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1.0 Title
Calibration of Dial Gauge-product quality
2.0 Objectives
1) To understand how calibrate a Dial Gauge using Calibration Tester and find the error on
each reading of the dial gauge and to obtain the accuracy of the gauge.
2) Study how to calibrate dial gauge by using Digital Calibration Tester.
3) To determine the error of the dial gauge reading according to JIS and determine the
validity of the dial gauge reading.
3.0 Introduction
Dial gauge is a precision measurement commonly used to measure machined parts for
production tolerances or wear. Dial gauges are capable of producing extremely fine measurement
values. Accuracy of the dial gauge is important when doing the measuring process as the
sensitivity of the dial gauge is very high and the measurement value increment can measure very
small value of tolerance. Therefore, the calibration of the dial gauge need to be perform at least
once a month so we can determine whether the reading of the dial gauge still valid and accurate
or not.
In this experiment, we have done a calibration process for the dial gauge in two ways that
are manually and by using a computer technique. From the result of the experiment we can
identify the error in the dial gauge measurement reading and justify whether the dial gauge still
can be used or not that is by refer to the error tolerance standard, if the error of the dial gauge
reading exceed the tolerance than we can considered the dial gauge is broken and cannot be use
anymore. The accuracy of the dial gauge reading also have been identify by using digital
indicator process using the computer which will produce more accurate result and faster than the
manual analog style. The type of error indicator that have been identify from the experiment are
whole measuring range, 1/2 revolution, 1 revolution, 2 revolution, Narrow range adjacent error,
Retrace error and Repeatability error. All of these errors have been identify according to standard
tolerance for testing routine according to Japan Indicator Standard, JIS. This error will be
compare with the tolerance error that is allowable to the dial gauge to confirm the validity of the
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dial gauge reading. The result will be used to form a graph that is Error of Dial Gauge against
Dial Gauge Reading Graph and Repeatability Graph so that we can understand the result
with easier and more accurate.
4.0 Apparatus
Figure 3: Thimble
10
4.5
4.0
3.8
3.6
3.4
3.2
3.0
2.8
2.6
2.4
2.2
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
4.4982
4.0016
3.8044
3.6016
3.3984
3.1976
3.0016
2.8044
2.6006
2.3988
2.1996
1.9996
1.9016
1.8032
1.7038
1.5996
1.4980
1.3974
1.2982
1.1980
1.0988
1.0008
0.9032
0.8048
0.7026
0.6000
0.4972
0.3974
0.2964
0.1982
0.0978
0.0006
Table 1 : Error on Dial Gauge
0.0018
-0.0016
-0.0044
-0.0016
0.0016
0.0024
-0.0016
-0.0044
-0.0006
0.0012
0.0004
0.0004
-0.0016
-0.0032
-0.0038
0.0004
0.0020
0.0026
0.0018
0.0020
0.0012
-0.0008
-0.0032
-0.0048
-0.0026
0.0000
0.0028
0.0026
0.0036
0.0018
0.0022
-0.0006
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Results
Tolerances
-2.80
15.00
1/2 revolution
-3.00
9.00
1 revolution
-1.50
10.00
2 revolution
-1.60
15.00
-0.2
8.00
Retrace error
-9.00
5.00
Repeatability error
-0.02
5.00
Indication error
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SAMPLE CALCULATION
1) Error on Dial Gauge
g
3) 1/2 revolution
4) 1 revolution
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5) 2 Revolution
6) Repeatability Error
8) Retrace error
(
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Result
Manual Calibration
Object
: Dial Indicator
Indicator range
: 5mm
Manufacturer : Mitutoyo 1
Indicator resolution
: 0.01mm
Type
: Dial Indicator
Revolution
:5
Serial No.
: 2046F
Order No.
: APH750
Inspector
: Metrology
Test as per
: JIS B 7503
Date of Test
: 10/14/2014
Testing Increment
: 10 div
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Digital Calibration
17
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Systematic error can be identified by comparing the results of our experiment with other
experiment results.
Calibration is the easiest way to reduce systematic errors. Maybe, the error obtain because of
position eye is not perpendicular to the scale and the apparatus is very sensitive with movement.
Slightly movement will affect the scale.
8.0 Conclusion
Based on this experiment, the error on each reading of the dial gauge was obtained. It can
be stated here that numerous of error happened during carrying out the experiment. After
compared both, it can be conclude that by using computer, the dial gauge was more accurate.
This experiment also has helped us to understands the method in dial gauge calibration process
and how to identify the error in dial gauge so that the reading of the dial gauge are accurate and
valid. The objective of this experiment has been achieved.
From the analysis, by comparing the result of error in dial gauge reading and the
tolerance provided, we can conclude that the readings of this dial gauge are still valid as all the
indicator error of the dial gauge reading does not exceed the standard tolerance provided by the
dial gauge manufacturer according to Japan Indication Standard, JIS.
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9.0 Recommendation
1. The reading of the dial gauge must be repeated so the result obtained is more accurate.
2. The calibration tester that holds the dial gauge must be placed on a rigid table to avoid
shaking happens during the experiment.
3. Before starting the experiment, the dial gauge must be fixed to 0.0 mm to avoid parallax
error.
4. As the reading of the calibration tester is small, a magnifying glass can be used while
taking the reading so that the result is accurate.
5. The calibration tester must be replaced when the anvil shows any binding or twisting
when it is pushed towards the calibration tester.
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10.0 References
1) Serope Kalpakjian, W.R. Schmid, Manufacturing Technology and Fundamental, 5th edition,
Prentice Hall, 2004.
2) Mikell P. Groover, Automation, Production Systems and Computer Integrated
Manufacturing, 2nd edition, Prentice Hall, 2001
3) Mikell P Groover, Principles of Modern Manufacturing, SI Version, 4th Edition, John Wiley
& Son, Inc, 2011
4) John A. Schey, J.A., "Introduction To Manufacturing Processes", 5th Edition, McGraw-Hill,
2000.
5) Alan S. Morris, Measurement and calibration requirements for quality assurance, Wiley,
1997
6) Cornell University, Instruments and Control Systems, Chilton Company, 1954
7) Yi Qin, Micromanufacturing Engineering and Technology, William Andrew, 2010
8) Richard Crowson, Jack Walker, Handbook of Manufacturing Engineering, Second Edition,
CRC Press, 1996.
9) Alting, Manufacturing Engineering Processes, Second Edition, CRC Press, 1993
10) Bewoor, Metrology & Measurement, Tata McGraw-Hill Education, 1998
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