dimensional calibration technique on dial gauge and dial test indicator
PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
DIMENSIONAL CALIBRATION TECHNIQUE ON DIAL GAUGE AND DIAL TEST INDICATOR (CONCEPT & PRACTICAL) DURATION: 3 DAYS; TIME SCHEDULE Time - 9:00am to 5:00pm Break - 10:15am to 10.30am and 3:15pm to 3:30pm Lunch - 1:00pm to 2:00pm INTRODUCTION Metrology is the science of measurement that is included all theoretical and practical aspects of measurement. There are an infinite number of measurements are made every day in the world, especially in trade, industry, and scientific laboratories. The measurement results can be used to know the properties of the certain phenomenon in our daily live. A parameter under measurement can be either a physical parameter (Physical Metrology) or an analytical or chemical parameter (Chemical Metrology). The measurement based on the application of the measurement result leads to three branches of metrology; there are legal metrology, industrial metrology, and scientific metrology. In the field of scientific metrology, there are three types of laboratories; calibration laboratory, testing laboratory and research & development laboratory. All measurements made in calibration laboratories are using some type of testing and measuring instruments, such as reference measuring instruments, standard chemicals, and certified reference materials. A measurement result is valid only if it has been made with a measuring instrument that has been calibrated. Calibration is the process of ensuring the integrity accuracy of measuring instruments that is the accuracy of a measuring instrument compares with an appropriately calibrated laboratory reference standard. The process of calibration not just ensures the traceability of measurement results to national standards but also the measurements of uncertainties have to identify for the measurements are made. The calibration process is also sometimes called the calibration system, which has been defined as the collection of operations, procedures, device for measuring and other equipment, software, and personnel used to assign a number to the characteristics being measured, then this complete process used to obtain the measurement result. Calibration systems are used to verify that instruments or materials meet the requirements. This is an important activity used the measurement results to justify that instruments or materials are complying with their specifications. The calibration laboratory objective or fulfil customer satisfaction can be achieved by proper laboratory management system and competency on the calibration skill. These requirements can be referred ISO/IEC 17025: General requirements for the competence of testing and calibration laboratories, and SAMM (Laboratory Accreditation Scheme of Malaysia) that is cover management and technical requirements for calibration laboratory. The international standard methods of calibration published by ASME, ASTM, BS, JIS, MS, NIST and so on is available as references for competency on calibration skill. The fulfilments of these requirements, the laboratory shall have appropriate guidelines in management, calibration techniques, documentation, and control of records or data and so on. One of the most importance documents is standard operating procedure that may cover the step by step to perform calibration and calculation of measurement errors and uncertainties.
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PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
Dimensional Metrology or dimensional measurement is using physical measurement equipment to quantify the physical size of or distance from any given object. Dimensional measurement requires the use of a variety of physical scales to determine the dimension, with the most common tools are calipers, micrometers, dial test indicator, height gauges, measuring scopes and so on, and for three-dimensional measurement such as coordinate measuring machine up to be most accurate at these being laser interferometers. The end of this measurement traceability is defined as the length of the path traveled by light in a vacuum during a time interval of 1/299,792, 458 of a second. It is no longer defined as a material artifact and unit is meter or “m”. Dial Gauge and Dial Test Indicator are one-dimensional measuring device and commonly used in the industrial. The Dial Gauge can be measured the length up to 100mm, whereas Dial Test Indicator just measures the small length normally used to measure flatness and parallelism of a surface. The best discriminations for Dial Gauge and Dial Test Indicator are 10 micrometer and 1 micrometer respectively for analog type, but for the digital or electronic type may have better discriminations. The calibration characteristics for these small tools are the discrimination, repeatability, adjacent errors and retrace errors of the linear travelling. The main factors for making quality of measurement results by using these instruments is shall comply with Abbe’s law. When we rely on results of measurement, these factors must be established before making any measurement The national and international metrology organization and discipline of metrology may be classified into legal, industrial, and scientific categories depending upon the application of measurement results. The types of laboratories that are depending on their function, especially calibration laboratory will be introduced in this training. This training provides knowledge of the calibration systems such as measurement traceability, measurement uncertainty, proficiency test to determine the uniformity of calibration performance, calibration procedures, method and technical skill to perform calibration follow metrological requirements such as selection of appropriate reference standard instruments, collection data, calculation of errors and measurement uncertainty, recording calibration condition, preparation calibration certificate and so on. This training covers general knowledge of dimensional metrology tools as per mention of the above. The maintenance and calibration, measurement awareness that includes the concept of measurement, methods & technical skill to perform calibration, control of measurement errors and use Microsoft Excel to document measurement uncertainties. The references use in this training are ISO/IEC 17025, SAMM, JIS B7503 and BS 907. The reference standards used for these calibrations are Precision Calibration Tester or Optimar 100 and granite surface plate. The ranges of these units under calibration are 10mm for Dial Gauge and 1mm for Dial Test Indicator.
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PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
BENEFITS Upon completion of this program, participants will be able to: Understand the principle concepts on measurement and calibration. Know type of measurement errors and precaution about these errors. Handle measuring devises in appropriate way. Show confidence on calibration of the dimensional instruments Estimate measurement uncertainties appropriately by using Microsoft Excel. Monitor accuracy of dimensional instruments through calibration and maintenance program. Interpret contain of the measurement results and calibration certificates. Produce calibration certificate follow the metrological requirements. Justify calibration principle and requirements for dimensional instruments. Answer the questions are raised regarding the calibration of dimensional instrument during the quality auditing KEY CONTENT MODULE 1 - DIMENSIONAL METROLOGY Introduction To Metrology Metrology Organization In Calibration Base Units Dimensional Measurement Dimensional Tools Review Questions MODULE 2 - CALIBRATION AND ACCREDITATION LABORATORY Definition Of Calibration Standards Used o ISO/IEC 17025 (Management And Technical Requirements) o SAMM (Accreditation Requirements) o Standard Calibration Methods o Other Standards Documentation Accommodation And Environmental Conditions Calibration Certificates Calibration Directories Scope Of Accreditation Proficiency Testing Review Questions MODULE 3 - THE APPLICATION OF BASIC STATISTICAL AND PROBABILITY IN METROLOGY Statistical Probability Distributions Review Questions MODULE 4 - METROLOGICAL REQUIREMENTS Measurement Traceability Measurement Uncertainty Review Questions
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PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
MODULE 5 - INTRODUCTION TO DIMENSIONAL TOOLS Caliper External Micrometer Review Questions MODULE 6 - STANDARD CALIBRATION METHODS Calibration Criteria o Linear Travelling Accuracy o Measuring Faces Accuracy Flatness Parallelism Caliper, JIS B 7507: Vernier, Dial And Digital Calipers External Micrometer, JIS B 7502: Micrometer Calipers For External Measurement Review Questions MODULE 7 - STANDARD WORK INSTRUCTION FOR DIAL GAUGE AND DIAL TEST INDICATOR Purpose Scope References And Tolerances Calibration Standards (Masters) And Tools Environment Control Pre Functional Check (Unit Under Calibration) Check Sheet Calibration Steps Calculation On Measurement Errors And Uncertainties Judgments Post Functional Check Calibration Certificate Terminology And Nomenclature References MODULE 8 - CALIBRATION WORK EXAMPLE BY USING MICROSOFT EXCEL Functions And Formulas Preparation Reports Format Upload Calibration Data Generate Measurement Uncertainty Reports And Calibration Certificates Presentation Of Calibration Certificates MODULE 9 - MULTIPLE CHOICE QUIZ QUESTIONS Exercise (50 Objective Questions) MODULE 10 - APPENDIX Terminology Statistical Table REFERENCES
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PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
AUDIENCE This program is suitable for Engineers, Technician and person closely concern with calibration and measurement. METHODOLOGY This stimulating program will maximizes the understanding and learning through Training slides, Review Questions, Quiz, Case Study, Q&A and Calibration Demonstration.
141216 5|P a g e
Website: www.quorse.com
DIMENSIONAL CALIBRATION TECHNIQUE ON DIAL GAUGE AND DIAL TEST INDICATOR (CONCEPT & PRACTICAL) DURATION: 3 DAYS; TIME SCHEDULE Time - 9:00am to 5:00pm Break - 10:15am to 10.30am and 3:15pm to 3:30pm Lunch - 1:00pm to 2:00pm INTRODUCTION Metrology is the science of measurement that is included all theoretical and practical aspects of measurement. There are an infinite number of measurements are made every day in the world, especially in trade, industry, and scientific laboratories. The measurement results can be used to know the properties of the certain phenomenon in our daily live. A parameter under measurement can be either a physical parameter (Physical Metrology) or an analytical or chemical parameter (Chemical Metrology). The measurement based on the application of the measurement result leads to three branches of metrology; there are legal metrology, industrial metrology, and scientific metrology. In the field of scientific metrology, there are three types of laboratories; calibration laboratory, testing laboratory and research & development laboratory. All measurements made in calibration laboratories are using some type of testing and measuring instruments, such as reference measuring instruments, standard chemicals, and certified reference materials. A measurement result is valid only if it has been made with a measuring instrument that has been calibrated. Calibration is the process of ensuring the integrity accuracy of measuring instruments that is the accuracy of a measuring instrument compares with an appropriately calibrated laboratory reference standard. The process of calibration not just ensures the traceability of measurement results to national standards but also the measurements of uncertainties have to identify for the measurements are made. The calibration process is also sometimes called the calibration system, which has been defined as the collection of operations, procedures, device for measuring and other equipment, software, and personnel used to assign a number to the characteristics being measured, then this complete process used to obtain the measurement result. Calibration systems are used to verify that instruments or materials meet the requirements. This is an important activity used the measurement results to justify that instruments or materials are complying with their specifications. The calibration laboratory objective or fulfil customer satisfaction can be achieved by proper laboratory management system and competency on the calibration skill. These requirements can be referred ISO/IEC 17025: General requirements for the competence of testing and calibration laboratories, and SAMM (Laboratory Accreditation Scheme of Malaysia) that is cover management and technical requirements for calibration laboratory. The international standard methods of calibration published by ASME, ASTM, BS, JIS, MS, NIST and so on is available as references for competency on calibration skill. The fulfilments of these requirements, the laboratory shall have appropriate guidelines in management, calibration techniques, documentation, and control of records or data and so on. One of the most importance documents is standard operating procedure that may cover the step by step to perform calibration and calculation of measurement errors and uncertainties.
1|P a g e
PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
Dimensional Metrology or dimensional measurement is using physical measurement equipment to quantify the physical size of or distance from any given object. Dimensional measurement requires the use of a variety of physical scales to determine the dimension, with the most common tools are calipers, micrometers, dial test indicator, height gauges, measuring scopes and so on, and for three-dimensional measurement such as coordinate measuring machine up to be most accurate at these being laser interferometers. The end of this measurement traceability is defined as the length of the path traveled by light in a vacuum during a time interval of 1/299,792, 458 of a second. It is no longer defined as a material artifact and unit is meter or “m”. Dial Gauge and Dial Test Indicator are one-dimensional measuring device and commonly used in the industrial. The Dial Gauge can be measured the length up to 100mm, whereas Dial Test Indicator just measures the small length normally used to measure flatness and parallelism of a surface. The best discriminations for Dial Gauge and Dial Test Indicator are 10 micrometer and 1 micrometer respectively for analog type, but for the digital or electronic type may have better discriminations. The calibration characteristics for these small tools are the discrimination, repeatability, adjacent errors and retrace errors of the linear travelling. The main factors for making quality of measurement results by using these instruments is shall comply with Abbe’s law. When we rely on results of measurement, these factors must be established before making any measurement The national and international metrology organization and discipline of metrology may be classified into legal, industrial, and scientific categories depending upon the application of measurement results. The types of laboratories that are depending on their function, especially calibration laboratory will be introduced in this training. This training provides knowledge of the calibration systems such as measurement traceability, measurement uncertainty, proficiency test to determine the uniformity of calibration performance, calibration procedures, method and technical skill to perform calibration follow metrological requirements such as selection of appropriate reference standard instruments, collection data, calculation of errors and measurement uncertainty, recording calibration condition, preparation calibration certificate and so on. This training covers general knowledge of dimensional metrology tools as per mention of the above. The maintenance and calibration, measurement awareness that includes the concept of measurement, methods & technical skill to perform calibration, control of measurement errors and use Microsoft Excel to document measurement uncertainties. The references use in this training are ISO/IEC 17025, SAMM, JIS B7503 and BS 907. The reference standards used for these calibrations are Precision Calibration Tester or Optimar 100 and granite surface plate. The ranges of these units under calibration are 10mm for Dial Gauge and 1mm for Dial Test Indicator.
2|P a g e
PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
BENEFITS Upon completion of this program, participants will be able to: Understand the principle concepts on measurement and calibration. Know type of measurement errors and precaution about these errors. Handle measuring devises in appropriate way. Show confidence on calibration of the dimensional instruments Estimate measurement uncertainties appropriately by using Microsoft Excel. Monitor accuracy of dimensional instruments through calibration and maintenance program. Interpret contain of the measurement results and calibration certificates. Produce calibration certificate follow the metrological requirements. Justify calibration principle and requirements for dimensional instruments. Answer the questions are raised regarding the calibration of dimensional instrument during the quality auditing KEY CONTENT MODULE 1 - DIMENSIONAL METROLOGY Introduction To Metrology Metrology Organization In Calibration Base Units Dimensional Measurement Dimensional Tools Review Questions MODULE 2 - CALIBRATION AND ACCREDITATION LABORATORY Definition Of Calibration Standards Used o ISO/IEC 17025 (Management And Technical Requirements) o SAMM (Accreditation Requirements) o Standard Calibration Methods o Other Standards Documentation Accommodation And Environmental Conditions Calibration Certificates Calibration Directories Scope Of Accreditation Proficiency Testing Review Questions MODULE 3 - THE APPLICATION OF BASIC STATISTICAL AND PROBABILITY IN METROLOGY Statistical Probability Distributions Review Questions MODULE 4 - METROLOGICAL REQUIREMENTS Measurement Traceability Measurement Uncertainty Review Questions
3|P a g e
PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
MODULE 5 - INTRODUCTION TO DIMENSIONAL TOOLS Caliper External Micrometer Review Questions MODULE 6 - STANDARD CALIBRATION METHODS Calibration Criteria o Linear Travelling Accuracy o Measuring Faces Accuracy Flatness Parallelism Caliper, JIS B 7507: Vernier, Dial And Digital Calipers External Micrometer, JIS B 7502: Micrometer Calipers For External Measurement Review Questions MODULE 7 - STANDARD WORK INSTRUCTION FOR DIAL GAUGE AND DIAL TEST INDICATOR Purpose Scope References And Tolerances Calibration Standards (Masters) And Tools Environment Control Pre Functional Check (Unit Under Calibration) Check Sheet Calibration Steps Calculation On Measurement Errors And Uncertainties Judgments Post Functional Check Calibration Certificate Terminology And Nomenclature References MODULE 8 - CALIBRATION WORK EXAMPLE BY USING MICROSOFT EXCEL Functions And Formulas Preparation Reports Format Upload Calibration Data Generate Measurement Uncertainty Reports And Calibration Certificates Presentation Of Calibration Certificates MODULE 9 - MULTIPLE CHOICE QUIZ QUESTIONS Exercise (50 Objective Questions) MODULE 10 - APPENDIX Terminology Statistical Table REFERENCES
4|P a g e
PROFESSIONAL TRAINING MADE EASY
Website: www.quorse.com
AUDIENCE This program is suitable for Engineers, Technician and person closely concern with calibration and measurement. METHODOLOGY This stimulating program will maximizes the understanding and learning through Training slides, Review Questions, Quiz, Case Study, Q&A and Calibration Demonstration.
141216 5|P a g e
