Advance lab uitm

8/10/2019 Advance lab uitm

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1.0 Title

Calibration of Dial Gauge-product quality

2.0 Objectives1) To understand how calibrate a Dial Gauge using Calibration Tester and find the error on

each reading of the dial gauge and to obtain the accuracy of the gauge.

2) Study how to calibrate dial gauge by using Digital Calibration Tester.

3) To determine the error of the dial gauge reading according to JIS and determine the

validity of the dial gauge reading.

3.0 Introduction

Dial gauge is a precision measurement commonly used to measure machined parts for

production tolerances or wear. Dial gauges are capable of producing extremely fine measurement

values. Accuracy of the dial gauge is important when doing the measuring process as the

sensitivity of the dial gauge is very high and the measurement value increment can measure very

small value of tolerance. Therefore, the calibration of the dial gauge need to be perform at least

once a month so we can determine whether the reading of the dial gauge still valid and accurate

or not.

In this experiment, we have done a calibration process for the dial gauge in two ways that

are manually and by using a computer technique. From the result of the experiment we can

identify the error in the dial gauge measurement reading and justify whether the dial gauge still

can be used or not that is by refer to the error tolerance standard, if the error of the dial gauge

reading exceed the tolerance than we can considered the dial gauge is broken and cannot be use

anymore. The accuracy of the dial gauge reading also have been identify by using digital

indicator process using the computer which will produce more accurate result and faster than themanual analog style. The type of error indicator that have been identify from the experiment are

whole measuring range, 1/2 revolution, 1 revolution, 2 revolution, Narrow range adjacent error,

Retrace error and Repeatability error. All of these errors have been identify according to standard

tolerance for testing routine according to Japan Indicator Standard, JIS. This error will be

compare with the tolerance error that is allowable to the dial gauge to confirm the validity of the


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dial gauge reading. The result will be used to form a graph that is Error of Dial Gauge against

Dial Gauge Reading Graph and Repeatability Graph so that we can understand the result

with easier and more accurate.


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4.0 Apparatus

Figure 1: Manual Dial Indicator Tester

Figure 2: Automatic Dial Indicator Tester


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Figure 3: Thimble

Figure 4: Automatic Dial Indicator Tester with PC


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Checker 170 series - MITUTOYO

4.1 Industrial Apparatus

Figure 5: Dial indicator tester - i- Checker 170 series - MITUTOYO

Figure 6: Dial Indicator tester- ZL20062- SHENZEN CHOTEST


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Figure 7: Dial Indicator tester- ISO 9000-KUDALE

INSTRUMENS


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Advantages and disadvantages of industrial dial indicator tester

Advantages

1. Industrial dial indicator tester provide wide range accuracy

2. Since it is digital and automatic, there is no parallax error or error in reading

3. This tester can save time and the operation is not difficult.

4. The dial indicator can be tested for not only at 90position, but also can be tested for

range 0to 360

5. Adjustment of the measurement position is very easily accomplished because of semi-

automatic measurement and fully automatic measurement functions.

Disadvantages

1. Complete set for dial indicator tester is usually highly cost and its sometimes not practical

for barely use.

2.

Since this is electrical operated instrument, it may affect the operating cost.

3. Misaligned the direction of indicator can cause cosine effect. To avoid this happened,

always minimize the angle between movement directions during use.


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5.0 Experimental Procedure

Note: student should be in proper attire with indoor slippers to reduce dust that will affect the

specimen calculation and avoid touching the specimen area to be measured.

Test 1(Manual Calibration)

1) The dial gauge for calibration is selected.

2) The Dial gauge up on the calibration tester is prepared.

3) The readings over the dial gauge within 0-5 mm range are taken in a series.

4) Micrometer head of the calibration tester is set to zero.

5) The dial gauge reading is adjusted to zero with respect to reference plane.

6) The Micrometer head is turned until the dial gauge reached 0.1.

7) The reading at Micrometer head is taken and the data are recorded.

8) The test is continued from 0.2 until 2.0 with interval of 0.1.

9) Starting from 2.0 until 5.0 the reading is taken with the interval of 0.2.

10)The Micrometer head is then turned backward values.

11)As such, from 5.0 to 2.0 the reading is taken with the interval of 0.2 while, from 2.0-0.0

the reading is taken with the interval of 0.1.

12)After the dial gauge reached 0.0, the micrometer head is turned until the dial gauge

reached 0.1. The reading is taken.

13)

The step 10 is repeated another 4 times.

14)All the data are recorded.


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Test 2 ( Digital Calibration )

1) The Dial gauge is prepared for computer test.

2) The value 0.0 is inserted and the button ENTER is pressed.

3) The Dial Gauge and the computer is set to the value of 0.1 respectively.

4) The test is continued from 0.2 until 2.0 with interval of 0.1.

5) Starting from 2.0 until 5.0 the reading is taken with the interval of 0.2.

6) Dial gauge is then turned backward values.

7) As such, from 5.0 to 2.0 the reading is taken with the interval of 0.2 while, from 2.0-0.0

the reading is taken with the interval of 0.1.

8) After the dial gauge reached 0.0, value 0.1 is ENTER

9) The step 8 is repeated another 4 times.

10)Print the graph and data.


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6.0 Result & Data Analysis

Data Analysis

Manual Calibration

Dial Gauge Reading (mm)

Calibration Tester Reading (Std)

(mm)

Error on Dial Gauge

(mm)

0.0 0.0000 0.0000

0.1 0.1004 -0.0004

0.2 0.2006 -0.0006

0.3 0.3004 -0.0004

0.4 0.4004 -0.0004

0.5 0.5002 -0.0002

0.6 0.6016 -0.0016

0.7 0.7018 -0.0018

0.8 0.8036 -0.0036

0.9 0.9042 -0.0042

1.0 1.0038 -0.0038

1.1 1.1010 -0.0010

1.2 1.2002 -0.0002

1.3 1.3002 -0.0002

1.4 1.4002 -0.0002

1.5 1.4992 0.0008

1.6 1.6014 -0.00141.7 1.7038 -0.0038

1.8 1.8062 -0.0062

1.9 1.9040 -0.0040

2.0 2.0008 -0.0008

2.2 2.2004 -0.0004

2.4 2.4006 -0.0006

2.6 2.6016 -0.0016

2.8 2.8074 -0.0074

3.0 3.0046 -0.0046

3.2 3.2074 -0.00743.4 3.4018 -0.0018

3.6 3.6038 -0.0038

3.8 3.8064 -0.0064

4.0 4.0050 -0.0050

4.5 4.5002 -0.0002

5.0 5.0044 -0.0044


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4.5 4.4982 0.0018

4.0 4.0016 -0.0016

3.8 3.8044 -0.0044

3.6 3.6016 -0.0016

3.4 3.3984 0.0016

3.2 3.1976 0.0024

3.0 3.0016 -0.0016

2.8 2.8044 -0.0044

2.6 2.6006 -0.0006

2.4 2.3988 0.0012

2.2 2.1996 0.0004

2.0 1.9996 0.0004

1.9 1.9016 -0.0016

1.8 1.8032 -0.0032

1.7 1.7038 -0.0038

1.6 1.5996 0.0004

1.5 1.4980 0.0020

1.4 1.3974 0.0026

1.3 1.2982 0.0018

1.2 1.1980 0.0020

1.1 1.0988 0.0012

1.0 1.0008 -0.0008

0.9 0.9032 -0.0032

0.8 0.8048 -0.0048

0.7 0.7026 -0.00260.6 0.6000 0.0000

0.5 0.4972 0.0028

0.4 0.3974 0.0026

0.3 0.2964 0.0036

0.2 0.1982 0.0018

0.1 0.0978 0.0022

0.0 0.0006 -0.0006

Table 1 : Error on Dial Gauge


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Dial Gauge Reading (mm)

Calibration Tester Reading (Std)

(mm)

Error on Dial Gauge

(mm)

0.1 0.1000 0.0000

0.1 0.1002 -0.0002

0.1 0.0998 0.0002

0.1 0.1002 -0.00020.1 0.0998 0.0002

Table 2 : Repeatability

Results Tolerances

Indication error

whole measuring range -2.80 15.00 m

1/2 revolution -3.00 9.00 m

1 revolution -1.50 10.00 m

2 revolution -1.60 15.00 m

Narrow range adjacent error -0.2 8.00 m

Retrace error -9.00 5.00 m

Repeatability error -0.02 5.00 m


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SAMPLE CALCULATION

1) Error on Dial Gauge

g

2) Whole measuring range

() ()

3) 1/2 revolution

() () () () ()

4) 1 revolution

() () ()


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5) 2 Revolution

() () ()

6) Repeatability Error

()

7) Narrow range adjacent error

()

8) Retrace error

()


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Result

Manual Calibration

Object : Dial Indicator Indicator range : 5mm

Manufacturer : Mitutoyo 1 Indicator resolution : 0.01mm

Type : Dial Indicator Revolution : 5

Serial No. : 2046F Order No. : APH750

Inspector : Metrology Test as per : JIS B 7503

Date of Test : 10/14/2014 Testing Increment : 10 div


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Digital Calibration


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7.0 Discussion of Results

Based on this experiment, we had obtained several results and sample of calculations. In

this experiment, there were two types of methods using Calibration Tester, that is manually to

calibrate a Dial Gauge and the other method is by using computer. Both of methods were used to

find the error on each reading of the dial gauge and to obtain the accuracy of the gauge.

From manual calibration of the dial gauge, the result that we obtain from the test is error

on dial gauge reading that is by calculating the different between the Dial gauge reading and the

Calibration Tester Reading. From the result obtain the indicator error has been calculated by

using the definition of each of the indicator error like whole measuring range, 1/2 revolution, 1

revolution, 2 revolution from the Japan Indication Standard. From the comparison between the

result and the tolerance we have observe that none of the error reading exceed the tolerance

provided, this shows that the dial reading is still valid. Next we have identify the narrow range

adjacent error and retrace error by using the error definition of JIS, for the narrow range adjacent

error and retrace error the result value is not exceed the tolerance but the result of the result are

in negative value. Then the graph of Error of Dial Gauge against Dial Gauge reading was plotted

and from the graph we have identify the highest Error of Dial Gauge reading is around negative

0.007mm at 2.5mm to 3.3mm range of Dial Gauge reading which is still below the tolerance

provided. In manual calibration of dial gauge, we also have performed the repeatability test errortest, from the repeatability test result we have identified that the result value does not exceed the

tolerance and from the repeatability graph we have determine the highest error of repeatability

was +0.0002mm and -0.0002mm which is under the tolerance provided.

By using Digital Calibration, it was calibrated by the computer; we can see the error

obtained is slightly different with manually calibration. All of the error is not over exceeding the

tolerances stated. From the graph of Error of Dial Gauge against Dial Gauge plotted by computer

we have identify that the highest value of Error of Dial Gauge are around 0.007mm which is

almost same as the result in manual calibration. This is maybe it was handled by computer which

is obtaining a little bit systematic compared to manually calibration.


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Systematic error can be identified by comparing the results of our experiment with other

experiment results. However, it may not be clear which of the sets of data is accurate.

Calibration is the easiest way to reduce systematic errors. Maybe, the error obtain because of

position eye is not perpendicular to the scale and the apparatus is very sensitive with movement.

Slightly movement will affect the scale.

8.0 Conclusion

Based on this experiment, the error on each reading of the dial gauge was obtained. It can

be stated here that numerous of error happened during carrying out the experiment. After

compared both, it can be conclude that by using computer, the dial gauge was more accurate.

This experiment also has helped us to understands the method in dial gauge calibration process

and how to identify the error in dial gauge so that the reading of the dial gauge are accurate and

valid. The objective of this experiment has been achieved.

From the analysis, by comparing the result of error in dial gauge reading and the

tolerance provided, we can conclude that the readings of this dial gauge are still valid as all the

indicator error of the dial gauge reading does not exceed the standard tolerance provided by the

dial gauge manufacturer according to Japan Indication Standard, JIS.


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9.0 Recommendation

1. The reading of the dial gauge must be repeated so the result obtained is more accurate.

2. The calibration tester that holds the dial gauge must be placed on a rigid table to avoid

shaking happens during the experiment.

3. Before starting the experiment, the dial gauge must be fixed to 0.0 mm to avoid parallax

error.

4. As the reading of the calibration tester is small, a magnifying glass can be used while

taking the reading so that the result is accurate.

5. The calibration tester must be replaced when the anvil shows any binding or twisting

when it is pushed towards the calibration tester.


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10.0 References

1) Serope Kalpakjian, W.R. Schmid, Manufacturing Technology and Fundamental, 5th edition,

Prentice Hall, 2004.

2)

Mikell P. Groover, Automation, Production Systems and Computer Integrated

Manufacturing, 2nd edition, Prentice Hall, 2001

3) Mikell P Groover, Principles of Modern Manufacturing, SI Version, 4th Edition, John Wiley

& Son, Inc, 2011

4) John A. Schey, J.A., "Introduction To Manufacturing Processes", 5th Edition, McGraw-Hill,

2000.

5) Alan S. Morris, Measurement and calibration requirements for quality assurance, Wiley,

19976) Cornell University, Instruments and Control Systems, Chilton Company, 1954

7) Yi Qin, Micromanufacturing Engineering and Technology, William Andrew, 2010

8) Richard Crowson, Jack Walker, Handbook of Manufacturing Engineering, Second Edition,

CRC Press, 1996.

9) Alting, Manufacturing Engineering Processes, Second Edition, CRC Press, 1993

10)Bewoor, Metrology & Measurement, Tata McGraw-Hill Education, 1998

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Advance lab uitm