Fundamentals Of Dimensional Metrology, 6th Edition Solution Manual

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LabManualSteveHastingsFundamentalsofDimensionalMetrologySixthEditionConnieL.Dotson

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iiiTable of ContentsPreface ......................................................................................................... ivLab 1 - Chapter 1: Measurement and Metrology ........................................ 1Lab 2 - Chapter 2: Language and Systems of Measurement ....................... 6Lab 3 - Chapter 5: Measurement with Graduated Scalesand Scaled Instruments ....................................................................... 12Lab 4 - Chapter 6: Vernier Instruments ..................................................... 16Lab 5 - Chapter 7: Micrometer Instruments .............................................. 20Lab 6 - Chapter 8: Development and Use of Gage Blocks ....................... 24Lab 7 - Chapter 9: Calibration ................................................................... 27Lab 8 - Chapter 10: Measurement by Comparison .................................... 30Lab 9 - Chapter 11: Reference Planes ....................................................... 33Lab 10 - Chapter 12: Angle Measurement ................................................ 37Lab 11 - Chapter 13: Surface Measurement .............................................. 41Lab 12 - Chapter 14: High-Amplification Comparators ........................... 44Lab 13 - Chapter 15: Pneumatic Measurement ......................................... 47Lab 14 - Chapter 16: Optical Flats and Optical Alignment ....................... 50Lab 15 - Chapter 17: Optical Metrology ................................................... 53Lab 16 - Chapter 18: Coordinate Measuring Machines ............................ 57Appendix ..................................................................................................... 60

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ivPREFACEThis is the first edition of the lab manual that is being introduced in association with therelease of the 6thedition ofFundamentals of Dimensional Metrologyby Connie L.Dotson. This lab manual may be used as a guide or as a complete workbook to provide ahands-on lab experience with select chapters of the book. In addition to the experience ofusing various metrological instruments, technical writing is a critical feature of this labmanual. The goal is to help students develop their writing abilities as they become skilledin using metrological instruments and are more able to accurately and succinctlydocument their data findings.IntroductionOf the many challenges associated with teaching metrology, students’ ability to gainhands-on experience with various measurement instruments and systems is important. Tothis end, the following recommendations are made:Consider dividing the class of students into teams comprised of just of twomembers. Each team will then be able to have one student conduct a measurement whilethe other student records the data. It has been my experience that this mutual supportworks very well with larger class sizes. However, this approach does not negate thestudent’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 thecontent, 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 possibleto provide as broad an exposure as possible, reduce the delay of team use, and increasethroughput. Certainly, having more than one of the more technically advanced systemssuch as the optical comparator, or the coordinate measuring or vision system may presenttheir own unique challenges.

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vPREFACEThe labs in this manual generate data, so students should bring their own writingutensils and paper to record their data. An emerging trend is the use of personal electronicdevices such as phones with cameras and electronic tablets to take pictures of lab setupsand 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 keyingredients to successful measurements and process control. Statistical calculations havebeen incorporated into the lab process to allow insight into the usefulness of the generateddata. It is recommended that GD&T be incorporated into the CMM demonstration.Lab SafetyA safe learning environment is required for any lab to be successful. Standard safetyoperating procedures and the use of personal protection items should be reviewed at thebeginning of each new term. The following suggestions are the minimumrecommendations that should be considered for any metrology lab.•Provide a map showing the location of emergency exits and that describes exitprocedures and review it often.•ANSI Z87.1 certified safety glasses. Preferably non-tinted. Students alreadywearing glasses should verify the impact resistance of their glasses andincorporate the use of appropriate side shields.•Closed-toe shoes.About the AuthorSteve gained over 37 years of experience working in the automotive industry in a numberof capacities and functions. His experiences included engineering labs, original equipmentsales, marketing and aftermarket sales, and service distribution networks. During the latterpart of his career, he returned to his passion of engineering and gained varied experiencesin product engineering, systems engineering, and engineering management. His globalexperiences gave him valuable insight into the integration of science, technology,engineering, and manufacturing. He is currently working at a major state university as asenior lab coordinator and has taught a metrology class for a number of years.

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1LAB1Prerequisite:Chapter 1, Measurement and MetrologyIntroduction:This lab has three exercises designed to provide insight into the sources from whichvarious lab standards can be traced the art of observation and the ability to accuratelyrecord an observation. Finally, the lab will help your students gain insight and practicetechnical and descriptive writing.Items needed:•For Exercise 2, choose objects for students to prepare a written description.Objectsmay include various size gage blocks, steel rules, sine plates, angle blocks, feelerguages, or other classroom objects. The purpose of Exercise 2 is, not it to providepractical technical writing practice.

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2LAB1Name:Date:EXERCISE1Use the Internet to visit the National Institute of Standards and Technology (NIST.gov).Answer the following questions:1.What is the purpose of NIST?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________2.Who can use NIST resources?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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LAB133.In what areas of expertise does NIST offer support?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________4.Where are NIST’s primary locations?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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4LAB15.Why does the United States need NIST?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________6.List three organizations similar to NIST that reside in other countries.a._________________________________________________________________b._________________________________________________________________c._________________________________________________________________

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LAB15EXERCISE2Select an item provided by your instructor and give enough written detail for others to beable to identify the item you are describing. All reports from this exercise must bedetailed enough that if the report was handed to someone else, and the experiment ormeasurement repeated, the results would be the same or nearly the same.________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________EXERCISE3Technical writing is crucial to successful engineering communication. The metrologicaldocument must provide complete, concise, accurate information and data to allow thereader to reconstruct the activity over the course of time. Discuss the differences that mayexist between descriptive writing and technical writing.________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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6LAB2Prerequisite:Chapter 2, Language and Systems of MeasurementIntroduction:In this lab, students will explore variation, accuracy, precision, and repeatability. The labincludes a number of exercises, each adding more variation to the simple process ofcutting a straw, until the final exercise, which is designed to help improve accuracy andprecision, and to reduce variation as much as possible.Items needed:•A variety of scissors and plastic straws•SAE and metric rulers of various lengths and discriminations•The more variants of each tool, the better

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LAB27Name:Date:EXERCISE1Cut a plastic straw into six one-inch increments using the lined instrument provided bythe instructor. Once each section is cut, line your segments up and compare the lengths ofeach to all the others. Now, answer the following questions:1.Was there variation in the length of each segment compared to the other? If so, how much?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________2.Was each segment cut accurately?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________3.Was each segment cut with the same precision?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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8LAB2EXERCISE2Pair with another student and compare your straw segments to each other.Answer the following questions:1.Is there any variation in the length of each of your segments compared to your partners’?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________2.Was each segment cut accurately?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________3.Was each segment cut with the same precision?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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LAB29EXERCISE3Line up your straw segments with the segments from the rest of the class.Compare thelengths of all straw segments and answer the following questions.1.Is there any variation in the lengths of the entire class’s segments?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________2.If so, why?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________EXERCISE4As a class, discuss possible methods of improving precision and accuracy and reducingvariation. Repeating this exercise achieve better results? Why or why not?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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10LAB2REPORTWrite a report summarizing Exercises 1, 2, and 3. Use the following sections to organizeyour report.________________________________________________________________________________________________________________________________________________________________________________________________________________________Objective: ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Outcome(s): _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Data: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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LAB211Observations: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Conclusion: _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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