SteveHastings - Sixth Edition    Connie L. Dotson  iii ©...

      Lab Manual  Steve Hastings        Fundamentals of Dimensional Metrology  Sixth Edition    Connie L. Dotson 

iii © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.Table of Contents Preface ......................................................................................................... iv Lab 1 - Chapter 1: Measurement and Metrology ........................................ 1 Lab 2 - Chapter 2: Language and Systems of Measurement ....................... 6

Lab 3 - Chapter 5: Measurement with Graduated Scales

and Scaled Instruments ....................................................................... 12 Lab 4 - Chapter 6: Vernier Instruments ..................................................... 16 Lab 5 - Chapter 7: Micrometer Instruments .............................................. 20 Lab 6 - Chapter 8: Development and Use of Gage Blocks ....................... 24 Lab 7 - Chapter 9: Calibration ................................................................... 27 Lab 8 - Chapter 10: Measurement by Comparison .................................... 30 Lab 9 - Chapter 11: Reference Planes ....................................................... 33 Lab 10 - Chapter 12: Angle Measurement ................................................ 37 Lab 11 - Chapter 13: Surface Measurement .............................................. 41 Lab 12 - Chapter 14: High-Amplification Comparators ........................... 44 Lab 13 - Chapter 15: Pneumatic Measurement ......................................... 47 Lab 14 - Chapter 16: Optical Flats and Optical Alignment ....................... 50 Lab 15 - Chapter 17: Optical Metrology ................................................... 53 Lab 16 - Chapter 18: Coordinate Measuring Machines ............................ 57 Appendix ..................................................................................................... 60

iv © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.

PREFACE

This is the first edition of the lab manual that is being introduced in association with the release of the 6 th edition of Fundamentals of Dimensional Metrology by Connie L.Dotson. This lab manual may be used as a guide or as a complete workbook to provide a hands-on lab experience with select chapters of the book. In addition to the experience of using various metrological instruments, technical writing is a critical feature of this lab manual. The goal is to help students develop their writing abilities as they become skilled in using metrological instruments and are more able to accurately and succinctly document their data findings.Introduction Of the many challenges associated with teaching metrology, students’ ability to gain hands-on experience with various measurement instruments and systems is important. To

this end, the following recommendations are made:

Consider dividing the class of students into teams comprised of just of two members. Each team will then be able to have one student conduct a measurement while the other student records the data. It has been my experience that this mutual support works very well with larger class sizes. However, this approach does not negate the student’s responsibility to individually complete their own work and lab reports.The chapters are divided into two sections. The first part of each chapter describes the content, learning objectives, and required classroom material or tools for you as the instructor.The second part contains student exercises, which may be printed as handouts.Provide as many variations of measurement instruments and equipment as possible to provide as broad an exposure as possible, reduce the delay of team use, and increase throughput. Certainly, having more than one of the more technically advanced systems such as the optical comparator, or the coordinate measuring or vision system may present their own unique challenges.

v P REFACE © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.The labs in this manual generate data, so students should bring their own writing utensils and paper to record their data. An emerging trend is the use of personal electronic devices such as phones with cameras and electronic tablets to take pictures of lab setups and parts, as well as to record data directly to a spreadsheet format for the lab report.Geometric and dimensional tolerancing, as well as statistical analysis, are key ingredients to successful measurements and process control. Statistical calculations have been incorporated into the lab process to allow insight into the usefulness of the generated data. It is recommended that GD&T be incorporated into the CMM demonstration.Lab Safety A safe learning environment is required for any lab to be successful. Standard safety operating procedures and the use of personal protection items should be reviewed at the beginning of each new term. The following suggestions are the minimum recommendations that should be considered for any metrology lab.• Provide a map showing the location of emergency exits and that describes exit procedures and review it often.• ANSI Z87.1 certified safety glasses. Preferably non-tinted. Students already wearing glasses should verify the impact resistance of their glasses and incorporate the use of appropriate side shields.• Closed-toe shoes.About the Author Steve gained over 37 years of experience working in the automotive industry in a number of capacities and functions. His experiences included engineering labs, original equipment sales, marketing and aftermarket sales, and service distribution networks. During the latter part of his career, he returned to his passion of engineering and gained varied experiences in product engineering, systems engineering, and engineering management. His global experiences gave him valuable insight into the integration of science, technology, engineering, and manufacturing. He is currently working at a major state university as a senior lab coordinator and has taught a metrology class for a number of years.