Gaging Tips

Semi-Automatics – The In-between Gages
George Schuetz, Mahr Federal Inc.

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 http://www.mahrfederal.com/

The faucet has been opened a little and you've just received a long-awaited contract to produce 10,000 large trunnion caps for a manufacturer of earth moving equipment. Despite the joy, you realize you have a problem. The machines will be in place and ready to run the part shortly, but you haven't given much thought to the gaging.
Manual gaging is not going to cut it because it is too slow. Operator-introduced variation may be too large for the tolerance, and there are too many parts to inspect over a relatively short period. On the other hand, the size of the job just won't justify the expense of a fully automatic gage.
There is something in between that can solve the problem: a semi-automatic gage—one that makes multiple checks, classifies the part, and can mark or stamp it for identification. These are frequently, manually loaded/unloaded, but can also incorporate a disposal system.
In certain applications, these features offer the user a number of distinct advantages. Since part of the gaging cycle is automatic, semiautomatic gages are much faster than completely manual, individual gages. And, when manually loaded, they can handle work pieces that may be difficult and costly to feed or orient manually. Manual loading of the part also permits visual inspection for scratches, discoloration and unclean finishes prior to the gaging process.
Semi-automatic gages will check a relatively large volume of parts quickly and accurately, enabling the inspector to keep up with production by taking over the gaging function. Many manually loaded gages can be operated at speeds close to one part per second. Disposal is automatic, eliminating operator interpretation or sorting errors. Most semiautomatic gages are controlled by a small gaging computer that takes over the complete gaging function—positioning gage heads, moving the part, collecting data, marking the part, and disposing of it in the correct class. Operator fatigue and misclassification can be a big problem when handling many parts. Since the semi-automatic gage is tireless and consistent in its decision-making, many of the operator influenced problems go away.
Today there are many choices in semiautomatic gages, and design time is not as long as is sometimes perceived. A semi-automatic, built with off-the-shelf gaging components and supplemented with motion control and gaging computers, can be designed quickly and delivered ready to meet its gaging challenge.
Now if we could only get it to put the parts in boxes and deliver them to ……

Kurt Workholding

 

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Kurt Workholding

Your One Stop Advanced Technology Solutions Provider

Kurt provides a full line of innovative workholding products, including custom engineered workholding systems, that can be integrated into your current and future machining set ups.  From manual and hydraulic vises to zero-point clamping, Kurt has a workholding system that meets your application’s requirements.
The original Kurt AngLock® vises were designed to provide precision part clamping on basic machines.  Our line includes CNC vises, 5 Axis vises, Rotary Table workholding solutions for VMC's and the ToolBlox tombstones, providing you with increased versatility at your machining stations.  Precision measuring systems and accessories are also available to complement your Kurt workholding system.
All Kurt products are original equipment, ensuring their strength, precision, and durability.  We offer a Lifetime Iron Clad Warranty™ on our products. 

HDM690

Part No. HDM690

6" vise with a full 9" opening between jaws.
Less deflection of the stationary jaw. Wider more stable stationary jaw equals less deflection.
Stationary Jaws bolts down from the top. No need to remove from table to disassemble the vise for cleaning. Bolting the stationary from the top reduces the stress in the body and will stay flatter after assembly.
Narrower body width allows for more vises in the same work envelope
Taller body design equals less deflection under clamping loads
"Pull-Type" body design reduces stress in the body resulting in more accurate clamping.
Quick change movable jaw. The HD platform movable jaw allows for quick change and carvability to hold that odd shaped part.
GrooveLock® jaw and workstop included.
Bolts and locates directly on standard grid plates; 40mm, 50mm or 2".
Adaptable to hydraulic actuation.
Uses sine keys for alignment.

MIDCO Tunnel Buggy™

MTB-101  $409.95
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MIDCO Tunnel Buggy™

Features:

MIDCO “Tunnel Buggy”™, with offset handle, is ideal for material handling, carting and moving pipes, lumber, tools boxes, equipment and materials on any jobsite.

Packed with features, the MIDCO Tunnel Buggy™ is constructed of heavy-duty 3/15” plate steel and still lightweight, (weighing 90 lbs.) allows for easy storage and handling.

Tunnel Buggy™ features pneumatic tires, 4.80-8 2 ply and roller bearing axels for smooth operation over most surfaces. 

MIDCO “Tunnel Buggy” with offset handle allows worker to move standard 20” lengths without interference.

MIDCO ”Tunnel Buggy” Specifications

Product No. MTB-101

Weight: 125 lbs.

Length: 27”

Gauge: 3/16 plate steel  
Load Capacity:

Carry's up to 20” diameter pipe

Load Limit: 1,000 lbs.

Carrier Bed: 3/16” x 12” x 12”
Note: Ship via truck only.

Baileigh Horizontal & Vertical Mitering Bandsaws BS-712MS

Baileigh 

Horizontal & Vertical Mitering Bandsaws BS-712MS

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Horizontal and Vertical Band Saw

This bandsaws head, pivot mechanism and vise base are constructed of the highest quality cast iron. It's saw head can operate in a vertical or horizontal mode offering more bang for the buck. All BS-712 bandsaws come with a solid three speed direct drive gear transmission that extends blade life.
The BS-712MS band saw has a swivel head that allows the entire bow to miter up to 45 degrees. The blade guides consist of six hardened roller bearings to ensure straight cuts. The band saw is on a well constructed cart with wheels that allows the user to take it to job sites or push it out of the way if space is required. Perfect for the home or small shop.
Baileigh bandsaws are made to some of the highest quality standards on the market.

Specifications

Capacity Round (90/45deg)

7”/4.33”

Capacity Rectangular (90/45deg)

7”x10.23”/4.72”x4.13”

Blade Size (H/W/L)

.75” / .035” / 92.91”

Blade speed (fpm)

125/215/270

Blade Guide

Roller

Miter Angle

0 – 45 deg

Miter Adjustment

Swivel Head

Table Height

23”

Descent Control

Hydraulic

Return

Manual

Drive

Gear

Motor

1 hp

Power Requirement

110v / 220v, 1 phase

Shipping Dimensions (L/W/H)

51” / 23” / 43”

Shipping Weight

397 lbs

THE PLANE TRUTH ABOUT FLATNESS

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THE PLANE TRUTH ABOUT FLATNESS
George Schuetz, Mahr Federal Inc.
http://www.mahrfederal.com/  

The flatness of machined planar surfaces is often critical to the performance of parts and assemblies.  The plane is also the basis or reference for most dimensional and geometric measurements; including height, location of features, squareness, and datum’s.  A reference plane may be a feature on the part itself, or it may be part of the measuring instrument; but in either case, the measurement can only be as accurate as the reference.  So, whether you're making parts or measuring them, you may have to measure flatness.
There are many tools and methods available, depending upon the nature of the part and the degree of accuracy required.  Surface plates serve as a general-purpose reference for many flatness measurements. If the flat surface of the work-piece can be put in direct contact with the plate, it is possible to measure flatness using feeler stock. Although this is a low-resolution method, and only the perimeter of the part is accessible.  An air or electronic gaging probe installed flush in the surface plate can provide much higher resolution, if the part is small enough to move around on the plate.  Each type of probe has its benefits.  Air jets are self-cleaning and non-contact, while electronic transducers can be connected with gaging amplifiers or remote indicators with dynamic measuring capabilities, to automatically capture the maximum deviation, or to output data for SPC.
If the part is too big to slide around, or if its configuration is such that the flat surface can't be put in direct contact with the surface plate, then it must be staged.  A test stand with a mechanical indicator or an electronic gage head is slid around on the surface plate to explore the part.
This however may fail to distinguish between errors of flatness and errors of parallelism.  To break out flatness, measurements are taken at equally spaced points on the surface, then the data is plotted on a graph and a best-fit line calculated.  Deviations from the best-fit line represent errors of flatness.  If the measurements are taken on a vertical surface (using, for example, a "smart" height gage with the gage head turned 90 degrees), one would duplicate the procedure to break flatness out from possible squareness errors.
To measure really large areas like machine beds or surface plates, electronic levels are often the appropriate tool.  Levels may be connected to gaging amplifiers that will automatically convert angular readings into dimensional error.  Large areas can also be measured with electronic probes, using a precision straightedge as the reference, as described last month.
With the proper software, the data obtained from large-area flatness measurements can be converted into a 3D plot.  This information can be used in at least three ways: the user can do his setups on the flattest areas and avoid the worst sections of the surface plate or machine tool; he can use the data to compensate mathematically for out-of-flatness; and he can use it as a guide to correct the out-of-flat condition.
Optical flats are references for measuring small, high-precision parts, such as gage blocks.  Usually made from fused quartz or high quality glass, the puck-shaped optical flat is certified to within 1, 2, 4, or 8 micro-inches.  It is wrung to the part and viewed under a monochromatic (helium) light source.  A perfectly flat part will reflect straight, regularly spaced, easily visible interference bands, each representing an interval of 11.6 micro-inches (the half-wavelength of helium light).  Air gaps (i.e., low spots) between the part and the flat will distort the interference bands proportionally to the flatness error: a band that is "bent" by one half its thickness indicates out-of-flatness of 5.3 micro-inches (1/2 x 11.6).  The location of low spots can be identified by the direction of the distortion.
Regardless of the method, before a part can be measured for flatness it is important to know the level of uncertainty in the reference.  Flatness may be transferred from certified standards to masters, then from masters to gages, and thence to work-pieces, but be aware that the level of uncertainty increases at each step.

#Kurt Manual #Vise, 8" w/ 10" opening

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Part No. D810

Kurt’s D810 vise has a large 10" jaw opening and a clamping force up to 11,600 lbs. The top down, four bolt design on the stationary jaw reduces vise deflection by 25% while allowing total disassembly of the vise without removing the body from the machine table. Special brush seals shield and protect vise screw threads from machined chips and residue. The nut has been shortened so as not to protrude past the end of the vise body. Powder coat paint resists coolant-induced peeling for greater corrosion protection. The overall vise footprint is identical to earlier models so both can be used interchangeably and in tandem. The D810 vise locks parts precisely including very large parts for aggressive “hogging out” operations.

Price

:  $1,350.00

Dimensional Data

	Inch	Pounds
A	3.310	x
B	8.000	x
C	21.810	x
D	4.686	x
E	0.813	x
F	1.965	x
G	3.652	x
H	2.200	x
J	1.075	x
K	6.190	x
L	1.865	x
N	1.220	x
O	4.750	x
P	5/8-11	x
Q	11.500	x
R	11.000	x
S	4.940	x
T	8.500	x
U	0.880	x
V	2.375	x
W	0.875	x
AA	10	x
AA MIN	0	x
BB	14.730	x
BB MIN	4.730	x
CC	17.260	x
CC MIN	7.260	x
DD	21.990	x
DD MIN	11.990	x
Ship Wt.	x	158

 

Clamping Force Pounds

Torque Ft. Lbs.	D810
20	1834
40	3843
60	4349
80	5706
100	7042
120	8688
140	10413
160	11596

 

Metalworking info for the Day

Light Tool Supply Metalworking info for the Day
Blade Patch:The distance between the centers or other corresponding points on one saw tooth to the adjacent tooth.

 

Saw head moves laterally making it possible to get extremely close to the vise holding the workpiece when making the cut affording a vibration-free and burr-free cut.

Ergonomically correct grip with integrated switch and saw head release mechanism.

Continually adjustable (may be tightened in any position) round table made of pressure-cast aluminum swivels 45º in both directions with positive stops at 15º intervals.

Integrated tightening mechanism with self-centering clamps. V-groove for round pieces. Front side groove for clamping thin work pieces.

Made in Germany.

 

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Abrasive dressing sticks:

Light Tool Supply

Abrasive dressing sticks:

Usually hand held in a holder used to dress the face of smaller size grinding wheels. Often used for roughing or preshaping,prior to final dressing with a diamond dresser. Abrasive dressing sticks are made of hard material such as silicon carbide or boron grains with a hard bond such as fluorcarbon ploymer.

 

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