads being measured. The micrometer displays the measurement on a scale, dial, or digital display. How it shows the measurement depends on how it’s designed.

Screw thread micrometers are used in many industries like machining, metalworking, and manufacturing. They accurately measure threads to keep product quality and process efficiency.

• Digital Micrometers

Digital micrometers, also called electronic micrometers, are a modern option to the older mechanical micrometers. The device has a screen that shows the measurement directly. You don’t need to do calculations manually and it reduces mistakes. Digital micrometers have extra features. You can switch between metric and imperial units. They can set zero at any position and send data to other devices, such as computers.

Industries, like electronics, medical, and precision engineering, use digital micrometers for precise measurements because they are becoming more popular. These tools measure the sizes of small parts, look at delicate components, and check quality.

Calipers are tools used in many industries to measure length, width, and depth accurately. They are essential in fields like manufacturing, engineering, and aerospace. Dial and digital calipers are very accurate, easy to use, and versatile. They are the most popular types of calipers available. We’ll compare the dial vs. digital caliper in this article. You’ll learn about their unique features, advantages, and disadvantages. This will help you choose the right measuring tool for your needs.

Dial Calipers

Dial calipers are tools that show measurement using a dial. The dial indicator has a needle that moves around a scale. You can read the measurement in metric or imperial units. The caliper’s jaws adjust to fit the object being measured. The needle shows the measurement on the dial.

           Advantages of Dial Calipers

• Dial calipers tend to last longer than digital calipers. This is because they don’t rely on electronic parts that can easily get damaged by impacts, moisture, or temperature changes.
• Dial calipers don’t need batteries or external power. They are great for users who want a measuring tool that’s always ready. They are reliable and low-maintenance.
• Dial calipers are simple and easy to use. You can read the measurement directly on the dial. This makes them perfect for those who like straightforward tools.

Disadvantages of Dial Calipers

• Dial calipers have lower resolution than digital ones. This can make precise measurements harder, especially for small or complex parts.
• Dial calipers can have reading errors. This is because users have to read the dial’s measurement by themselves. It can lead to misinterpretation or parallax errors.

Digital Calipers

Electronic calipers, or digital calipers, display measurements on a screen, so you don’t need a dial or scale. The display shows the measurement in metric or imperial units. It can do other things, too, like switch the units, set zero at any place, and output data for computers or devices.

Advantages of Digital Calipers

• Digital calipers have better resolution than dial calipers. This makes it easier to measure small and intricate parts with precision.
• Digital calipers show measurements on a screen, so it’s easier to get accurate readings. That way, you don’t have to worry about making reading mistakes.
• Digital calipers have more features to make measuring easier, like changing units, resetting the zero point and sending out data.

Disadvantages of Digital Calipers

• Digital calipers need batteries or external power. This could be a problem if you need a measuring tool that’s always ready, or if you work where it’s hard to replace batteries.
• Digital calipers may not be as durable as dial calipers due to their sensitivity to impacts, moisture, and temperature. This can cause reliability issues as they contain electronic components.

Factors to Consider When Choosing Between Dial and Digital Calipers

• Accuracy and Resolution: Dial and digital calipers give precise measurements. But digital ones are easier to get exact measurements for small or complex parts due to their higher resolution. Your work may need high-resolution measurements. In that case, a digital caliper could be a better option.
• Ease of Use and Reading: Digital calipers show the measurement directly on the screen. This makes it easy for users to get accurate readings and reduces the risk of errors. Dial calipers need users to read measurements from the dial. This can cause mistakes by making it hard to know where to read. If ease of reading is crucial for your work, a digital caliper may be the better option.
• Durability: Dial calipers last longer than digital ones because they don’t have electronics that are easily affected by impacts, moisture, or changes in temperature. A dial caliper might work better if you work in tough places or need a sturdier measuring tool.
• Additional Features: Digital calipers have extra features like unit conversion, zero-setting, and data output. These features can make it easier and faster to measure things. If you need more features, a digital caliper might be the best choice.

Calipers are important measuring tools used in many industries, including manufacturing, engineering, automotive, and aerospace. They measure objects with high precision, both inside and out. There are many types of calipers, each with different features and benefits. It’s important to know what they do and where to use them. This article gives an overview of calipers. It explains their functions and uses in different industries.

Calipers Introduction

Calipers are tools used to measure the size of an object – its length, width, height, or diameter. These tools have two jaws that adjust to measure the size of an object accurately. Industries need precise measurements to make good products and work well. So they use calipers a lot. Technicians and engineers can ensure accurate measurements and high-quality standards by knowing different types of calipers and their functions.

• Vernier Calipers

 Vernier calipers are common and have a main scale and a sliding vernier scale. The main scale measures in millimeters or inches. The vernier scale gives more precision for smaller measurements. The user places the jaws around or inside the object being measured. Then, they combine the main scale and vernier scale values to get the reading.

Vernier calipers are cheap and easy to use. They are favored in many industries. People use these to measure mechanical parts, inspect products and assure quality.

• Dial Calipers

 Dial calipers look like vernier calipers but use a dial instead of a scale. The dial indicator shows the measurement directly. It’s easy to read and reduces errors. You can get dial calipers in metric or imperial units. They’re very accurate and precise.

Industries like aerospace, automotive, and manufacturing use dial calipers for precise measurements. They are often used to measure the size of mechanical parts, check finished products, and control quality.

• Digital Calipers

 Digital calipers are a modern option to traditional vernier and dial calipers. They are also called electronic calipers. They have a digital display that shows the measurement directly. This removes the need for manual calculations and lowers the chance of errors. Digital calipers have added features. You can switch between metric and imperial units and zero-set them at any position. They also offer data output that lets you connect them to computers or other devices.

Industries like electronics, medical, and precision engineering use digital calipers for exact measurements. These calipers are becoming more popular. These tools measure small parts, inspect fragile components, and verify that quality standards are met.

• Inside Calipers

Inside Calipersare made for measuring the inside of objects. For example, they can measure the size of holes, slots, or the space between two surfaces facing each other. They have bent or curved jaws which can adjust to fit inside the object being measured. This gives an accurate measurement of its internal size.

Many industries, like machining, metalworking, and woodworking, need to make precise measurements inside products. To ensure quality and efficiency, they use inside calipers.

• Outside Calipers

Outside Calipers measure the outside of things like rods, flats, and plates. These devices have jaws that adjust to fit around the object you want to measure. This gives an accurate measurement of its size.

Industries like metalworking, woodworking, and manufacturing commonly use outside calipers. Accurate external measurements are crucial for maintaining product quality and process efficiency.

• Divider Calipers

Divider calipers, also called compasses, mark distances and transfer measurements between objects. They have two sharp, pointed legs that can be moved to the desired distance. You can use them to draw lines or mark points on an object’s surface.

Divider calipers are often used in industries like woodworking, metalworking, and drafting. They help ensure accurate marking and layout, which are important for quality and efficiency.

Calipers are important measuring tools used in many industries, including manufacturing, engineering, automotive, and aerospace. They measure objects with high precision, both inside and out. There are many types of calipers, each with different features and benefits. It’s important to know what they do and where to use them. This article gives an overview of calipers. It explains their functions and uses in different industries.

Calipers Introduction

Calipers are tools used to measure the size of an object – its length, width, height, or diameter. These tools have two jaws that adjust to measure the size of an object accurately. Industries need precise measurements to make good products and work well. So they use calipers a lot. Technicians and engineers can ensure accurate measurements and high-quality standards by knowing different types of calipers and their functions.

• Vernier Calipers

 Vernier calipers are common and have a main scale and a sliding vernier scale. The main scale measures in millimeters or inches. The vernier scale gives more precision for smaller measurements. The user places the jaws around or inside the object being measured. Then, they combine the main scale and vernier scale values to get the reading.

Vernier calipers are cheap and easy to use. They are favored in many industries. People use these to measure mechanical parts, inspect products and assure quality.

• Dial Calipers

 Dial calipers look like vernier calipers but use a dial instead of a scale. The dial indicator shows the measurement directly. It’s easy to read and reduces errors. You can get dial calipers in metric or imperial units. They’re very accurate and precise.

Industries like aerospace, automotive, and manufacturing use dial calipers for precise measurements. They are often used to measure the size of mechanical parts, check finished products, and control quality.

• Digital Calipers

 Digital calipers are a modern option to traditional vernier and dial calipers. They are also called electronic calipers. They have a digital display that shows the measurement directly. This removes the need for manual calculations and lowers the chance of errors. Digital calipers have added features. You can switch between metric and imperial units and zero-set them at any position. They also offer data output that lets you connect them to computers or other devices.

Industries like electronics, medical, and precision engineering use digital calipers for exact measurements. These calipers are becoming more popular. These tools measure small parts, inspect fragile components, and verify that quality standards are met.

• Inside Calipers

Inside Calipersare made for measuring the inside of objects. For example, they can measure the size of holes, slots, or the space between two surfaces facing each other. They have bent or curved jaws which can adjust to fit inside the object being measured. This gives an accurate measurement of its internal size.

Many industries, like machining, metalworking, and woodworking, need to make precise measurements inside products. To ensure quality and efficiency, they use inside calipers.

• Outside Calipers

Outside Calipers measure the outside of things like rods, flats, and plates. These devices have jaws that adjust to fit around the object you want to measure. This gives an accurate measurement of its size.

Industries like metalworking, woodworking, and manufacturing commonly use outside calipers. Accurate external measurements are crucial for maintaining product quality and process efficiency.

• Divider Calipers

Divider calipers, also called compasses, mark distances and transfer measurements between objects. They have two sharp, pointed legs that can be moved to the desired distance. You can use them to draw lines or mark points on an object’s surface. Divider calipers are often used in industries like woodworking, metalworking, and drafting. They help ensure accurate marking and layout, which are important for quality and efficiency.

Dial bore gages are important tools in the automotive, aerospace, and manufacturing industries. They measure the size of cylindrical holes and can detect if they are not round. Before using the dial bore gage, it’s important to set it up correctly. This ensures that your measurements are precise and trustworthy. We’ll talk about how to set a dial bore gauge in this article. There are three common methods: using a micrometer, setting ring, or master bore. We’ll guide you in choosing the best method for your application.

Setting a Dial Bore Gage Using a Micrometer

Knowing how to set a dial bore gage accurately assures that measurements are correct. This helps maintain high standards of quality and efficiency in processes.

One of the most common methods for setting a dial bore gage is using an outside micrometer. To make measuring more accurate, use a micrometer as a reference standard and adjust the dial bore gage to match it. Here’s a step-by-step guide on how to set a dial bore gage using a micrometer:

• Select the appropriate micrometer: Choose an outside micrometer that can measure the diameter of your intended bore.
• Measure the bore diameter with the micrometer: To measure the diameter of the bore, use a micrometer. You can also get the target diameter from a blueprint or specification.
• Adjust the dial bore gage: Adjust the micrometer’s spindle to extend the measuring head to the target diameter. Make sure the gage is parallel and aligned with the micrometer’s anvil and spindle.
• Zero the dial indicator: To make sure the needle points to zero, keep the gage in touch with the micrometer and turn the dial indicator’s bezel.
• Verify the setting: Double-check the gage’s setting by measuring the bore diameter again with the micrometer. Make small changes to the dial indicator to match the micrometer’s reading on the gage.

Setting a Dial Bore Gage Using a Setting Ring

Another common method for setting a dial bore gage is using a setting ring. Setting rings are cylindrical rings with a precise internal diameter. They act as a reference standard for adjusting the gage. Here’s a step-by-step guide on how to set a dial bore gage using a setting ring:

• Select the appropriate setting ring: Select a setting ring that has an inner diameter close to the bore diameter you want to measure.
• Insert the dial bore gage into the setting ring: Insert the measuring head of the gage carefully into the setting ring. Make sure the contact points are parallel and aligned with the ring’s inner surface.
• Zero the dial indicator: To make sure the gage and setting ring stay in touch, turn the dial’s bezel until the needle shows zero.
• Verify the setting: Double-check the gage’s setting by inserting the gage into the setting ring again. If needed, adjust the dial until the gage matches the internal diameter of the setting ring.

Setting a Dial Bore Gage Using a Master Bore

In some cases, a master bore can be used to set a dial bore gage. A master bore is a precisely machined cylindrical bore with a known diameter. It is used to set the measuring gauge accurately. Here’s a step-by-step guide on how to set a dial bore gage using a master bore:

• Select the appropriate master bore: Select a master gauge that has a similar diameter to the bore you wish to measure.
• Insert the dial bore gage into the master bore: Insert the measuring head of the gage into the master bore carefully. Make sure the contact points are aligned with the internal surface of the bore.
• Zero the dial indicator: To make sure the gage and the master bore stay connected, turn the dial indicator until the needle points to zero.
• Verify the setting: Double-check the gage’s setting by inserting the gage into the master bore again. Make small changes to the dial gauge if needed until it shows the same diameter as the master bore.

In the early 1980s, the introduction of digital electronic indicators caused quite a stir in the industry. It was believed they would eventually overshadow mechanical dial indicators due to their enhanced resolution, accuracy, and utility in systems of statistical process control and data collection. Yet, mechanical indicators managed to hold their ground, largely due to certain advantages they possessed and the continued preference of many users.

Today, the digital versus dial debate is no longer about which is superior, but more about which is suitable for specific applications. The selection between the two relies heavily on the application in question and user preference. Nonetheless, digital indicators are emerging as the preferred choice for an increasing number of applications.

The Technological Advantage: Digital Indicators in Process Control

The primary advantage of digital indicators lies in their use for data collection in process control. With digital indicators, operators can output measurements directly, eliminating operator errors in reading or recording. This process has become even more streamlined in recent years with the introduction of wireless technology, which allows greater portability of gages. The only manual step is positioning the workpiece and pressing a button, the rest is taken care of by the digital indicator.

Conversely, dial indicators involve a more complicated, error-prone process where the operator must interpret the pointer’s position, record it manually, and then enter the data into a computer. As a result, digital indicators are the most logical choice when data needs to be entered into a computer system.

Affordability and Utility: The Cost-Benefit Analysis

Historically, the cost of digital indicators was considerably higher than that of dial indicators. However, this has changed in recent times, and basic digital indicators are now competitively priced alongside high-quality dial indicators. Moreover, digital indicators often come with additional standard features such as reversal of measuring direction, auto-zeroing, data output, in/mm switchable reporting, and actual values. This provides exceptional value in what used to be a premium product.

The Cognitive Appeal: Dial Indicators’ Unique Strengths

Despite the cost advantage being wiped out, there is still something intriguing about mechanical dial indicators. The human brain, like an analog device, can often glean more information quickly from an analog readout. Dial indicators also provide more intuitive information than digital ones. However, modern digital indicators have overcome some of these cognitive disadvantages by incorporating analog-like displays, providing an indication of direction, and showing how far over or under the part tolerance the item being inspected is.

The Digital Ascendancy: Today’s Digital Indicators

Many of today’s digital indicators are becoming increasingly powerful and feature-rich, rivaling bench amplifiers in performance. With features such as dynamic measurements, multiple factors, unilateral tolerances, different output formats, and micro-inch resolutions, these advanced digital indicators offer exceptional value, usually at a fraction of the price of a bench amplifier and probe.

Additionally, digital indicators eliminate certain common issues associated with dial indicators, such as overlooking when the pointer makes a full revolution or two. By displaying the actual part size, they eliminate the problem of returning to “0” or reading deviations.

Charting the Future with Digital Indicators

Digital indicators have proven to be highly reliable in the shop floor environment and are widely accepted by operators, thereby, gaining dominance in more applications. With only a single moving part, digital indicators require less frequent cleaning than their mechanical counterparts and now feature clear IP ratings that define their usable environments. Although dial indicators can last virtually forever and do not need batteries, finding professionals who can repair them is becoming increasingly challenging.

At Willrich Precision Instrument, we offer a comprehensive range of metrology products, from the most sophisticated metrology products to basic measuring tools, including both dial and digital indicators. Experience the ease and accuracy of digital indicators with us.

Foreword

This book stems from many years of discussion and tireless introduction of measurement and inspection technology to those in industry responsible for the control of product quality. It became clear that there are few outside of the quality profession who understand and appreciate the measurement process, its implications and its techniques. I hope that through the use of this primer there can be a better understanding of what it takes to “take a measurement”.

MEASUREMENT

By:

Richard G. Chitos

What is measurement?

By Richard G Chitos- Willrich Precision Instrument Company, Inc

Chapter 1

Measurement- (Latin mensura) A figure, extent or amount obtained.

We are surrounded by measurement.  Almost everything we do involves measurement of some kind.  We measure the distances we run, the mileage we reveal to work each morning, the ingredients of a cake, and the scores on our kid’s report cards.  Just because it’s not a manufactured product doesn’t mean that measurement is not taking place.  Sometimes we use perceptive measurements such as “Tom’s nose is too big for his face” or “Betty is surely built well”.  Whether you realize it you’ve taken measurement mentally.  Unlike the “2000-year-old man” I can’t say when all of this measurement got started.  It probably all began when man began.

You’ve heard some stories about how we arrived at some very popular units of measurement.  You know the stuff about the king’s foot being considered a standard measurement so “Presto!’ We get the standard foot.  Unfortunately, the standard holds up for only a particular king’s foot; obviously this proved to be a rather poor measurement standard. Some other standards have been, the width of a thumb for an inch, the distance from the nose to the outstretched arm as a value of a yard etc. It seems those many years ago there was quite a hang-up on various body parts.

Measurement came into its own when groups of men were needed to build things. A solidarity artisan making a piece of pottery dealt with his individual perception of the size or volume of his work. But when it came to using hundreds and sometimes thousands of workers for time periods that could last for a hundred years or more, measurement and standards became essential. Can you imagine building the pyramids, the Parthenon or the Great Wall of China without some hard and fast rules and regulations. Although individual design plate it’s role, individual standards could not be tolerated. Henry Ford heralded the modern production line and the interchangeability of parts, yet it is obvious that these concepts had to be understood by those master builders of old.

Thousands of years ago in Egypt units of measurement known as “cubits” were used. The cubit was based on the length of the forearm from the elbow to the tip of the middle finger. (Here’s that hang-up on body parts again). What is important is that standards are established. If a number of stones were needed two cubits by three cubits by two cubits, the first of these was made and designed as a standard, to which all others could be compared. Here we  have the birth of comparative measurements. A principle that has stayed with us for thousands of years. It’s clear in today’s world we can’t walk around dragging a bunch of standards behind us, but we can readily obtain and uses tools that have been compared to a standard somewhere.

Just as our culture, its drama art and architecture is based on the works and the thinking of those great masters in the distant past, so does our ability to make reliable and meaningful measurements have its beginnings way back when. Had Euclid, and Pythagoras been busy thinking other thoughts we would not be able to accomplish much today. The old adage says “if you can’t measure it you can’t make it”. Few, if any high schoolers, as they suffer through their geometry classes can appreciate the implication and application of what they are being taught. I can appreciate this better than most as I had to take the subject twice and it surely wasn’t because I was enamored with its principles.

Without measurement we can neither produce or progress. You certainly could not produce a toaster or an automobile, that has thousands of parts without knowing that “this will go into that.” The designers of whatever is being produced demand that their specifications are met so that the finished product meets their ideal of fit, form, and function. That is that it performs its intended job. When the various parts of an assembly are designed there is included very specific instructions as to the materials to be used, the processes required and the nominal sizes of features along with the tolerances applied to those features. Tolerances are the amounts that the features of the apart are allowed to deviate from the perfect or ideal. No process is so exact that in our attempt to manufacture parts that we can make them 100 percent perfect. Tolerances recognize that there is going to be variations. Tolerances allow for some variation that will still permit the product to function.

Measurements are critical to all products. It is clear that parts of the space shuttle require some very critical measurements be taken. However, to the maker of chewing gum the thickness of the gum may be equally important. Make the gum too thick and the pieces won’t fit in their intended package, too thin and they’ll rattle around in the package. Besides, government regulations require that packages of consumer goods meet the package weights indicated. Too thin a product could lower the package weight and be construed as consumer fraud. Making the product purposefully thicker leads us back to the package problem again, but also increases the cost of raw materials. Giving away just a few grams of product on each package, when one could possibly be producing billions of packages, could equate to hundreds of thousands of dollars of additional costs.

In the beginning…………………………………………………………………………………….

Every product starts with an idea. Some gizmo or widget is needed to fill a need. The burden of designing these gizmos and widgets is given to the design engineers who come up with the plans to build the product. We can think of their specifications as the laws that need to be followed to assure product performance. These laws could be likened to the laws created by our legislative branch of government (the congress and the senate) their laws (specifications) are transmitted to the executive branch (the president) in the hopes that they will be carried out as congress intended, just as our design engineers pass on their “laws” to production to carry out the requirements to produce the product. And just as in our government something is sure to go wrong in the process, there is a need for judges to define if the law of the land is being observed, so it is true that judged are required in industry. Quality inspectors confirm or deny that the desired design specifications have been met. The similarity stops, in that generally inspectors are not asked to interpret the laws necessarily but to pass in the adherence of them (although every seasoned inspection professional has certainly done his or her share of interpreting).

So, just as our forefathers created a system of checks and balances in our government similar checks and balances are used in industry. These checks and balances can often times be aborted by having those responsible for quality inspection reporting to supervisors in the production group. That is why supreme court justices are appointed for life. They needn’t fear that their decisions will affect their positions. Maybe this is a call for guaranteed job security for the inspection department?

More and better products have to be made in order to secure our standard of living and that of the rest of the world. Greater productivity and quality products will secure America’s position as a world leader. Metrology- The science of measurement can help us reach those goals.

Nominal- The basic size

Tolerance- The amount the feature is allowed to vary from the perfect or ideal

Gizmo- Gadget

Widget- An unnamed article considered for purposes of hypothetical example

If .001 is “one thousandths” then 10 of them have to be… you got it! “Ten thousandths”.

If we see the value .010” we know we are ten times greater than .001”

Moving right along, if we multiply ten times ten we get one hundred likewise .010” x 10 = .100” or “one hundred thousandths”.

If we double any of these values the rules remain the same, the value just doubles.

.001” x 2 = .002” – – “Two thousandths”

.010” x 2 = .020” – – “Twenty thousandths”
.100” x 2 = .200” – – “Two hundred thousandths”

Remember now that the third place after the decimal is the starting place. In one of our examples we had shown the fraction 7/16 to be .4375” hey, that’s a fourth place after the decimal. Now the rules change a bit.

The fourth place is expressed as the “tenths” position. Why? Because it is ten times smaller than the “thousandths” place. It is “one tenth of a thousandths”.

.0001” is 1” divided up 10,000 times.

.0001” is 1/10,000

.0001” is .001/10

.0001” x 10,000 = 1”

Five of these little buggers (.0005”) is expressed as “five- tenths of a thousandths”.

Getting back to our example .4375” is therefore expressed as “four hundred thirty-seven thousandths and five tenth thousandths”.

In shop talk in order to shorten this mouthful a bit the value is sometimes referred to as “four hundred thirty-seven thou and five tenths”.

Most of you may want to stop here for those who need to or who are just curious the trek continues.

There is a fifth, sixth, seventh, etc. place after the decimal. For our purposes we’ll deal with the 5th and 6th places, so expression of the value doesn’t become too cumbersome.

Let’s look at a real wild number. .437532”. All the rules for the first part of the number remain unchanged (.4375) what changes is the last part. Instead of deferring to the popularity of the “thousandths” position a new position reign supreme “the millionths position”. Which is the sixth position after the decimal place (.000001).

.000001 x 1,000,000 = 1”

.000001” = One millionth

Guess what? Ten of these are ten millionths .000010”. Getting back to expressing the value we say .437532” is “four hundred thirty-seven thousandths and thirty two millionths”. Quite a mouthful, but sometimes necessary. In some cases, the millionth or ten millionths place is referred to in scientific notation.

1 x 10-6 equals .000001” One millionth

2 x 10-6 equals .000002” Two millionths

1 x 10-5 equals .000010” Ten millionths

2 x 10-5 equals .000020” Twenty millionths

For the first example all you need to do is take 1 consider there is a decimal place assumed after the number (1.) then move the decimal, in this case six times.

Angles on Angles

Any circle can be broken into 360 parts (degree). No matter how big or small the circle, you can get the same number of pieces from a pie no matter how big or small it is, the only difference is the size of the slice’s changes. As you have heard each of these parts is called a degree. Now, just as we have seen before units of measurement can be broken into smaller and smaller units. Just as hours in the day can be broken into minutes so can degrees. There are 60 minutes in a degree which is a breeze to remember. The next step is to chop these minutes down even further. The next step down is seconds. There are 60 seconds in a minute. Not so tough?

If you sliced a pie every 90 degrees, you’d get 4 slices. Every 45 degrees and you’d have 8 slices (typical with pizza pies). Taking it further, half that or 22 degrees 30 minutes would yield you 16 slices. And so on until you could (if you slice very carefully) wind up with 1,296,000 slices each one being 1 second (360 degrees x 60 minutes x 60 seconds=1,296,000 seconds). An arc is a part of the periphery of a circle and looks like this – – – – – – –

So, when we refer to the parts of this circle we’ve been dissecting we call them “arcs”.  So, 90 degrees becomes 90 degrees of arc, and looks like this – – – – – –

45 degrees would be 45 degrees arc, and looks like this – – – – –

22 degrees, 30 minutes (22 and a half degrees) looks like this – – – – –

1 second of arc (the smallest we’ll ever deal with) could look like this – – – – –

Of course, the larger the circle the larger the arc. A circle going around the waist of the earth (the equator) is 25,000 miles around (periphery), and 1 second of arc would be approximately 102 feet.

How we arrived at this is fairly simple. (25,000 miles divided by 1,296,000 seconds=.0192 miles. There are 5280 feet in a mile so, 5280 x .092 = 101.8 feet).

Therefore, large circles have large arcs and small circles have smaller ones.

If you were driving a car up a steep incline the steeper the incline the steeper the incline the sooner you’d reach the top of the hill. That means for every degree increase in steepness greater heights are achieved. Here’s an example.

Therefore, a relationship exists between angles and linear measurement. If we shot an arrow at the moon and we were off in our aim by 1 second of arc we would miss it by more than a mile. (Boy, those little seconds can sure get in the way). 1 minute over an inch length has a rise of .000291”. The same 1 minute over 10 inches rises from a plane .002909” and over 1 foot the rise is .00341”.

I like to remember that 1 second has a rise of .000005” over 1 inch, this way it’s easy to multiply to get other values. Here’s one for you.

What’s the rise of 2 seconds of arc over 10 inches.

.000005” x 2 = .000010” x 10 = .0001” Approx.

It’s approximate because the value for 1 second is not exactly .000005” but really .00000484” (see chart) though not exact it sure is close enough for most applications.

As you can see in the chart the conversion goes both ways that is linear measurements can be readily changed into angular ones.

You may be thinking how is this done. Actually the conversions are done using trigonometry. Pages through define the process of conversion.

Ok, you’re ready, using the chart as a guide convert 15 seconds over 10 inches into linear measurement.

Next which is greater 22 degrees 15 minutes 10 seconds or 22 degrees 17 minutes 59 seconds?

Linear: Relating to, consisting of, a line: straight

Answers to questions page

• .000727”
• 22^ 17 59”

The manner in which these angles are expressed on a print is again similar to how we express time. Minutes are followed by a ’ and seconds by a ”. The change comes when we express degrees but then again another similarity exists this time between angular degrees and temperature degrees both are expressed using a bubble (o).

Putting this all together we can use the following example to get some practice.

15 o 7’ 42” is actually 15 degrees, 7 minutes, 42 seconds.

Recently there has been a trend to express parts of a degree in decimals. 45 degrees 30 minutes then becomes 45.500 degrees. We divided 30 minutes by 60 minutes and got .500

45 o 20’ would therefore become 45.3 o

45 o 59’ is the  45.98333 or almost 46 o

22 o 59’ 59” which is just a second shy of 23 degrees therefore 22.0031 o

If a full circle has 360 degrees then a semi-circle has 180 degrees. The supplement of an angle is the amount by which an arc or an angle falls short of 180 ^.

 SUPLLEMENTAL 40 Deg

Continuing along the same thought a complement is the amount by which an arc or an angle falls short of 90 ^.

Finally, angles can be right, acute, or obtuse. As per the following examples.

If you’re starting now to feel somewhat obtuse yourself, about angles it’s time to go on to the next chapter.

Accuracy, Resolution, Repeatability

I used to own one of those digital watches which told me the time of day to one tenth of a second. Then one day I realized it didn’t matter very much to me whether I was doing whatever I was doing at 3:15 or 3:15:1?42. So, I bought one of those European looking models that has a graduation every five minutes. I still tell time but not as closely as I used to.

Both watches are very accurate it’s just that with my current one I’ve got lousy resolution. Now I can tell that it’s approx. 3:15 give or take a minute or so. So, what’s suffered? Certainly not the accuracy but rather the resolution – that is the least significant digit that can be read, the digital watch had a LSD of .1 giving it as wristwatches go a high order of resolution. I’m measuring resolutions typically start of mechanical gages having resolutions of .001” (one thous) down to (.00001”) or lower. Don’t confuse resolution with accuracy. I could of course have a watch that resolves to .1 seconds but be “off” by hours. Accuracy is the difference read on the measuring device as it is? being compared to a standard. In the case of the watch the question is what time I do have as compared to the standard which is ticking away in Greenwich England, if it’s exactly the same time I’m accurate if I’m “off” some amount that’s my level of accuracy or inaccuracy – now I’m pretty sure my new watch is accurate but I’ve got a problem. It’s resolution is so coarse that I’ve no way of reading it. Determine how close or “off” I am from the standard.

Lesson #1- It doesn’t pay to have a lot of high accuracy in a gaging system if you’re no way of confirming it. By high resolution now just let’s say my watch is “off: by a full minute = what if I could better its resolution by placing grads on the face every 30 seconds. Now I’ve got lots of resolution, but the watch is still inaccurate. Because the resolution is better, I can see the inaccuracy better but it sure hasn’t helped make the time correct.

Lesson #2- Higher resolution doesn’t buy you much except higher resolution. Accuracy stands alone + hazed? Now what if I check the same watch every day + at the same time + one day it’s running a minute late and the next day it’s exactly on time. The problem we are then facing is one of repeatability. The watch that is a minute off but accurate can be set to the correct time and stay that way, but the one that fails to repeat leaves us with a problem which to reckon.

Lesson #3- I’d rather have a system that is off that I can reset than one that varies all over the place.

Lesson #4- You can never be more accurate than you are repeatable.

Metrology: Distance between two points

Millimeter: Thousands of a meter

Tenths – Micron = Millionth of a meter

Inch – Micron = Million of an inch

Microinch much smaller than micron

Tenth = 100 Microinch

Micron = .004 (HAIR)= .0001                 HAIR (.004)   = Microinch

                —————                             ——————

                  40                                              4000

1 Micron = 40 Millionths

7 Microns = 280 Millionths

.1 Micron = 4 Millionths

20 Microinches = 20 Millionths

4 Microinch = 1 Micron

2 Microinches = .5 Micron

Variable Gage Study

The number of operators (2 or 3) and the number of trials (2 or 3) may vary. Each operator measures 3 – 10 parts in random order for each trial. Data storage is optional. An option of tests are described:

1. Gage Repeatability and Reproducibility

Gage repeatability is the variation in measurements obtained when one operator uses the same gage for measuring identical characteristics of the same parts; reproducibility is the variation in the average of measurements made by different operators using the same gage when measuring identical characteristics of the same parts. For each trial, have each operator measure parts in random order. Repeat the cycle, with the parts measured in another random order, for the number of trials required.

2. Gage Accuracy

Gage accuracy is the difference between the observed average of measurements and the true average. Establishing the true average is best determined by measuring with the most accurate measuring equipment. Have one operator measure the same parts, using the gage being evaluated.

3. Gage Stability

Gage stability refers to the difference in the average of at least two sets of measurements obtained with the same gage on the same parts taken at different times. How gage stability is determined depends on how often the gage is used between normal calibrations. If a gage is used intermittently, then have the gage calibrated before and after each trial to determine the amount of calibration change. If a gage is used constantly, then conduct another gage R&R study.

4. Gage Linearity

Gage linearity is the difference in the accuracy values through the expected operating range. Conduct two accuracy studies, one at each end of the operating range.

TYPES OF GAGES

REVERSIBLE WIRE TYPE PLUG GAGES

A wire type plug gage is a plug gage comprising a gaging member of straight cylindrical section throughout its length held in a collect-type handle. This design is standard in the range above .030 to and including .760 inches. DU-WELL offers this type of gage up to 1.010. Sizes below .030 are available on requested note.

TAPERLOCK PLUG GAGE

A taperlock plug gage is a plug gage in which the gaging member has a taper shank, which is forced into a taper hole in the handle. This design is standard for plug gages in the range above .059 to and including 1.510 inches. DU-WELL offers taperlock gages in this range.

TRILOCK PLUG GAGE

A reversible or trilock plug gage is a plug gage in which three wedge-shaped locking prongs in the handle are engaged with corresponding locking grooves in the gaging member by means of a single through screw, thus providing a self-centering support with a positive lock.This design is standard for all plug gages in the range above 1.510 and including 8.010. DU-WELL shows up to 4.010 in the catalogue and will quote prices on larger sizes.

PROGRESSIVE SETTING DISCS

A master setting disc is a cylinder provided with insulating grips, used for setting comparators, snap gages, etc. There are three styles. Style 1 is a plain cylinder approximately twice the length of Style 3. The gagemakers’ tolerance is split plus-minus from the nominal size. Style 2 is two cylinders each approximately one-half the length of the cylinder in Style 1. Generally one cylinder is the “GO” master and the other the “NOT GO”. The gagemakers’ tolerance on the “GO” is minus and on the “NOT GO” it is plus. Style 3 is a plain cylinder approximately one half the length of Style 1. The gag makers’ tolerance is split plus-minus from the nominal size. The standard shows four designs – one for the range .105 to .365, one for .365 to 1.510, one for 1.510 to 2.510, and one for 2.510 to 8.010. DU-WELL lists size ranges for each of the three styles from .150 to 4.510, and will quote on sizes smaller and larger upon request.

PLAIN RING GAGES

A plain ring gage is an external gage of circular form employed for the size control of external diameters. In the smaller sizes it may consist of a gage body into which is pressed a bushing, the latter being accurately finished to size for gaging purposes. This design is optional in the range above .059 to and including .510 inches. Gages in sizes above 1.510 inches are flanged in order to eliminate unnecessary weight and to facilitate handling. An annular groove is provided in the periphery of the “NOT GO” ring gage as a means of identification.

SWIPE

(A lesson in Gage Repeatability and Reproducibility)

BY R.G. CHITOS

There used to be an old rule of thumb that if given a part’s total tolerance the gage selected to measure the part should have a resolution of 10% of the total part tolerance. Until recently no formal mention was made to this method. Today Gage R&R (Repeatability and Reproducibility) tolerances are  specified when ordering gaging inspection systems, as well as when applying these instruments to various production inspection tasks. The former method of purely relying on resolution made no provision for gage repeatability, gage accuracy or operator influence. Gage R&R methods and supporting formulas make an effort to resolve the issue by considering all of these variables.

The move to Gage R&R practice is welcome as it finally addresses some of the important areas that all good gaging practitioners have always known. The shortfall is that many of those who interpret the Gage R&R results do not fully understand the results. When specifying a 10% R&R, that is that the result of the test shows that the application of the specific gage tested does not consume more than 10% of the part’s total tolerance, many fail to realize that given standard practices and budgets 10% is not readily achievable. Many Inspection Managers will readily accept results of 20% of the tolerance and even 30% in some cases.

It is surprising how many companies have no idea what percentage of their total tolerance is being “eaten” by poor gages and poorer gaging practice. Routinely, when finally analyzed, gages and their application have consumed 50-60 and 100% of a parts tolerance.

The methods used to perform Gage R&R studies employ the use of several operators to take repeated readings on gaging masters as well as finished parts. The procedures allow for separation of operator reproducibility from gage error. This divides the blame, but in reality the gage supplier is generally saddled with the full brunt of the lack of adherence to the desired specification without regard to all of the variables that affect the final outcome. The very term GAGE R&R places the blame for whatever the problem directly on the gage.

SWIPE

Swipe is a mnemonic which stands for the following influencers of total measurement performance:

S- The Standard, is it certified and when, is it the proper class. For example in setting a bore gage to gage a 1” hole having a .00005” Bandwidth tolerance, if one were to use a class Y tolerance master, the uncertainty of the master alone could be as much as .0001” which is 20% of the total tolerance of the hole to begin with. The roundness of the master may be up to .00005” which is already 10% of the Gage R&R.

W- The Workpiece, every part varies, some more than others. Are the R&R operators aware of the variation within a part? Does the part have intrinsic taper, out of roundness conditions, surface finish variations etc. that can affect the measurements. Just by not taking measurements in the same place or zone on the part repeatedly can cause the R&R to suffer significantly. A .0001” out of roundness condition can consume 20% of the total part tolerance using the example above.

I- The Instrument itself obviously has linearity, and repeatability characteristics. Whatever they may be, clearly they add to the gaging uncertainty. In addition, certain instruments are more prone to operator loading, use, and care.

P- The Personnel and their ability to adapt the gage to the part is an ever important factor. Surely the gages vulnerability to operator influence can be considered the gage’s fault. However one should not discount the variation in touch and experiment that the operator brings to these tests. With some operators and their influence there may be no gages or inspection equipment made to perform the measuring task at hand. Surely an enigma, but best handled when best understood.

E- The Environment. Parts that are dirty, oily, or hot or even cold are poor candidates for R&R testing methods. They may represent the real world conditions but offer no stable ground on which to buyoff on a gages ability.

So there you have it, the SWIPE scenario. The answer may very well be that considering all of the variables, the only one that can be rectified is the gage’s intrinsic accuracy and repeatability. In this case it becomes necessary to obtain gages of a higher order. This may mean changing from Mechanically applied hand tools to Electronic or Air Gage tooling. These tools permit higher resolution and linearity and repeatability. They limit operator influence and offer output to SPC and signaling modules. The cost may increase but the value per item measured makes these types of tools irreplaceable.

Gage R&R, while an important measure in the measure of the measurement system requires careful consideration in its application.

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Equipment calibration has always been a necessary part of maintenance. Regardless of the type of gaging equipment, calibration is a must for the purpose of maintaining quality. The accuracy of measurements taken with gaging equipment can start to degrade over time due to wear and tear brought on by extreme temperatures and harsh conditions. Without regular calibration, it can result in parts being made with incorrect dimensions. This can lead to costly rejections and repairs, as well as a decrease in product quality.

The following points will further explain the reasons gage calibration is important.

Maintain Accuracy

Gaging equipment is used in the field of engineering and design for measuring parts. Using gage devices is essential to get dimensional information and determine whether a part or an object meets a standard or a system. As mentioned, the accuracy of a gage device can degrade over time. Hence, to ensure that it provides accurate readings and is performing its job correctly, regular calibration is a must. This process verifies and restores the accuracy of the gage as needed.

Quality Assurance

Poorly calibrated gage creates inefficiency and can significantly impact quality and safety. When there’s no accuracy, the rate of rejected parts will be high. On the other hand, accurate gaging devices improve product quality. Also, they help with quality control as they can quickly spot parts that do not meet standards earlier in production. It is important to calibrate devices in order to maintain the integrity of readings and the accuracy of measurements.

Compliance

OEMs these days are demanding suppliers and companies to establish calibration programs for their measuring equipment. According to ISO 9000, companies should continuously examine their programs for weaknesses and make improvements. Meanwhile, ISO 9002 states that suppliers must calibrate equipment and devices used for inspection, measuring, and testing at prescribed intervals against certified equipment. To help them stay compliant, some large companies hire specialists in calibration methods while others use calibration services.

Keep the Company’s Reputation

If a company doesn’t detect rejected or poor-quality parts, its customers soon will. These errors or inaccuracies can lead to costly consequences, including damaging a company’s reputation. To protect the company’s image, gage calibration is necessary.

Tips on Gage Calibration

How to choose the right calibration company? Take note of these tips:

• Ask for Certificates – When choosing a calibration house, make sure that they provide you with a certificate of calibration. This is important for compliance. The certificate must include the following information:
  • The serial number and description of the gaging equipment
  • The serial number of the gage used for the test
  • Tolerances of the data or level of uncertainty of the calibration
  • A statement of traceability to nationally recognized standard
  • The serial number of the NIST test where the house based its standards
  • Reference temperature
  • Date of calibration
  • Signature of the technician
  • Test results

The house must also indicate that the gage was adjusted or recalibrated in the certificate.

• Look for Documentation – ISO 9000 requires calibration houses to document their methods and procedures in a manual. You should ask about them before enlisting their services. If unavailable, find a different calibration house.
• Consider Reputation – To date, there haven’t been any standards for calibration houses. That’s why you must be extra cautious. Reputation can be a good starting point when choosing a company. Still, don’t be afraid to ask a lot of questions to gauge the company’s experience, expertise, and reliability.

A bore gage is an instrument used to determine the inside diameter (ID) of a hole, a cylinder, or any spherical object. Bore gages differ in measuring techniques. Although, a typical bore gage features anvils that expand until they touch the inner surface of the bore. Measuring bores is an essential step when assembling or building an engine. It is also done as part of equipment routine maintenance of equipment to check for wear-out parts.

Is There a Different Method for Measuring Small Bores?

For many years, our experts have tried air gaging as well as back pressure for measuring small bores that are below 1 mm. This method can be instrumental in taking measurements of small bores. However, it’s not the best tool as it provides details about flow area and, not form information. The problem with these bores in question is that they are too small. It is possible that there is no other economical way to measure small bores other than air gaging.

If the bore measures more than 1mm, then there will be various bore gages in the market to use. You will find gages that measure 1 mm – 20 mm bores.

Can You Use a Plug Gage for Measuring Small Bores?

The short answer is no. To get the bores’ sizes and deviations, this type of mechanical bore gages use comparison. However, they don’t work the way fixed plug gages do. They neither need a ground cylinder nor a sensitive contact when making a comparison of a master to a bore. Instead, they use the plug’s mechanical transfer as the only probe for measurement. Because centralizing plug is not present, the probe is rocked inside the bore. This way, it can measure its diameter.

In other words, a plug gage is used to check if the internal diameter of a bore falls within the specified tolerance. Meanwhile, a bore gage simply measures the size of a bore.

This method is actually similar to adjustable bore gage technique that many people are familiar with. However, the small-probe gage can take the measurement of bores that are significantly smaller as compared to the holes that an adjustable bore gage usually measures. The former gage can be used for different kinds of holes or parts. That means, a user doesn’t have to use different tools for their measuring tasks.

Although, one must take note that its measuring range is limited. A small-bore probe that has a 1 mm nominal size measures 0.95 mm – 1.15 mm bores. A probe with a 10 mm nominal size measures 9.4 mm – 10.6 mm bores. Lastly, a probe with a 20 mm nominal size measures 19.4 mm – 20.6 mm bores. Nevertheless, they have repeatability and a measuring range accuracy of 1%, which are great advantages.

How Does This Type of Probe Work?

As mentioned, a small-bore probe work like a fixed plug gage, but with a few differences. Its sensitive contacts change to determine the bore diameter. As they do that, the size is being measured which will be seen in its indicating device. Depending on the small-probe gage, the indicating device could be a digital indicator, a dial, a comparator, or an LVDT.

Like any gage, this small probe gage needs a setting master. The master should be placed on the probe and then rock the plug. While rocking it, the user shall observe the indicator readout until it reveals the smallest value or reversal point. Next, the user shall set it to zero. Sometimes, it is also set the point to nominal size. Only after these steps shall the user start measuring the bore to find its diameter.

Fortunately today, there are digital indicators that simplify the process, thanks to their advanced features. They now have a memory feature. That way, the user doesn’t have to keep remembering the smallest value while measuring bores. Thus, speeds up the entire process.

Small probe gages offer a precise way to measure bores ranging from 1 mm – 5 mm. They provide the users with the necessary information for tight tolerance bore measuring applications.

Introducing the Marameter 844 K Bore Gage System from Mahr Metrology

Marameter 844 K self-centering dial bore gage system is ideal for measuring bores ranging from 0.95mm – 1.55 mm. A self-centralizing gage is among the basic types of bore gages, which include the go/ no-go plug gages, indicating plug gages, and non-self-centralizing rocking gages.

Why use self-centering dial bore? Rocking the adjustable gage takes a lot of effort. The user has to develop the right skill through performing the method conscientiously. A poorly trained operator is likely to produce inaccurate measurements. The greatest benefit of this type of gage is that it eliminates the need of “rocking” to center the gage in the bore. It also avoids operator influences and doesn’t require a lot of training. A user can easily learn how to operate it.

Our Marameter 844 K self-centering dial bore gage system has been a part of the Marameter hole measuring system for many decades. It has been tried and tested and has undergone innovative upgrades for maximum linearity accuracy. You can use this for determining the diameter and testing the roundness and tonicity of bores. It can also be recommended for testing batches. Our product comes with a measuring holder 844 Kg, a probe, and an expanding pin. It is packaged in a quality wooden case.

For more than 50 years, Willrich Precision has been dedicated to bringing high-precision gear, measuring tools, and metrology products. Our team strives to ensure top quality products and services. We are an ISO:9001:2015 company that constantly is in the mission to help businesses streamline their measuring processes while taking their quality assurance to a new level.

Our company is a proud partner of Mahr Technology, a five-generation family business that operates globally. For high-quality measuring instruments from Mahr that you can use for analysis and evaluation of workpieces, visit our website. You can also contact us if you need quick and reliable support from our service experts.