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Fundamentals Of Dimensional Metrology, 6th Edition Solution Manual

Fundamentals Of Dimensional Metrology, 6th Edition Solution Manual helps you prepare for exams with a complete textbook overview.

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

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    iii 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

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    iv P REFACE 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.

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    v P REFACE 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.

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    1 L AB 1 Prerequisite: Chapter 1, Measurement and Metrology Introduction: This lab has three exercises designed to provide insight into the sources from which various lab standards can be traced the art of observation and the ability to accurately record an observation. Finally, the lab will help your students gain insight and practice technical and descriptive writing. Items needed: • For Exercise 2, choose objects for students to prepare a written description. Objects may include various size gage blocks, steel rules, sine plates, angle blocks, feeler guages, or other classroom objects. The purpose of Exercise 2 is, not it to provide practical technical writing practice.

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    2 L AB 1 Name: Date: E XERCISE 1 Use 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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    L AB 1 3 3. In what areas of expertise does NIST offer support? ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 4. Where are NIST’s primary locations? ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

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    4 L AB 1 5. 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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    L AB 1 5 E XERCISE 2 Select an item provided by your instructor and give enough written detail for others to be able to identify the item you are describing. All reports from this exercise must be detailed enough that if the report was handed to someone else, and the experiment or measurement repeated, the results would be the same or nearly the same. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ E XERCISE 3 Technical writing is crucial to successful engineering communication. The metrological document must provide complete, concise, accurate information and data to allow the reader to reconstruct the activity over the course of time. Discuss the differences that may exist between descriptive writing and technical writing. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

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    6 L AB 2 Prerequisite: Chapter 2, Language and Systems of Measurement Introduction: In this lab, students will explore variation, accuracy, precision, and repeatability. The lab includes a number of exercises, each adding more variation to the simple process of cutting a straw, until the final exercise, which is designed to help improve accuracy and precision, 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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    L AB 2 7 Name: Date: E XERCISE 1 Cut a plastic straw into six one-inch increments using the lined instrument provided by the instructor. Once each section is cut, line your segments up and compare the lengths of each 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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    8 L AB 2 E XERCISE 2 Pair 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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    L AB 2 9 E XERCISE 3 Line up your straw segments with the segments from the rest of the class. Compare the lengths 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? ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ E XERCISE 4 As a class, discuss possible methods of improving precision and accuracy and reducing variation. Repeating this exercise achieve better results? Why or why not? ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

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    10 L AB 2 R EPORT Write a report summarizing Exercises 1, 2, and 3. Use the following sections to organize your report. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Objective: ______________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Outcome(s): _____________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Data: ___________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

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    L AB 2 11 Observations: ____________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Conclusion: _____________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

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