Electronics Almen Gage TSP-3 Manuale utente

IM0085 2021-02

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for the Electronics Inc. #2 Almen Gage and Almen Gage Jr



US Patent 5,780,714 • US Patent 6,289,713 B1

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

Description ................................................................................................................................................................... 3

TSP-3 Almen Gage ................................................................................................................................................... 3

TSP-Jr Almen Gage .................................................................................................................................................. 3

Requirements ............................................................................................................................................................... 3

Forms ....................................................................................................................................................................... 3

Equipment ................................................................................................................................................................ 3

SAE J442 #2 Almen Gage Construction .................................................................................................................... 4

Instructions for Calibration of TSP-3 Almen Gage ...................................................................................................... 5

Inspection ................................................................................................................................................................. 5

Ball and Post Position Measurement Check ............................................................................................................. 5

Minimum Ball Height Check ..................................................................................................................................... 6

Ball Plane Flatness Check ......................................................................................................................................... 6

Indicator Battery ...................................................................................................................................................... 7

As Found .................................................................................................................................................................. 7

As Found Spindle Starting Position .......................................................................................................................... 7

Step Block Readings ................................................................................................................................................. 7

As Returned .............................................................................................................................................................. 8

Curved Check Block .................................................................................................................................................. 8

Paperwork ................................................................................................................................................................ 8

TSP-3 Certification of Calibration (Metric) ........................................................................................................... 9

TSP-3 Certification of Calibration (English) ........................................................................................................ 10

Instructions for Calibration of Almen Gage Jr ........................................................................................................... 11

Inspection ............................................................................................................................................................... 11

Ball and Post Position Measurement Check ........................................................................................................... 12

Minimum Ball Height Check ................................................................................................................................... 12

Ball Plane Flatness Check ....................................................................................................................................... 13

As Found ................................................................................................................................................................ 13

As Found Bezel – Spindle Starting Position ............................................................................................................ 13

Step Block Readings ............................................................................................................................................... 13

As Returned ............................................................................................................................................................ 14

Flat Check Block ..................................................................................................................................................... 14

Paperwork .............................................................................................................................................................. 14

TSP-Jr Certification of Calibration (Metric) ........................................................................................................ 15

TSP-Jr Certification of Calibration (English) ........................................................................................................ 16

Replacement Parts ..................................................................................................................................................... 17

Calibration Services ................................................................................................................................................... 18

Contacting Electronics Inc. ......................................................................................................................................... 18

Table of Contents

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

Description

The Almen Calibration Kit Instruction Manual is intended for individuals skilled in the use of the measuring

equipment described herein. The manual is based upon recommendations from ISO 10012-1. This procedure will

confirm Almen gage compliance with requirements of the following specifications.

TSP-3 Almen Gage

TSP-Jr Almen Gage

Digital Indicator

Analog Indicator

• SAE J442

• SAE AMS 2430

• SAE AMS 2432

• Boeing BAC 5730

• MIL-S-13165C

• SAE AMS-S-13165

• MIL-S-13165C

• SAE AMS-S-13165

Requirements

SAE J442 Test Strip, Holder and Gage for Shot Peening and SAE AMS 2432 Shot Peening, Computer Monitored

are the primary references used for the construction and calibration of the TSP-3 Almen gage. J442 is the primary

specification and AMS 2432 includes tighter tolerances for aerospace applications. SAE AMS-S-13165, successor to

MIL-S-13165C, is the primary reference for the Almen Gage Jr. Note: Both of these documents have been canceled

but may still be used if desired. The cancellation notice recommends users use AMS 2430 that defers to J442 for

Almen gage requirements.

Note: This procedure must be performed in an environment with temperature in the range of 60˚F - 90˚F (16˚C -

32˚C) and a relative humidity of 30% - 90%.

Forms

The results of the calibration procedure can be documented in the Certification of Calibration forms found in this

manual. Both Metric and English versions are provided.

Equipment

The calibration kit includes:

• 9-hole template for the inspection of the position of the balls, posts and indicator tip

• Five (5) step blocks (either Metric or English) to check the accuracy of the indicator

• Commercial-grade .05 mm feeler gage to check the ball plane flatness

The 9-hole template also serves as the certified 2.0 mm feeler gage for ball height inspection. Any commercial-

grade feeler gage of .05 mm may be used. The feeler gage is for reference only and is not certified.

The step blocks may also be purchased individually. See “Replacement Parts” in this manual.

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

SAE J442 #2 Almen Gage Construction

The TSP-3 Almen gage meets the requirements of SAE J442 as shown below.

Four (4) hardened precision balls (4.76 mm in diameter) are installed in the gage head. Balls must be in the same

plane (perpendicular to the indicator stem) within .05 mm.

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

Instructions for Calibration of TSP-3 Almen Gage

Make a copy of the Certification of Calibration form (Metric or English) provided in this manual. Note: Do not

repair, adjust or replace any items until the “Attribute” and “As Found” readings are completed.

Record the Serial Number of the Almen gage and its step block on the form. Record the Serial Numbers, Certified

Values and Calibration Due Dates for the five (5) step blocks and 9-hole template.

Inspection

Indicator Free Movement - Check the indicator stylus for free movement and full range of travel. If the indicator

stylus sticks, the gage must be repaired. Record “Pass” or “Fail” in the column of the form. Record any notes if

necessary.

Indicator Tip - Without the use of magnification, look for signs of wear or damage. Replace the indicator tip if

there is wear or damage. For example, a flat spot of 1 mm (0.039 inch) requires the replacement of the indicator

tip. Record “Pass” or “Fail” in the column of the form. Use the Notes column to record repairs or replacements.

Ball Condition - Inspect the magnetic strength of the four balls. Verify there is sufficient attraction to hold the test

strip securely in place. If not, replace entire gage head. Inspect the condition of four balls. If there are flat spots

greater than 1.0 mm (0.039 inch) in diameter on top of any ball, the gage head must be repaired or replaced.

Record “Pass” or “Fail” in the column of the form. Use the Notes column to record repairs or replacements.

Post Condition - Without the use of magnification, inspect the posts for signs of wear. If grooves on the posts

could prevent the test strip from being properly seated, the posts should be rotated or replaced. To rotate the

posts: Press the posts out from the bottom of the gage head, rotate them approximately 180 degrees, and press

them back into the gage head. Record “Pass” or “Fail” in the column of the form. Use the Notes column to record

any repairs or replacements.

Ball and Post Position Measurement Check

The 9-hole template verifies the position of the balls, posts, and indicator tip on the Almen gage head.

This is a pass/fail test. Place the template over the balls and posts. The template should lie flat on the base

surface—a ball or post should not interfere with this placement. The indicator tip should pass freely through the

center hole with no interference. If the template does not rest securely on the Almen gage head, the gage head

must be rejected. There are no adjustments or other remedies for this out-of-tolerance condition. The entire gage

head must be replaced. Record “Pass” or “Fail” in the column of the form. Record any notes if necessary.

9-hole template

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

Minimum Ball Height Check

The 9-hole template is certified to be a minimum of 2.00 mm in thickness. It is used to verify the ball heights are

equal to or greater than 2.00 mm in height.

This is a pass/fail test. Place a certified flat surface, such as a step block or the flat side of the curved check block,

on the Almen gage head and attempt to insert the 2.00 mm template between the gage head and the flat surface.

If the template cannot be inserted, the ball height is less than 2.00 mm and the gage head must be replaced.

Record “Pass” or “Fail” in the column of the form. Record any notes if necessary.

The 9-hole template verifies that the ball heights are at least 2.00 mm in height

Ball Plane Flatness Check

This is a pass/fail test. Place a certified flat surface, such as the flat side of the curved check block, on the gage

head to determine if one of the balls is lower than the other three balls. Check if the gap is larger than 0.05 mm by

attempting to insert a 0.05 mm feeler gage between any one of the four balls and the flat surface. If the feeler

gage can be inserted between any ball and the flat surface while the remaining three balls are in contact with the

flat surface, the ball plane flatness exceeds the tolerance and the gage head must be replaced. Record “Pass” or

“Fail” in the column of the form. Record any notes if necessary.

A 0.05 mm feeler gage verifies the ball plane flatness is within tolerance

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

Indicator Battery

Batteries should be replaced annually or during calibration. The warning symbol “bA Lo” appears on the digital

indicator when the batteries are low. Two (2) CR2450 lithium cells are required. Set-up and calibration information

are saved during battery replacement.

As Found

The “As Found” readings are the initial observations of the gage. These are made before any adjustments are made

(including adjustments to the Spindle Starting Position) and entered into the appropriate cell on the Certification

form. If no adjustments are made, these values are then copied into the “As Returned” columns of the form. Note:

If adjustments are made, the new value must be within tolerance allowed and entered into the “As Returned”

section. If adjustments cannot bring the gage reading into the allowed tolerance, the gage must be returned for

repair to Electronics Inc.

As Found Spindle Starting Position

Read and record the Spindle Starting Position in the “As Found” column before making any step block readings. Do

not adjust the Spindle Starting Position regardless of the setting since this could affect the actual “As Found”

conditions for other measurements. Place a calibrated flat surface, such as a step block or the flat side of the

curved check block, on the Almen gage head. Press and hold the “ZERO/ON” button to place the indicator into the

True Spindle Position mode (the “x1” on the bottom of the indicator screen will disappear). The value now shown

in the display is the Spindle Starting Position.

Step Block Readings

Five (5) step blocks are used to display the indicator accuracy over the expected range of travel (-0.200 mm to +

0.600 mm or -0.005 inch to + 0.025 inch, depending on which kit option used). Note: The .200 mm or the 0.005

inch step blocks may be used in reverse order to achieve negative calibration readings.

Place a step block on the gage head and slide it against one side of the end post, allowing the indicator tip to touch

the flat zero reference surface of the step block (not the recessed step). Press the “ZERO/ON” button to acquire a

zero in the indicator display. Next, slide the step block to the other side against the opposite end post to allow the

indicator tip to extend into the recessed step. Read and record the value shown in the indicator display in the “As

Found” column. Repeat the procedure and record the values for the remaining four (4) step blocks. Use the 0.200

mm or 0.005-inch step block in reverse sequence to check the negative range of the indicator.

Photograph on left: Place the step block to one side, allowing the indicator tip to touch the flat zero reference surface of the step

block. Photograph on right: Slide the step block to the other side to allow the indicator tip to extend into the step.

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

As Returned

Any features that failed during the inspection procedure must be repaired or replaced at this time.

The factory recommended value of the Spindle Starting Position is set to 0.000 mm ± 0.025 mm (0.000 inch ± 0.001

inch). If the spindle setting is out of tolerance, it should be adjusted before recording the remaining “As Returned”

values of the step blocks. Note: Spindle Starting Position is not a requirement of J442. It is a factory recommended

practice. Therefore, if the Spindle Starting Position is not within the recommended range, it should not fail its

inspection. However, the Spindle Starting Position should be set to the recommended range as stated above

before the gage is returned to service.

To adjust the Spindle Starting Position: Place a calibrated flat surface, such as a step block or the flat side of the

curved check block, on the Almen gage head. Press and hold the “ZERO/ON” button to place the indicator into the

True Spindle Position mode (the “x1” on the bottom of the indicator screen will disappear). Loosen the 8 mm gland

nut that holds the indicator and adjust the indicator placement on the frame until the Spindle Starting Position is

within tolerance. Carefully tighten the gland nut and be sure the indicator is secure (does not move or rotate) and

the Spindle Starting Position does not change as the gland nut is tightened. Record the adjusted Spindle Starting

Position in the “As Returned” column. Place a dab of proof lacquer at the gland nut and stem as a tamper-proof

seal.

Place each of the five (5) step blocks on the gage and record the “As Returned” values on the Certificate of

Calibration. The step block readings must be within ± 0.0025 mm (± 0.0001 inch) of the step block value. Adjust the

indicator span as described in the Indicator Owner’s Manual or replace the indicator if a step block reading fails.

Curved Check Block

A Curved Check Block is supplied with the TSP-3 #2 Almen gage. It is flat on one side and curved on the other. The

flat side is precision lapped to a flatness of 2 HLB (2 Helium Light Bands) or better, and is used to set the zero

datum reference for the gage. The curved side is not calibrated but has a curvature that will represent an arc

height of approximately .600 mm ± .05 mm or .024 inch ± .001 inch, which is the upper range of the intended use

of the gage. The curved side is used as a weekly check to verify that the gage is still functioning as intended. A

Certification of Calibration for flatness for the flat side is included with the Curved Check Block. The curved side is

not certified. It is for reference only.

Zero the gage by using a certified flat surface (such as one of the certified step blocks). Place the flat side of the

Curved Check Block on the gage. If the reading exceeds ± .005 mm (± .0002 inch), reject the block and replace it

with a new Curved Check Block.

Paperwork

Indicate next calibration due date and sign and date the Certification of Calibration. Fill out and place a

“Calibrated” decal on the gage with the date of calibration. The next calibration due date will depend upon quality

system calibration requirements which is usually a date one year later. Some organizations allow calibration one

year after first use in the event the gage is placed into inventory prior to use.

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

TSP-3 Certification of Calibration (Metric)

(Qualifies for SAE J442, AMS 2430, AMS 2432, BOEING BAC5730, MIL-S-13165C and SAE AMS-S-13165)

Model:

TSP-3

Manufactured by Electronics Inc. Mishawaka, Indiana USA

Serial Number

Procedure:

IM0085

Attribute

Pass / Fail

Notes

Indicator Free Movement

Indicator Tip (Max. 1.0 mm Dia. Flat)

Ball Condition (Max. 1.0 mm Dia. Flat)

Post Condition (No Grooves)

Ball and Post Position (9-Hole Template)

Minimum Ball Height (2.0 mm)

Ball plane Flatness (.05 mm)

Spindle Starting Position

Recommended 0.000 with a

tolerance of +/- 0.025

As Found

As Returned

Step block readings must be within ± 0.0025 mm of the Certified Value

Size

Serial Number

Calibration Due

Date

Certified Value

As Found

As Returned

.6 mm

.5 mm

.4 mm

.3 mm

.2 mm

-.2 mm

Same as above

Old Serial Number

New Serial Number

New Gage Head – (Separate certification supplied)

New Check Block – (Separate certification supplied)

We hereby certify that this instrument has been inspected and is in conformity with the requirements of SAE J442,

AMS 2430, AMS 2432, BOEING BAC5730, MIL-S-13165C and SAE AMS-S-13165.

Next calibration due date: ______________________________

Performed by

Date

Equipment

Serial Number

Calibration Due Date

9-Hole Template

Serial Number

As Found

Tolerance

Pass/Fail

Curved Check Block

0 + .005 mm (0 ±.0002”)

Electronics Inc. • (574) 256-5001 • www.electronics-inc.com

TSP-3 Certification of Calibration (English)

(Qualifies for SAE J442, AMS 2430, AMS 2432, BOEING BAC5730, MIL-S-13165C and SAE AMS-S-13165)

Model:

TSP-3

Manufactured by Electronics Inc. Mishawaka, Indiana USA

Serial Number

Procedure:

IM0085

Attribute

Pass / Fail

Notes

Indicator Free Movement

Indicator Tip (Max. 0.039” Dia. Flat)

Ball Condition (Max. 0.039” Dia. Flat)

Post Condition (No Grooves)

Ball and Post Position (9-Hole Template)

Minimum Ball Height (0.079”)

Ball plane Flatness (0.002”)

Spindle Starting Position

Recommended 0.000 with

a tolerance of ± 0.001 inch

As Found

As Returned

Step block readings must be within ± 0.0001 inch of the Certified Value

Size

Serial Number

Calibration Due Date

Certified Value

As Found

As Returned

0.025”

0.020”

0.015”

0.010”

0.005”

-0.005”

Same as above

Old Serial Number

New Serial Number

New Gage Head – (Separate certification supplied)

New Check Block – (Separate certification supplied)

We hereby certify that this instrument has been inspected and is in conformity with the requirements of SAE J442,

AMS 2430, AMS 2432, BOEING BAC5730, MIL-S-13165C and SAE AMS-S-13165.

Next calibration due date: ______________________________

Performed by

Date

Equipment

Serial Number

Calibration Due Date

9-Hole Template

Serial Number

Calibration Due Date

Tolerance

Pass/Fail

Curved Check Block

0 + .005 mm (0 ±.0002”)

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