RYERSON UNIVERSITY DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGINEERING

MEC322 Manufacturing Fundamentals INSTRUCTIONS FOR THE PREPARATION OF MANUFACTURING/METROLOGY

LABORATORY REPORTS The report may be divided into five sections; 1) Introduction and Procedure 2) Results 3) Analysis of Results 4) Conclusions and Discussions 5) Answer to Questions Title Page – download the lab report cover page from www.mie.ryerson.ca and have you and your lab partners sign. Introduction and Procedure A brief outline of how the experiment was carried out, and the instruments and accessories used in each section. Results All the data leading to the results as well as the results themselves should be included in this section. The individual gauge block sizes used, vernier height gauge readings, etc. (raw data) leading to the final results should all be included. The reported measurements must indicate the resolution of the measurement device. For example a a length measured using a vernier caliper with resoultion of 0.001” should be reported as 10.124 ± 0.0005. Analysis of Results The results of each part of the experiment should be queried to determine sources of error relating to environment, instrument, component or operator. In many cases it will be possible to pinpoint the limits of accuracy which may be expected due to the method used. Any difficulties which are found in using the instruments should also be defined. Conclusions Include in this section any trends, or highlights resulting from the experiment. Industrial applications should be discussed. Answer to Questions Most laboratory sheets have questions attached to them. These should be answered separately at the end of the report.

Ryerson University Department of Mechanical and Industrial Engineering

MEC 322 Manufacturing Fundamentals Measuring Instruments Lab

Purpose: To familiarize students with the construction and use of line gradated and micrometer type instruments and transfer tools Measurement Exercises: See the attached data sheets, measure the required dimensions, record the measurement directly on them. Attach these sheets to the report. Questions: 1. Discuss the term Parallax Error associated with steel scale measurements. 2. A micrometer type instrument achieves magnification by two basic principles. Explain these. 3. Describe possible errors when measuring outside diameter of a part using a vernier caliper. 4. Are these errors random or systematic? How would you reduce these errors? 5. What does Traceability mean when applied to measuring instruments?

Ryerson University Department of Mechanical and Industrial Engineering

MEC 322 Manufacturing Fundamentals Measurement by comparison and Dial Indictor Lab

Purpose: Understanding the principles of measurement by comparison and learning how to setup and use different types of comparators and dial indicators. Part A Measurement Exercises: 1. Setup the Sheffield pneumatic column gauge with the master ring gauge set provided and measure the inside diameters of the parts using the highest magnification possible ( record all settings and measurements). 2. Setup and adjust the Sigma pressure drop pneumatic comparator using the 12.74 mm. set, then measure the parts provided. 3. Use Sigma mechanical comparator to inspect the height of the cylindrical part. Use a gage block stack equal to nominal size. Questions – Part A: 1 . What advantages do electronic comparators have over mechanical comparators? 2. State one advantage, one disadvantage of the air gauge compared to other principles of magnification. 3. In your own words, define “resolution" as applicable. Does Sigma mechanical Comparator have enough resolution for measuring the cylinder in part 3? Explain why or why not.

Part B: Inspecting parallelism Tolerance Measure the deviation from parallelism for the part shown in Figure 1 using the mandrel provided (Figure 2)

Part C: Inspecting Runout and Total Runout Tolerances Measure the runout on section X of the shaft in Figure 3. Measure the total runout on section Y of the shaft. Part D: Inspecting Angularity Tolerance Measure the angularity tolerance for the specimen shown in Figure 4 by using the setup in Figure 5. Hint : Use a gage block stack to setup the sine bar equal to nominal angle. Questions – Part B, C and D: 1. Describe the procedure for calibrating a dial indicator? 2. What are some of the sources of systematic error when using dial indicators? 3. Describe sources of random error when using dial indicators.

Y Y X

Figure 3

Figure 4 Figure 5

0.007 -A-

0.002 -A-

0.010 -A-

A

Ryerson University Department of Mechanical and Industrial Engineering

MEC 322 Manufacturing Fundamentals Optical metrology Lab

Purpose: To familiarize students with measuring tools that use optical methods Part A: Optical Projector 1. Check the zero of the vernier protractor on the screen. First set the protractor scale on zero. Then, using the test in gauge on the table, project the image (shadow) of the vertical pin on the screen and adjust the table vertically until the tip of the shadow just contacts the horizontal cross line. Traverse the table horizontally using the micrometer and note if the shadow moves in contact with the cross line, adjust if screen position if necessary. 2. Determine system magnification by measuring: a) magnified pin diameter. b) actual pin diameter. 3. Setup the given tap between centers and measuring directly from the screen determine the following screw thread dimensions: a) Major diameter b) Minor diameter c) Average Pitch (use 4 pitches) Note: Dimensions measured directly off the screen are affected by system magnification. 4. For the same tap, this time using the micrometers on the projector measure: a) the pitch b) the pitch diameter c) calculate the lead angle

Part B: Toolmakers Microscope 1.Check and set, if necessary, the zero of the eyepiece vernier protractor as follows: Set the protractor scale at zero as shown in Fig. I. Then verify that the horizontal cross line is parallel to the cross travel of the stage. To do this, rotate the side micrometer knob and note that any object viewed thru the eyepiece runs parallel to the cross line. 2. Setup the watch plate (Fig II) such that the pins centre line is parallel to the horizontal cross line on the eye piece, then take measurements to determine the centre distance of the pins. Record the measurements to four decimal places. 3. Measure the diameter of the hole on the watch plate.

Figure I Figure II

Part C: Measurement Using Optical Flats In the Figure A (highly exaggerated) height of the gage-block stack is 0.9420 in. The other dimensions are as given . Use a monochromatic helium light source (λ=23.2 μin.), to measure the diameter of the cylindrical plug gage within the resolution provided by this setup. Figure A Questions: 1. Describe possible errors when measuring major diameter of the screw. Are these errors random or systemic? How would you reduce these errors? 2. Describe possible errors when measuring the pin using the toolmakers microscope. Are these errors random or systemic? How would you reduce these errors? 3. Suggest the reason why the cross lines on optical projector and the microscope are broken lines and not solid lines What is the resolution of the measurement using optical flat.

Ryerson University Department of Mechanical and Industrial Engineering

MEC 322 Manufacturing Fundamentals Coordinate Measuring Machine

Measurement & Reverse Engineering

This lab will illustrate the application of a coordinate measuring machine (CMM) for quality control in industry and as a measuring tool for a part’s dimensions

Equipment:

• Brown & Sharp Micro-Hite CMM with pcDMIS software. • TesaSTAR Touch trigger ball probe. • Rectangular part to be measured. • 1 pair clamps. • USB key to save your files – student to supply

Experimental Setup:

Before measurements can be taken, the probe must be calibrated and the part coordinate system (datum) must be defined. To calibrate the probe, a minimum of 5 “hits” must be taken on the reference sphere. The Precision Reference Sphere is 0.7500 inches in diameter and is calibrated to 0.00002 inches. Usually, it is mounted on the CMM table at a location that does not interfere with the normal movements of the probe during part measurement. The axis of the part must now be defined relative to the machine’s axis. The part should be placed on the table so that its axis lines up approximately with the axis of the machine (within 30°). The axis of the part is defined by taking several hits on the part surface. During measurement, the computer will make the necessary calculations to compensate for the misalignment between the part and machine axis and for the radius of the probe ball.

To measure with the ball probe, firmly hold the probe as close as possible to the end of the arm and gently make contact with the surface of the part. Be sure there are no vibrations or bouncing and that the probe has come completely to rest against the part. Be careful not to slide the probe on the part surface. Make sure you move away perpendicular to the surface being measured. BE VERY CAREFUL AS THE TOUCH PROBE IS VERY FRAGILE! Make sure you lock all the axis when you are not moving the CMM.

Part A - Calibration and Alignment Setup

1) Make sure that your USB key is in the computer 2) From the computer’s desktop, select the pcDMIS icon (looks like a blue globe) 3) Once up, we will tell pcDMIS save the data files to your USB key:

a. EDIT SET SEARCH PATH enter the path to your USB key Note: you must do this for both: “Default Part Program Directory” “Probe Directory”

4) FILE NEW PART NAME “name your file” Select “inches” radio button and hit OK.

5) Probe Calibration VIEW OTHER QUICK START

A new window will pop up – first we will define the probe by selecting the icon on the left that looks like a probe. CALIBRATE PROBE – find the “PROBE_TESASTAR” from the list TIP#1 – find the “TIP3BY12mm” for the 3mm tip from the list MEASURE – hit that button for a new window to pop up NUMBER OF HITS 5 and click the MANUAL radio button. Hit the MEASURE button – now a new pop up window will tell you to “Take Hit 1 of 5” Once you’ve taken 5 hits on the calibration ball, click CONTINUE You are now ready for the part alignment.

6) Setting the part alignment and origin From the QUICK START window select ALIGNEMENT PLANE/LINE/LINE

The origin and axis alignment will be defined by the intersection of a plane on the top of the part (touch pts. 1-3 on the part top and hit END) and a line across the front of the part (pts. 4-5 and hit END) and a line up the left side (pts. 6-7 on the lower step edge and hit END). You may need to scroll down your quick start menu to see the entities that you are measuring.

7) Your origin should now be placed in the lower right hand corner of your part. To verify, you can move the CMM probe over that point and see the X and Y go to zero. You can now close your quick start menu.

ASIDE – Shortcut Keys CTRL-W - to turn on the live co-ordinates. CTRL-N - move cursor to end of the program. CTRL-E - to redo a whole measurement entity in the edit window ALT- minus - to delete the last measurement hit. END or CMM scroll wheel button - to finish a series of measurements F9 - change parameters of an entity in the EDIT window F5 - set up menu

2

3

1

4 5

6

7

Part B – Measurement Exercise and Manual Reverse Engineering

You will be required to record the measurements listed on Table 1. Use your measurements to finish reverse engineering the part (incomplete drawing shown under table, you are to redraw this in Solidworks with your actual measurements).

Simple Entities – to measure a simple entity, select the correct one from the measurement toolbar (point, line, circle, plane, etc) and then collect the points with the touch probe. Press END after you have collected your points for that entity. ie. POINT min 1 pts., LINE min of 2 pts., CIRCLE and PLANE min of 3 pts. After you hit END, you will see the data show up on the EDIT window on the left hand side. For example, to measure the thickness of the part, measure a POINT on the CMM table.

Measurement – for simple measurements such as (1) from Table 1, measure a point on the CMM table. This is now PNT2. Select the [+] button on the GD&T toolbar. A pop up window will now show all the entities. To calculate the distance, select PLN1 and PNT2, select the appropriate axis, and whether its parallel or perpendicular. Click CREATE, and CLOSE to close the pop-up window.

Creating a CMM Report – WINDOW REPORTS WINDOW will create a cmm report on the right hand side of the screen. It will create a line of data for every GD&T Measurement entity. You’ll need to hit the REFRESH icon each time [looks like a broom]. To go back to your graphical screen WINDOW GRAPHICAL. For example, if you hit REFRESH is should create a line for the measurement between PNT2 and PLN1 from the paragraph above.

Constructions – Sometimes, certain measurements must be constructed from other measurement entities. For example, (4) from Table 1 is the intersection of a cone with the top surface. First measure the cone using the CONE icon. (For a CONE: take 3 hits in a circle inside the cone, move the z-axis further down and take another 3 hits in a circle) Go to INSERT FEATURE CONSTRUCT and select CIRCLE. Now select your cone, and the top plane (if you have the graphical screen up, it turns red) and select INTERSECTION radio button and hit CREATE (then CLOSE). It will now create a circle in the EDIT window. You will need to use the [+] icon in the GD&T toolbar and select your newly created circle to add the measurement to your CMM report.

For GD&T – you will need 2 entities for measurement (12) in Table 1, parallelism. First, measure a line along the top of the part. Then select the [//] from the GD&T toolbar. In the pop-up window, select DATUM DEFINITIONS and define your A and B datums as in the drawing. Select CREATE and then CLOSE. Now select the line feature you just created, and change the feature control box as per the drawing. (note: you’ll need to remove the Ø symbol in this case)

PDF of your CMM report – FILE PRINTING REPORT WINDOW PRINT_SETUP. Make sure FILE is checked and select PDF. Now go to FILE PRINTING REPORT WINDOW PRINT, and a CMM report will be written to your USB Key.

Part C – Geometric Dimensioning and Tolerancing

One of the great advantages to the CMM is its ability to measure a variety of GD&T with ease. Using the CMM, check measurements 7-12.

Extra Lab Report Requirements In addition to the normal Metrology lab report requirements the following extra Questions are also expected: Part B • Table 1 with your measurements (hand written) and the CMM report. Label the corresponding

measurements on your CMM report with the measurement number on Table 1. • Comment on how the measurements can be used to finish the reverse engineering of the part. • Re-draw the part to ½ scale fully dimensioned in Solidworks with the ACTUAL DIMENSIONS that you

gathered with the CMM, label the GD&T with the appropriate feature control frames. Part C • Comment on measurements 7 through 12 and whether and by how much they satisfy the GD & T • If they do not satisfy GD&T, how can the part be modified such that they can pass inspection. • Also consider the following positional GD&T. Do your measurements indicate that the part meets

the tolerance? By how much? Show any calculations. (bonus tolerance, etc.) Circle Distance

from –A- Distance from –B-

Tolerance GD & T

CIR 5 1.000 3.000 φ1.000

0.990

CIR 6 6.000 3.300 φ0.700

0.750

CIR 7 4.500 2.000 φ2.000

1.995

Table 1 - Data record sheet for Part B: Feature Description Measured Value

1 Thickness of block

2 Height of block

3 Position and diameter of hole CIR 5

X = Y = D =

4 Position and diameter of cone CIR 6 at the top surface.

X = Y = D =

5 Position and diameter of hole CIR 7

X = Y = D =

6 Angle-upper left corner

Degrees =

7 Flatness of top surface

8 Concentricity CIR7 to CIR8

9 Straightness of Surface B

10 Roundness of CIR7

11 Perpendicularity of Surface A to Surface B

12 Parallelism of Surface B to Top Surface