measure skills methods caliber screw bolt nut ruler thread head flatness .pptx

Training for measurement hand skills tools methods caliber screw bolt nut ruler thread head flatness

1. Measuring skills CD2100005EN Name Surname

2. Itinerary Knowledge Quiz Measuring Units Measurement Types Equipment Care Measurement types 2 Equipment Selection Measuring Equipment Fasteners, threads and HeliCoil™ Thread Repair Practical Measuring Activities.

3. System International (SI) Measuring Units System International (SI) units (Metric) When measuring any component, exact data is available in the Specifications section of the Workshop Manual on TOPIx However, it is important to have a thorough understanding of the numbers and values in use. Measuring skills 3

4. Linear Measurements Linear Measurements Most measurements carried out in the workshop are linear The ‘line’ measured between two points For Example: The length of a bolt The track or wheelbase of a vehicle. Measurement types 4

5. Non-Linear Measurements Non-linear Measurement Essential to assess service components for the following conditions: Flatness Roundness and Ovality Taper Run-out. Measurement types 5

6. Non-Linear Measurements Flatness The deviation of a flat surface from its perfect flat form Checked by running a straight edge over the surface and using feeler gauges to measure the distortion Essential in certain components for the correct mating of surfaces For Example: Cylinder Head Straightness. Measurement types 6

7. Non-Linear Measurements Roundness Whether or not an object is truly circular Can be checked by: Multiple readings using an External Micrometer Using Dial Test Indicator (DTI) to check for deflection For example: Main Bearing Journal Wear. Measurement types 7

8. Non-Linear Measurements Ovality Term used to measure how ovular an oval is For Example: Cylinder Bore Wear Brake Drum Roundness Calculated by measuring the diameter of the oval through its longest axis and shortest axis X - Y = Ovality . Measurement types 8

9. Non-Linear Measurements Taper The gradual thinning or narrowing towards one end of a shape Sometimes referred to as conicity Calculated by measuring the width of an object at the beginning of the taper (X) and the end of the taper (Y) X - Y = Taper. Measurement types 9

10. Non-Linear Measurements Run-Out The measurement taken to ensure a rotating item runs true and free from distortion Measured using a Dial Test Indicator (DTI) to measure the amount of lateral difference in surface measurements For Example: Brake Disc Run-Out measurement. Measurement types 10

11. Non-Linear Measurements Angular Measurement There are only a small number of opportunities for angular measurement in automotive applications For Example: Suspension and steering angles Using the torque angle gauge when tightening down a cylinder head. Measurement Types 11

12. Measurement Types Measuring skills 12 Question 1 What type of measurement is being carried out in Figure E188508? Linear

13. Measurement Types Measuring skills 13 Question 2 In Figure E157197, what are the cylinder head and engine block being checked for? Flatness or Distortion

14. Measurement Types Measuring skills 14 Question 3 What tools can be used to check for roundness? Dial Test Indicator (DTI) or External Micrometer

15. Equipment Care Measuring instruments are easily damaged, which can make them inaccurate Inaccurate readings can cause more damage than no reading at all This could be caused by: Drops Water/Corrosion Dirt and dust Extreme temperature changes. Measuring Equipment 15

16. Vernier Caliper Can be used to take a variety of measurements: Internal Measurements External Measurements Depth Measurements Error factor of ±0.02 mm Checked for accuracy by using calibration blocks Not to be used if measurements are critical to the component being measured E.g. where tolerance is < ±0.02 mm, a Micrometer should be used. Measuring equipment 16

17. Vernier Caliper 17 Construction 1 2 3 4 5 6 7 8 9 External jaws Internal jaws Depth probe Main scale (mm) Main Scale (inch) Vernier Scale (mm) Vernier Scale (inch) Retainer Lock

18. How to Measure Ensure the area to be measured and the tool is clean and dry Ensure the Vernier Scale slides freely '0' marks on both scales line up accurately when fully closed. Vernier Caliper 18

19. Internal Measurements How to Measure External Measurements Vernier Caliper 19 Depth Measurements

20. How to Read Two measuring scales and therefore should be read in two stages A – Main Scale B – Vernier Scale. Vernier Caliper 20

21. How to Read Stage One – Main Scale Taken from the marking on the Main Scale that aligns with the '0' on the Vernier Scale NOT the edge of the Vernier Scale If a marking does not align, then the Main Scale marking to the left of the '0' on the Vernier Scale should be used Whole millimetres - written as two digits before a decimal point Example = 10.__ mm. Vernier Caliper 21

22. How to Read Stage Two – Vernier Scale Taken from the marking on the Vernier Scale that closest aligns with a marking on the Main Scale More than one of the markings may appear to align Pay close attention as one marking will align closer than others. Vernier Caliper 22

23. How to Read Stage Two – Vernier Scale Numbered markings indicate Tenths of a millimetre - written as two digits after the decimal point Example : __.40 mm. Vernier Caliper 23

24. How to Read Stage Two – Vernier Scale Shorter markings between the numbered markings indicate Two hundredths of a millimetre - written as two digits after the decimal point Example : __.86 mm. Vernier Caliper 24

25. How to Read Total Reading To record the total reading, simply add the Main Scale and Vernier Scale measurements together Main Scale = 10 .__mm Vernier Scale = __. 86 mm Total Reading = 10.86 mm. Vernier Caliper 25

26. Activity 3 Vernier Caliper – Measurement examples Measuring equipment 26

27. Vernier Caliper 27 Measurement Examples – Question 1 10.00 + 00.16 = 10.16 mm. 10.00 mm 00.16 mm

28. Vernier Caliper 28 Measurement Examples – Question 2 20.00 + 00.68 = 20.68 mm. 20.00 mm 00.68 mm

29. Vernier Caliper 29 Measurement Examples – Question 3 25.00 + 00.78 = 25.78 mm. 25.00 mm 00.78 mm

30. Vernier Caliper 30 Measurement Examples – Question 4 30.00 + 00.02 = 30.02 mm. 00.02 mm 30.00 mm

31. External Micrometer As the name suggests, used to take external measurements Error factor of ±0.01 mm Calibrated using special blocks and test rods Available in a variety of sizes, for example: 0-25 mm 25-50 mm 50-75 mm 50-75 mm variant common for automotive use Adapter rods supplied to measure 0-25 mm / 25-50 mm. Measuring equipment 31

32. External Micrometer 32 Construction 1 2 3 4 5 6 7 8 Anvil Sample Spindle Lock Vernier Thimble Ratchet Frame

33. Zero Check Prior to carrying out any measurements, it is essential to carry out a Zero Check External Micrometer 33 How?

34. Zero Check Prior to carrying out any measurements, it is essential to carry out a Zero Check Ensure measuring surfaces are clean and dry Ensure thimble rotates freely Rotate thimble clockwise until spindle almost touches the anvil. External Micrometer 34

35. Zero Check Prior to carrying out any measurements, it is essential to carry out a Zero Check Continue to close the gap slowly using the ratchet until the spindle touches the anvil and the ratchet starts to click Ensure the '0' line on the Thimble accurately aligns with the datum line If the '0' line does not align, the Micrometer must be aligned. External Micrometer 35

36. How to Measure Ensure area to be measured and tool are clean and dry Ensure thimble rotates freely and the tool is calibrated Support the instrument using the frame External Micrometer 36

37. How to Measure Place item to be measured between spindle and anvil Turn thimble slowly until spindle is close to the item Close the gap slowly using the ratchet until spindle touches item and ratchet starts to click Apply lock if necessary and take your reading. External Micrometer 37

38. How to Read Three measuring scales and therefore should be read in three stages A - Upper Scale B - Lower Scale C – Thimble Scale The Upper and Lower scales are separated by the datum line - D. External Micrometer 38

39. How to Read Upper Scale markings indicate whole millimetres Lower Scale markings indicate half millimetres Therefore, the distance between a mark on the upper scale and lower scale is 0.50 mm. External Micrometer 39 = 0.50 mm

40. How to Read Thimble Scale is divided into one hundredths of a millimetre Each 360° turn of the thimble = 0.50 mm - Therefore each one of the 50 increments is 0.01 mm Readings are taken against the datum line and will always be less than 0.50 mm. External Micrometer 40

41. How to Read Stage One – Upper Scale Marking on the Upper Scale that aligns with the edge of the thimble Markings indicate whole millimetres - written as two digits before a decimal point If a marking does not align, the Upper Scale marking to the left of the edge of the thimble should be used Example = 03.__ mm. External Micrometer 41

42. How to Read Stage Two – Lower Scale Marking on the Lower Scale that aligns with the edge of the thimble Markings indicate half millimetres - written as two digits before a decimal point As one complete turn of the thimble is 0.5 mm, this reading will always be either: __.00 mm OR __.50 mm. External Micrometer 42

43. How to Read Stage Two – Lower Scale If the half millimetre mark can be seen after the whole millimetre reading on the Upper Scale, the reading is __.50 mm. External Micrometer 43

44. How to Read Stage Two – Lower Scale If the half millimetre mark cannot be seen after the whole millimetre reading on the Upper Scale, the reading is __.00 mm. External Micrometer 44

45. How to Read Stage Three – Thimble Scale Divided into hundredths of a millimetre - written as two digits after the decimal point Each 360° turn of the thimble = 0.50 mm - Therefore each one of the 50 increments is 0.01 mm Thimble Scale readings are taken against the number that lines up with the datum line Example = __.37 mm. External Micrometer 45

46. How to Read Total Reading To record the total reading, simply add the Upper, Lower and Thimble Scale measurements together Upper Scale = 03 .__ mm Lower Scale = __. 50 mm Thimble Scale = __. 37 mm Total Reading = 03.87 mm. External Micrometer 46

47. Activity 4 External Micrometer – Measurement examples Measuring equipment 47

48. External Micrometer 48 Measurement Examples – Question 1 8.00 + 00.00 + 00.20 = 8.20 mm. 8.00 mm 00.00 mm 00.20 mm

49. External Micrometer 49 Measurement Examples – Question 2 10.00 + 00.50 + 00.00 = 10.50 mm. 10.00 mm 00.50 mm 00.00 mm

50. External Micrometer 50 Measurement Examples – Question 3 13.00 + 00.50 + 00.15 = 13.65 mm. 13.00 mm 00.50 mm 00.15 mm

51. External Micrometer 51 Measurement Examples – Question 4 17.00 + 00.00 + 00.37 = 17.37 mm. 17.00 mm 00.00 mm 00.37 mm

52. Dial Test Indicator (DTI) Used to take dynamic measurements Dynamic means measuring something whilst it is moving For example: Brake Disc/Hub Run-Out Crankshaft/Camshaft End Play Error factor ±0.01 mm Scale may be unidirectional, typically measures up to 20 mm of movement. Measuring equipment 52

53. Dial Test Indicator (DTI) 53 Construction Setting Ring Stem Spindle Outer Scale Inner Counter Dial.

54. How to Use A DTI cannot be used independently Must be used in conjunction with a support tool Most common is the magnetic stand Some tasks require the use of special tools to support the DTI, such as a measuring bridge when measuring piston protrusion. Dial Test Indicator (DTI) 54

55. How to Measure Ensure the area to be measured and the tool is clean and dry Ensure the DTI is secured correctly to the supporting tool by the stem Ensure the supporting tool is sufficiently secured Position the DTI so the spindle is at a right-angle to the item to be measured Carefully set the DTI against the component so that spindle is touching the surface Move the DTI closer to the component until the Outer Scale Needle moves approximately one full turn, to apply some pre-load to the spindle. Dial Test Indicator (DTI) 55

56. How to Measure Secure the DTI in position Turn or move the component very slowly to find the smallest reading Turn the setting ring until the '0' on the Outer Scale aligns with the Large Needle Take note of the reading on the Inner Counter Turn or move the component very slowly to find the largest reading Always pre-load the DTI before any measurements are carried out to allow measurements in both directions. Dial Test Indicator (DTI) 56

57. How to Read Two measuring scales and therefore should be read in two stages A – Inner Counter B - Outer Scale. Dial Test Indicator (DTI) 57

58. How to Read Stage One – Inner Counter Markings indicate whole millimetres - written as two digits before a decimal point. Example = 09.__ mm Remember, DTIs can measure uni -directionally, so pay close attention to the readings you take. Dial Test Indicator (DTI) 58

59. How to Read Stage Two – Outer Scale Markings indicate hundredths of a millimetre - written as two digits after the decimal point. Example = __.89 mm Remember, DTIs can measure uni -directionally, so pay close attention to the readings you take. Dial Test Indicator (DTI) 59

60. How to Read Total Reading To record the total reading, simply add the Inner Counter and Outer Scale measurements together Inner Counter = 09 .__ mm Outer Scale = __.89 mm Total Reading = 09.89 mm It is essential you consider the amount of pre-load applied to the DTI when calculating your measurement. DTI measurements very rarely start from absolute zero. Dial Test Indicator (DTI) 60

61. Activity 5 Dial test indicator (DTI) – Measurement examples Measuring equipment 61

62. Dial Test Indicator (DTI) 62 Measurement Examples – Question 1 3.00 + 00.40 = 3.40 mm. 3.00 mm 00.40 mm

63. Dial Test Indicator (DTI) 63 Measurement Examples – Question 2 6.00 + 00.07 = 6.07 mm. 6.00 mm 00.07 mm

64. Dial Test Indicator (DTI) 64 Measurement Examples – Question 3 6.00 + 00.70 = 6.70 mm. 6.00 mm 00.70 mm

65. Dial Test Indicator (DTI) 65 Measurement Examples – Question 4 4.00 + 00.56 = 4.56 mm. 4.00 mm 00.56 mm

66. Feeler gauges Measuring equipment 66

67. Feeler Gauges Measuring equipment 67 Very simple, versatile measuring instrument with many applications Thin steel blades machined to a specific thickness with an accuracy of up to 0.01 mm Range of blade thickness varies depending on the set in use, however a typical set ranges from around 0.03 mm - 1.00 mm Blade thickness is indicated on the blade itself.

68. Feeler Gauges Measuring equipment 68 Very simple, versatile measuring instrument with many applications Used to measure tolerances between two components such as: Valve Tappet clearances Spark plug gaps End float clearances Flatness .

69. Feeler Gauges Measuring equipment 69 Ensure the area you are measuring and the tool itself are clean and dry Select an appropriate thickness blade and insert it between the components to be measured Slowly remove the gauge from between the components If the correct thickness gauge is being used, slight resistance will be felt whilst pulling it out If no resistance is felt, select a thicker blade, or combination of blades until the correct thickness is achieved The number of blades used as a combination must be kept to a minimum.

70. Feeler Gauges Never force the blades in between the components as damage can be caused to both the component and the blade itself Any damaged, bent, kinked or corroded blades must not be used. Measuring equipment 70

71. Spring gauge Measuring skills 71

72. Spring Gauges The Spring Gauge is generally used to check the turning load on a component For Example: Swivel hub pre-load Adjustment is made by removing or adding shims to the top swivel pin. Measuring equipment 72

73. Equipment Selection There are various measuring instruments used within the workshop, each with different applications It is essential to be able to confidently and accurately interpret readings when taking measurements When carrying out any measuring, it is important that the most appropriate tool is selected. Measuring Equipment 73

74. Equipment Selection For Example: Brake Disc Assessment Dial Test Indicator (DTI) and Micrometer Brake Pad Thickness Vernier Caliper Cylinder Head Straightness Feeler Gauges and Straight Edge Valve Tappet Clearances Micrometer and Feeler Gauges. Measuring Equipment 74

75. Equipment Selection Incorrect use of the appropriate measuring equipment may lead to inaccurate readings and potential component failure. Measuring Equipment 75

76. Fasteners A technicians understanding of fasteners is essential for safety and longevity of the vehicle Numerous types in are use in the automotive industry: Screws Bolts Studs Nuts Washers Stretch Bolts Encapsulated Fasteners Triolubular Bolts Many look similar but are NOT interchangeable. Fasteners, threads and HeliCoil™ inserts 76

77. Fasteners Screws: Less than 6 mm Threaded all the way up the shank Fits into a threaded hole Bolts: Over 6 mm Un-threaded portion of shank below the head Secured with a nut. Fasteners, threads and HeliCoil™ inserts 77

78. Fasteners Studs: Threaded both ends No ‘head’ One end in a threaded hole, secured with a nut Nuts: Used to secure bolts and studs Internally threaded Hexagonal head Washers Spread load evenly from nut to component Prevent a nut working loose. Fasteners, threads and HeliCoil™ inserts 78

79. Stretch Bolts All metals have an elastic limit (Limit of the ability to stretch and return to its original shape) Once a bolt has been stretched beyond its elastic limit it will not return to its original shape Stretch bolts are designed so that they can be elongated beyond their elastic limit into the plastic region Ensures a high and uniform bolt clamping force and no re-torque is necessary. Fasteners, threads and HeliCoil™ inserts 79

80. Stretch Bolts Reuse of stretch bolts will cause distortion to components and consequent damage In many cases the bolts may not be reused or have a limited, specified number of reuse applications Always follow the recommendations in TOPIx regarding stretch bolt replacement. Fasteners, threads and HeliCoil™ inserts 80

81. Encapsulated fasteners Thread locking agent applied to the threads during manufacture Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion Caution: Do not reuse self-locking fasteners. Fasteners, threads and HeliCoil™ inserts 81

82. Trilobular Bolts A unique fastening system utilizing TAPTITE™ fastener technology Various parts including replacement engines and cylinder heads now supplied with un-threaded bolt holes by design Bolt creates its own thread when inserted into a machined hole on first application No preparation required, no tapping Simply insert bolt in to machined hole and torque to specification. Fasteners, threads and HeliCoil™ inserts 82

83. Trilobular Bolts A unique fastening system utilizing TAPTITE™ fastener technology Comprises a triangular shaft circumference with a unique Radius Profile™ thread (Rolled) Triangular shape creates a locking effect Bolts can be re-used, make note of bolt locations Metric thread bolt can be used in its place if replacement is required. Fasteners, threads and HeliCoil™ inserts 83

84. Bolt Nut and Identification Markings indicating the strength grade For Example: 8.8, 10.9, 12.9, 14.9 Fasteners may also have the ‘M’ symbol marked to indicate a Metric thread. Fasteners, threads and HeliCoil™ inserts 84

85. Thread Identification Many different types of screw threads in use Some threads look similar but are not interchangeable Use a thread gauge to identify an unknown thread CAUTION: A thread file may be used to determine thread type and size and to repair minor thread damage – not to recondition a bolt Always replace bolts with excess damage to head and/or thread. Fasteners, threads and HeliCoil™ inserts 85

86. Activity 6 THREAD IDENTIFICATION Measuring equipment 86

87. HeliCoil™ Thread Repair HeliCoil™ Inserts are a method used to repair a damaged thread in a component This process saves money on replacement components The repair involves using specific drill and tap to cut a new thread in the damaged component A size specific helical coil is then inserted in to the freshly drilled and tapped hole Thread inserts are available in many sizes. Fasteners, threads and HeliCoil™ inserts 87

88. HeliCoil™ Thread Repair Measure depth to drill Drill out the hole with a special drill Tap a new thread with a special tap, to match the outside of the HeliCoil™ Insert the HeliCoil™ Snap off the insertion tang New thread is now ready to use CAUTION: When drilling out the damaged thread ensure that it is of the correct depth. Fasteners, threads and HeliCoil™ inserts 88