HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF MECHANICAL ENGINEERING REPORT ADVANCED MECHANICAL MEASURING EXPERIMENT TEACHER Đặng Minh Phụng . Toàn bộ tài liệu được viết bằng tiếng anh do Thầy Đặng Minh Phụng hướng dẫn. Nếu các bạn không biết bắt đầu từ đâu do khối lượng công việc Thầy giao quá nhiều thì đây là tài liệu rất có ích cho bạn.
HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF MECHANICAL ENGINEERING REPORT ADVANCED MECHANICAL MEASURING EXPERIMENT TEACHER: Đặng Minh Phụng STUDENT: MSSV Cù Thái Thiên Long 19143279 Lê Công Lập 19143276 Đặng Minh Hiếu 19143245 Lê Thị Mỹ Lệ 19143277 Châu Nữ Diễm Kiều 19143272 Ho Chi Minh.City, april 5, 2022 TABLE OF CONTENTS Chapter : CMM .1 1.1 What is a 3D measuring machine (CMM) 1.2 Structure of CMM 1.3 Classification of several types of CMM meters by structure 1.4 Classification of several types of CMM meters by control system 1.5 Application of CMM Chapter 2: VMM .3 2.1 What is a VMM machine? 2.2 Structure of VMM 2.3 Classification of VMM machine 2.4 Application OF VMN machine .3 2.5 Advantage OF VMM machine Chapter 3: 3D PRINTING .4 3.1 What is 3D Printing .4 3.2 How Does 3D Printing Work 3.3 Examples of 3D Printing .5 3.4 Types of 3D Printing Technologies and Processes .14 Chapter 4: 3D-SCANING .15 4.1 Introduction 15 4.2 What is 3D scanning 15 4.3 How does 3D scanning work 15 4.4 How to use 3D scanning .16 4.5 Types of 3D scaning technology 17 Chapter 5: DIAL GAUGE .18 5.1 Structure 18 5.2 Appliactions of dial gauge .22 5.3 How to use dial gauge 23 5.4 How to maintain dial gauge 26 Chapter 6: ROUGHNESS TESTER OVERVIEW .28 6.1 Features of instrument 29 6.2 Measurement principile .29 6.3 Genel structure 29 6.4 Options and usages 32 Chapter 7: CALIPER .36 7.1 Structure of caliper 36 7.2 Fuction of caliper 39 7.3 Working of priciple caliper 39 Chapter 8: MICROMETER 41 8.1 What is a Micrometer 41 8.2 Features of micrometer .41 8.3 Uses of the micrometer .41 8.4 The structure of the Micrometer 42 8.5 Classification of Micrometer 42 8.6 Instructions for using the Micrometer 43 8.7 How to read the Micrometer .45 REFERENCES 46 ` Chapter : CMM 1.1 What is a 3D measuring machine (CMM) CMM is an abbreviation for: Coordinate Measuring Machine This is a very common tool in metrology laboratories The machine has many different names such as: 3-D coordinate measuring machine, 3-D measuring machine or 3D measuring machine The CMM machine works on the principle of moving the probe to the surface of the product to be measured To determine the X, Y, Z coordinates of the points on the part Using 3-D coordinate measuring machine, users can measure product dimensions more accurately In the mechanical industry, 3D coordinate measuring machine CMM is often used to measure the accuracy of products machined from CNC machines 1.2 Structure of CMM CMM coordinate measuring machine consists of main parts: -Machine body -Measuring head -Mechanical transducer (mechanical) Optical Probe Laser Probe (laser) White light detector Control system Measurement software (PC-Dmis) 1.3 Classification of several types of CMM meters by structure Classification of CMM machines by structure, there are several types of machines as follows: Folding hand gauge: usually a small hand-held machine Allows the swivel head to be placed in different directions Bridge gauge: with measuring shaft mounted vertically with a horizontal girder placed on support piers This type of machine helps to expand the measuring range of the product to be measured (X-Axis Bridge Gauge) Key gauge: with the measuring shaft supported by a shaft-supporting structure Truss gauge: the machine has a frame structure that hangs on the piers so that the range can be extended over the objects being measured The truss gauges are structurally similar to the bridge gauges Horizontal type gauge: machine with a protruding transducer shaft One end is attached to a movable vertical support ` 1.4 Classification of several types of CMM meters by control system Manual CMM series: manual drive - Motor driven CMM series with automatic detection The CMM series of meters are controlled directly by the computer The CMM series of meters are linked with CAD, CAM, FMS 1.5 Application of CMM -Check product quality -CMM machine gradually becomes the main equipment for product quality inspection Due to the product processing shape becomes more and more complex, the precision is high -It is used to check the machined dimension To ensure the supply of qualified products for the next working process -In each processing process, when there is a change of state, it should be sent to the 3-D measuring machine CMM For example tool replacement, machining time or program -For extremely complex mechanical parts, traditional equipment cannot meet the quality control requirements At the same time, the fabrication and design of the measuring device became a difficult problem due to the complexity of the manufacturing process The CMM coordinate measuring machine has thus become the primary means of quality control -The same goes for modern CNC machines, so using a CMM to check machining accuracy is a necessity -Understand the tuning status of the device -If the measurement results from the CMM show that the processing of the dimensions of the parts is deflected to one side of the tolerance zone This means that equipment is not delivered at its best, allowing operators to adjust equipment as needed -By using CMM gauges, enterprises will save maximum processing costs by avoiding product errors Simultaneously with precision machined parts it helps to assemble those parts with other precision parts to create finished products ` Chapter 2: VMM 2.1 What is a VMM machine? Optical vision measuring machine (Abbreviation: VMM) is a coordinate metrology machine designed for the measurement of linear size and geometrical size in computer technology with machine vision for high accuracy measurement 2.2 Structure of VMM 2D measuring machines (VMMs) generally have main blocks: Sample trackpad Camera Software 2.3 Classification of VMM machine It is cantilever type for the manual, semi-auto of VMM, it is also for the economic and small-size of automatic VMM normally, the size is less than 500x400x300mm As for the bridge type, there are two-type for VMM, one is mobile - bridge and another is fixed-bridge 2.4 Application OF VMN machine High precision with fixed workbench and granite base RS-232 interface can communicate between measurement software and computer Users can manage and export charts in BMP and DWG formats by connecting to a PC and running the program It can measure linear dimensions 2.5 Advantage OF VMM machine Advantages vision measuring machine achieves high accuracy of micrometer (0.001mm) 3D measuring machine if the touch probe is integrated with a much more economical cost, the operation is simple and fast, does not require complicated product installation and highly qualified operators such as CMM machine Camera resolution, high magnification and combined with image processing measurement software help users easily measure objects less than 1mm in size ` Chapter 3: 3D PRINTING 3.1 What is 3D Printing 3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital file The creation of a 3D printed object is achieved using additive processes In an additive process an object is created by laying down successive layers of material until the object is created Each of these layers can be seen as a thinly sliced cross-section of the object 3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing out a piece of metal or plastic with for instance a milling machine 3D printing enables you to produce complex shapes using less material than traditional manufacturing methods 3.2 How Does 3D Printing Work It all starts with a 3D model You can opt to create one from the ground up or download it from a 3D library 3D Software There are many different software tools available From industrial grade to open source We’ve created an overview on our 3D software page We often recommend beginners to start with Tinkercad Tinkercad is free and works in your browser, you don’t have to install it on your computer Tinkercad offers beginner lessons and has a built-in feature to export your model as a printable file e.g STL or OBJ Now that you have a printable file, the next step is to prepare it for your 3D printer This is called slicing Slicing: From printable file to 3D Printer Slicing basically means slicing up a 3D model into hundreds or thousands of layers and is done with slicing software When your file is sliced, it’s ready for your 3D printer Feeding the file to your printer can be done via USB, SD or Wi-Fi Your sliced file is now ready to be 3D printed layer by layer 3D Printing Industry Adoption of 3D printing has reached critical mass as those who have yet to integrate additive manufacturing somewhere in their supply chain are now part of an evershrinking minority Where 3D printing was only suitable for prototyping and one-off manufacturing in the early stages, it is now rapidly transforming into a production technology ` Most of the current demand for 3D printing is industrial in nature Acumen Research and Consulting forecasts the global 3D printing market to reach $41 billion by 2026 As it evolves, 3D printing technology is destined to transform almost every major industry and change the way we live, work, and play in the future 3.3 Examples of 3D Printing 3D printing encompasses many forms of technologies and materials as 3D printing is being used in almost all industries you could think of It’s important to see it as a cluster of diverse industries with a myriad of different applications A few examples: – consumer products (eyewear, footwear, design, furniture) – industrial products (manufacturing tools, prototypes, functional end-use parts) – dental products – prosthetics – architectural scale models & maquettes – reconstructing fossils – replicating ancient artefacts – reconstructing evidence in forensic pathology – movie props Automotive Car manufacturers have been utilizing 3D printing for a long time Automotive companies are printing spare parts, tools, jigs and fixtures but also end-use parts 3D printing has enabled on-demand manufacturing which has lead to lower stock levels and has shortened design and production cycles Automotive enthusiasts all over the world are using 3D printed parts to restore old cars One such example is when Australian engineers printed parts to bring a Delage Type-C back to life In doing so, they had to print parts that were out of production for decades ` Aviation The aviation industry uses 3D printing in many different ways The following example marks a significant 3D printing manufacturing milestone: GE Aviation has 3D printed 30,000 Cobalt-chrome fuel nozzles for its LEAP aircraft engines They achieved that milestone in October of 2018, and considering that they produce 600 per week on forty 3D printers, it’s likely much higher than that now Around twenty individual parts that previously had to be welded together were consolidated into one 3D printed component that weighs 25% less and is five times stronger The LEAP engine is the best selling engine in the aerospace industry due to its high level of efficiency and GE saves $3 million per aircraft by 3D printing the fuel nozzles, so this single 3D printed part generates hundreds of millions of dollars of financial benefit GE’s fuel nozzles also made their way into the Boeing 787 Dreamliner, but it’s not the only 3D printed part in the 787 The 33-centimeter-long structural fittings that hold the aft kitchen galley to the airframe are 3D printed by a company called Norsk Titanium Norsk chose to specialize in titanium because it has a very high strength-toweight ratio and is rather expensive, meaning the reduction in waste enabled by 3D printing has a more significant financial impact than compared to cheaper metals where the costs of material waste are easier to absorb Rather than sintering metal powder with ` a laser like most metal 3D printers, the Norsk Merke uses a plasma arc to melt a metal wire in a process called Rapid Plasma Deposition (a form of Directed Energy Deposition) that can deposit up to 10kg of titanium per hour A 2kg titanium part would generally require a 30kg block of titanium to machine it from, generating 28kg of waste, but 3D printing the same part requires only 6kg of titanium wire Construction Is it possible to print a building? – yes it is 3D printed houses are already commercially available Some companies print parts prefab and others it on-site ` 6.4 Options and usages + Adjustable support : When measured surface of part is smaller than the bottom surface of the instrument, sheath of pickup and adjustable supporter of instrument options can be used for auxiliary support to complete the measurement (as shown in Figure) + Measurement Stand: Measurement Stand can adjust the positions between tester and measured part conveniently with flexible and stable operation and wider application range Roughness of complex shapes can also be measured Measurement stand enable the adjustment of the position of stylus to be more precise and measurement to be more stable If Ra value of measured surface is relatively low, Using measurement platform is recommended 32 ` + Extending Rod : Extending rod increases the depth for pickup to enter the part Length of extending rod is 50mm + Standard Sensor: Most of the standard sensor sensor, it can measure most of the plane, inclined plane, cone surface, inner hole, groove and other surface roughness, can be hand-held measurement, in addition to the standard sensor, other special sensors are needed to measure the measuring platform + Curved Surface Sensor Curved surface sensor is mainly used for measuring radius is larger than the smooth cylindrical 3mm surface roughness, for the larger radius smooth spherical surface and other surface 33 ` also can obtain good approximation, the radius of curvature, the surface is smooth, the better the effect of measurement + pinhole sensor : Using Pinhole pickup, the inner surfaces of holes with radius more than 2mm can be measured Refer to the following Figure for detailed dimension 34 ` + Deep Groove Sensor: With deep groove sensor, it is possible to measure groove with width wider than 3mm and depth deeper than 10mm, or the surface roughness of step with height less than 10mm, Also can used to measure the planar, cylindrical used with platform please see figure for detailed dimension 35 ` Chapter 7: CALIPER 7.1 Structure of caliper The structure of the caliper is quite simple, including a Vernier caliper, a main ruler, a holding knob and a clamping jaw The main body or frame has a large gauge that runs along its length and is divided in centimeters The smallest division of the caliper is millimeter The Vernier scale is smaller than the main scale and also contains up to 50 divisions Vernier Caliper Main Base The main base vernier caliper is the main component of the caliper to which all the other parts of the caliper are attached If vernier caliper is a house, this main base is the foundation Main Scale The main scale is a scale that is the main reference in reading the measurement results In another sense, the main scale becomes the starting point of measurement Usually, the main scale is expressed in units of cm In taking measurements with a caliper, this section is major concern before looking at the vernier scale However, the accuracy of this scale is only up to mm For this reason, the measurement results become more accurate as it is necessary to look at the vernier scale when using the caliper 36 ` It should be noted that there are other types of calipers that have two main types of scales, namely the units of cm and inches In this article, the caliper in the picture contains only one unit Nonius Scale The nonius scale or the vernier scale is a scale that is of secondary concern after seeing the main scale After getting the initial number from the main scale reading, the nonius scale will read the decimal value from the measurement results with an accuracy of up to 0.1 mm Both of these scales need to be considered and should not be reversed The nonius scale will only be obtained if the main scale has been found Similar to the main scale, there are other nonius scales in the caliper that have two types of nonius scales, namely the units of mm and inches The determination of the unit depends on the user of the caliper whether they want to use mm or inches Slider A slider is a component of the caliper that works to move the caliper’s jaws so that they can widen or narrow according to the object being measured It can be seen clearly in the picture that the slider is directly connected to the main base and there is a nonius scale in the slider Finger hook You can see in the picture that the finger hook is shaped like a semicircle connected to the slider This section serves as a place to move the slider As the name implies, you can use it is enough with the help of one finger (thumb) to rotate the finger hook and result in shifting the slider Lock Screw The lock screw works to hold the slider movement after a shift is made according to the size of the object This means that after the slider is shifted and it is ensured that it matches the object’s size, it won’t budge This way, an accurate reading can be made Fixed Inner Jaw Rahang dalam tetap adalah bagian rahang yang terletak pada tempatnya, yang tidak dapat digerakkan karena menyatu dengan main base Fungsi rahang ini adalah untuk mengukur diamater dalam suatu benda Moveable Inner Jaw A sliding inner jaw is a jaw that can be shifted according to the size of the object This jaw is attached to the slider so that it can be shifted wider and narrower for measurement needs The sliding inner jaw works to measure the inner diameter of an object This jaw works in conjunction with the fixed inner jaw Fixed Outer Jaw 37 ` The fixed outer jaw remains attached to the main case along with the fixed inner jaw This jaw serves to measure the outer diameter of an object Moveable Outer Jaw Similar to the moveable inner jaw, the moveable outer jaw is a jaw that can be shifted wider and narrower for measurement purposes This jaw serves to measure the outer diameter of an object that works in conjunction with a fixed outer jaw Depth Rod The depth rod is in the form of a long rod that is embedded in the main case so that only the ends are visible in the image This section is directly connected to the slider so that the shift of the slider also affects the depth rod position When the jaw is closed, which means that the slider moves closer to the fixed jaw, this part will only show the edges, as in the picture But when the jaw is opened, the depth rod will be more visible The wider it is, the longer the depth rod appears Depth rod is used to measure the depth of a hollow object/tube The components of the caliper need to be known, especially for those who frequently use them They have their respective functions and an error in understanding their function when using the tool will result in measurement errors In addition, the components of the caliper above are not always exactly the same as other types of calipers Given that there are different types of calipers, there may be a slight difference in the names of the components 38 ` 7.2 Fuction of caliper The caliper is a type of measuring instruments that works to determine the diameter, depth, and thickness of an object It has an accuracy of up to 0.1 mm This measuring instrument can function properly because it consists of various components that support each other with their respective functions The following is a picture of a caliper and the names of the components 7.3 Working of priciple caliper Principle Of Working Of Vernier Scale 39 ` The vernier scale works on the principle of using the alignment of line segments displaced by a small amount to make fine measurements The human eye can easily detect this alignment of lines which is the main fact that drives a vernier A vernier scale has a main scale and a vernier scale The main scale has the normal resolution with a least count of mm The vernier scale is attached to the main scale which can slide on it and has graduations that are spaced by the same mm only but are slightly displaced to the marks on the main scale The displacement is the key here When the vernier scale is closed, that is, it is making a measurement you will see that the zeros of the main scale and the vernier scale coincide But the first mm mark on the vernier is 1/10th mm short of the first mm mark of the main scale second mm mark of the vernier is 2/10th of an mm short of the corresponding main scale mark Similarly the third is 3/10th short fourth is 4/10th short until the ninth mark which is 9/10th of an mm short The 10th mark is 10/10th = mm short of the corresponding mark of the main scale and therefore aligns with the previous main scale reading which is (10-1) 40 ` Chapter 8: MICROMETER 8.1 What is a Micrometer The micrometer is a relatively accurate measuring instrument, widely used in the mechanical manufacturing industry, plastic, wood, aluminum, glass to accurately measure the thickness of the block, the outside and inside diameters of the shaft and the depth of the slot A micrometer is a device used to measure very small distances, usually accurate to 1/1000 of a millimeter, or a solution of this reading is accurate / 1,000 millimeter, or / 1,000,000 meters The micrometer has many advantages over other types of measuring tools such as calipers 8.2 Features of micrometer - This is an instrument designed for each specific type: micrometer for external measurement, micrometer for internal measurement, micrometer for measuring depth, so it has poor multimeter properties And the measuring range is narrow (within 25 mm) - Micrometer with many sizes: – 25mm, 25 – 50mm, 50 – 75mm, 75 – 100mm, 100 – 125mm, 125 – 150mm… - The unit of measurement is usually mm or inch - The most common type of micrometer is Mitutoyo - There are different levels of accuracy and different resolutions Currently on the market has a resolution of odd numbers (0.0001 mm) 8.3 Uses of the micrometer With the advantages of wide measuring range, relatively high accuracy, easy to use, Panme is often used to measure outer dimensions, internal dimensions, piston depth measurements, crankshaft dimensions, disc brakes, dimensions cylinder size and borehole depth… The micrometer has a number of applications that are superior to other measuring devices such as: being able to measure objects with a very small size but with high accuracy because when measuring with a micrometer, we see that the body of the micrometer and the aspect are on the same side a straight line, because the rotation of the micrometer causes the micrometer to translate (causes very little error) and the caliper is not in the same line between its face and body, we see it with a distance and the caliper has a sliding joint (translational joint), so the possibility of error is greater (due to dirt, and this gap always exists and cannot be overcome) In addition, when measuring, the object is not affected Use force like a caliper Therefore, when it is necessary to measure objects with high accuracy, using micrometer will give more accurate results 41 ` 8.4 The structure of the Micrometer The Micrometer has a fairly simple structure, including the following parts: - Anvil - Spindle - Lock - Sleeve - Thimble - Ratchet knob - Body 8.5 Classification of Micrometer According to use: - Outsite Micrometer - Insite Micrometer 42 ` - Depth Micrometer * According thread pitch - Threaded shaft with 1mm pitch - Threaded shaft with 0,5 mm pitch 8.6 Instructions for using the Micrometer Step 1: Check Before Taking Measurements 43 ` - Check the outer surface: Check if the micrometer is worn or chipped Typically, if the probe is worn or chipped, the measurement results will not be accurate - Check if the parts with the movement are smooth or not, check if the spin doll has a smooth movement or not - Clean the measuring surface to avoid dust accumulation - Check point 0: Before measuring, check point If point is deviated, even with accurate measurement, it will not give accurate measurement results - For micrometers from 0-25mm, we make direct contact with measuring surfaces Check point - For micrometers from 25-50, etc., we use the corresponding block gauge to check the point Step 2: Measure - Check again to see if the dial is really accurate or not - Loosen the clamp screw, screw the knob so that the measuring head moves according to the size larger than the size of the part to be measured - Apply the probe firmly to the reference surface of the aspect to be measured, then press the knob to move the movable measuring head until the movable measuring head touches the surface of the work piece to be measured (Make sure the contact of the probe is square angle with the size to be measured, if measuring diameter, the measuring head must be on the face meridian) - Must keep the center lines of the two measuring torches coincident with the size of the object to be measured - In case the micrometer must be removed from the measuring position, turn the lock nut (brake lever) to ensure that the measuring head moves before removing the micrometer from the measuring object - When measuring against the edge of the moving ruler, we can read the "mm" and half "mm" of the size on the main ruler - Based on the standard line on the main ruler, we can read the percentage "mm" on the secondary ruler (value for each line is 0.01 mm) Note: HOW TO ADJUST POINT This point is very important, it determines the accuracy of the measurement If in the case that the point is skewed, we proceed to adjust the point as follows: In case the point is skewed upwards: - Definitely spin the doll with the locking pin - Use the rotary tool to rotate the skewed value - Check if the points match or not 44 ` - If point is still skewed, start over In case the point is skewed downwards: - Definitely spin the doll with the locking pin - Use the rotary tool to rotate the skewed value - Check if the points match or not - If point is still skewed, start over 8.7 How to read the Micrometer The gauge size is determined depending on the position of the spool edge, which is the main part of the ruler to the left of the spool edge and this is the 'integer part' of the ruler In parallel, based on the number of lines on the moving tube that coincides with the reference line on a certain tube, multiplying that number of lines by the ruler value (or the precision of the ruler) will be the "odd part" value of the ruler, the same two values will be the value of the measured size Method of preserving the micrometer - Do not measure rough, dirty faces - Do not measure while the object is rotating - Do not forcefully press the measuring torches against the measuring object It is necessary to avoid collision, scratching or deforming the anchor - Limit taking the ruler out of the measuring object and then reading the measured value - Every day at the end of the working shift, the ruler must be cleaned with a clean rag and oiled with an anchor to tighten the locking object (brake lever) to ensure that the measuring head is moving and to place the Micrometer in the correct position in the box 45 ` REFERENCES Dial Gauge – Parts, Internal Arrangement, Internal Parts Working, Applications, Advantages, and Disadvantages http://www.mechanicalwalkins.com/dial-gauge-parts-internal-arrangementinternal-parts-working-applications-advantages-anddisadvantages/#:~:text=Dial%20Gauge%20is%20used%20to%20measure%20the%20f latness,flatness%20and%20alignment%20of%20different%20jobs%20and%20workpi eces Dial Indicator – Principle, Diagram, Working, Application https://learnmech.com/dial-indicator-principle-working-diagra/ 3.Indicator, https://en.wikipedia.org/wiki/Indicator_(distance_amplifying_instrument) 4.Roughness measument, https://www.sciencedirect.com/topics/chemistry/roughness-measurement 5.Roughness, https://pavementinteractive.org/reference-desk/pavement-management/pavementevaluation/roughness/ Máy đo độ nhám bề mặt SJ-410 Mitutoyo https://thietbido.us/may-do-do-nham-be-mat-sj-410-mitutoyo/ Máy đo độ nhám bề mặt Elcometer 7062 https://tktech.vn/may-do-do-nham-be-mat-elcometer-7062/ Surface Roughness Measuremen, https://youtu.be/UEcER1ar4_8 46 ... https://pavementinteractive.org/reference-desk/pavement-management/pavementevaluation/roughness/ Máy đo độ nhám bề mặt SJ-410 Mitutoyo https://thietbido.us/may-do-do-nham-be-mat-sj-410-mitutoyo/ Máy đo độ nhám bề mặt Elcometer 7062 https://tktech.vn/may-do-do-nham-be-mat-elcometer-7062/