Gage Mentor (Dimensional Gages) Course Outline -- 3 Units
Unit 1 - Gage Primer
Lesson 1: Why Measure?
· The importance of measuring in today's manufacturing world.
· The 5 critical aspects of measuring.
Lesson 2: Language of Measurement
· Key terms you need to know in order to speak the language of dimensional metrology.
Lesson 3: Measurement Standards
· The role of standards.
· Types of standards related to dimensional metrology including units of measure, dimensioning & tolerancing practices, laboratory practices, calibration standards, and documentation.
Lesson 4: Precision & Accuracy
· Key measurement concepts that serve as the foundation of a good measurement system.
· The 5 components of any measurement system.
· How variation in any component can lead to measurement error.
Lesson 5: Datums
· How measurements are referenced by design and manufacturing engineers on drawings.
· Datums, datum feature symbols, datum features, simulated datums, and target datums.
· The use of primary, secondary, and tertiary datums.
Lesson 6: Introduction to GD&T
· Comparison of coordinate tolerancing and GD&T techniques.
· How to read drawing symbols used with GD&T.
· The 14 GD&T geometric characteristics.
· The use of modifiers.
Lesson 7: Surface Finishes
· An overview of measurements used to characterize the finish of a surface.
· How to interpret lay and surface symbols.
Lesson 8: Math for Measuring
· A basic review of simple mathematical concepts such as converting fractions and working with decimals.
· Basic geometry concepts.
Challenge: An assessment of the learner’s progress in this unit.
Unit 2 - Using Gages
Lesson 1: Types of Gages
· A review of universal dimensional measurement techniques.
· An introduction of the gages to be explored in this Unit.
· A brief overview of specialty measurement devices.
Lesson 2: Calipers
· How to use and read vernier scales.
· How to use a caliper.
· The pros and cons of vernier scale, dial, and digital calipers.
Lesson 3: Micrometers
· The size vs. range of a micrometer.
· How to read micrometer scales.
· How to use outside and inside micrometers.
· Discrimination vs. accuracy of digital micrometers.
Lesson 4: Height & Depth Gages
· How to use a height gage for direct and comparative height measurements.
· How gage blocks and height masters are used with height gages.
· Potential problems with height gages.
· How to use depth gages.
· Potential problems with depth gages.
Lesson 5: Fixed Gages
· Explanations of the different types of fixed limit and GO/NOGO gages.
· Advantages and disadvantages of fixed gages and variable gages.
· Hints for using each type of fixed gage covered.
Lesson 6: Test Indicators & Dial Indicator
· The differences between the features and capabilities of test indicators and dial indicators.
· How to use test indicators with adjustable arm test sets for comparative length measurements.
· How to use dial indicators with comparator stands for comparative length measurements.
· Potential problems with indicators.
Lesson 7: Gage Blocks & Surface Plates
· Gage block and surface plate standards and grades.
· The use of gage blocks and surface plates.
· How to wring gage blocks.
· How to calculate combination stacks of gage blocks.
· Basic care points for gage blocks and surface plates.
Challenge: An assessment of the learner’s progress in this unit.
Unit 3 - Gaging Applications
Lesson 1: Application Overview.
· On overview of the dimensional measuring applications covered.
Lesson 2: Linear Measurements
· An exploration of which linear gage to use for a wide spectrum of specific measuring applications.
· Exercises looking at which gages are acceptable (and unacceptable) to use for measuring part features such as OD, ID, slot width, slot depth, differential height, and hole position.
Lesson 3: Roundness & Circularity
· How to take out-of-roundness measurements.
· Problems with measuring roundness and the OD with two-point contact gages.
· How to gage the effective diameter.
· How to select and use three-point contact devices for roundness and OD measurements.
· How to measure cylindricity.
Lesson 4: Common Misapplications
· 12 common measuring mistakes and misapplications.
· What to look out for and how to prevent these mistakes from happening.
Lesson 5: Measuring Complications
· 10 systemic problems that can lead to measuring complications.
· An exploration of why each complication may occur with suggested remedies to combat it and make the measurement system more robust.
Lesson 6: Care of Gages
· Universal care points that apply to all gages and instruments.
· Specific hints to ensure the proper care of specific gage families including surface plates, gage blocks, micrometers, calipers, height and depth gages, fixed gages, and indicators..
Challenge: An assessment of the learner’s progress in this unit.
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