3.1 Analyze necessary equipment and measuring tools.

- Detailed drawings and measurement and inspection diagrams.

- Necessary tools for measuring and checking operations.

- Necessary measuring and testing equipment.

- Measured ambient temperature.

- Standardize measuring fixtures.

- Measurement results record sheet.

Figure 3.1: Detail Drawing Sample 1

 Firgure 3.2: Detail drawing sample 2

Figure 3.3. Detail surface marking sample 2

%
O1111

N100 G99 G97 G90 G21

N116 T4 // gia công thô mặt ngoài

N118 G55

N120 S1100 M03

N122 G0 X31. Z2.
N124 G71 U0.2 R1.

N126 G71 P128 Q132 U0.05 W0.1 F0.15 N128

G01 X0. Z0.

N130 G01 X28. Z0.

N132 G01 X28. Z-40.
N134 G0 Z100.

N136 T2 // khoan
N138 G56

N140 S1400 M03

N142 G0 X0. Z5.

N144 G83 Z-40. R5. Q5. F.2

N146 G0 Z5.

N148 G0 Z100.

N150 T2 G59 // khoét rộng lỗ

N151 S700 M3

N152 G0 X17.5
N154 G0 Z5.

N156 G83 Z-18. R5. Q5. F.1

N158 G0 Z100.

N160 T2 // gia công tinh lỗ

N162 G57

N164 G97 S1500 M03

N166 G0 X17.3 Z1.25
N172 Z1.
 N206 G1 X25. F0.08
N208 G0 X35.

N210 G0 X26.
N212 G1 X20.
N214 G0 X35.
N216 G0 X21.
N218 G1 X15.
N220 G0 X35.
N222 G0 X16.
N224 G1 X10.
N226 G0 X35.
N228 G0 X11.
N230 G1 X6.
N232 G0 X31.
N234 G0 Z100.

N236 T1// lấy cữ phôi mới

N238 G54

N240 G0 X0.
N242 G0 Z0.2

N244 M05
N246 M30

Figure 3.4. Code on the Haas TL1 Lathe

%
O0003

N10 G90 G94 G97 G21 G54

N12 S1000 M03

N14 G0 Z20

N16 G0 X-22 Y100

N18 G0 Z-8

N20 G0 Y14

N22 G1 Z-15 F200

N24 G1 X-22 Y-14
N26 G0 Z20.

N28 G0 X-22 Y100

N30 M05
 Figure 3.5. Code on the VMC16 Milling machine

3.2. Procedure

- Record the environment temperature (330 C ).

- Check the “0” standard of the measuring tools.

Panme:

Caliper:
- Perform measurement operations based on measurements diagram and record the measured
data into the record sheet.

3.2 .1 Measure and check the quality of the machined surface

a. Required machine: Roughness meter of Mitutoyo company.
b. Mesuring the workpiece
i. Procedure
- Using the roughness meter to indicate the surface roughness of the 3rd face.
ii. Recording data

Table 3.1. The surface roughness data

No. Ra Rz
1 0.766 4.420
2 0.961 6.094
3 0.734 3.688
4 0.714 3.489
5 0.728 3.510
iii. Conclusion
- We compare with the requirement (Ra 0.8), we get the roughness of surface 1
(datumn A) meets the requirement.

3.2.2 Measure and check dimensional tolerances and errors in shape,

position, relative position
3.2.2.1Using traditional measuring tools (required)
a. Requirement
From the detail drawing, we get these technical requirement

- Dimension: ∅28ℎ7, ∅18𝐻7, ∅8𝑗𝑠12, 24𝑗𝑠10, 35𝑗𝑠10, 18𝑗𝑠12, 20𝑗𝑠12.

- GD&T: flatness tolerance and perpendicularity tolerance of face 4; parallelism
tolerance of face 1; concentricity tolerance of face 11 and the position tolerance of
among 5, 6, 7, 8, 9, 10 faces.

b. Procedure: using the equipment at 203B11

 Dimension:

Check the zero point of micrometers (measure the sample 25mm and 50mm) and
the vernier caliper (clamp and clean lower jaws as well as upper jaws).

Measure 5 different sections on the bushing by the micrometer and the vernier
caliper.

 GD&T:
 Flatness:
1. Using straight gauge

Set the ruler according to the edge, border of the part Figure 1 and use the scale to
determine the height of the gap between the ruler and the edge of the part.

Figure 3.5. Diagram for checking straightness and flatness by steel leaf gauge

2. Using granite surface plate and dial indicator

- Slide the meter along the edges of the part to determine the straightness (Figure 2).
- Measure each surface twice on 6 directions.
- Determine the flatness of the plane as the greatest non-linearity.
 Figure 3.5. Check diagram for straightness and flatness using round type dial gauge and
granite surface plate

 Perpendicularity:

Measure the perpendicularity using triangle square and straight edge feeler gauge to
determine the gap ∆𝑚𝑖𝑛, ∆𝑚𝑎𝑥 (Figure 3). Making 3 measurements with L segments as
required (50mm) at different location then write the result in table below.

Figure 3.6. Check squareness by triangle square and steel leaf gauge

 Parallelism:
- Put the surface datum B in place on the granite surface plate.
- Fix the dial indicator so that the tip is perpendicular to that surface.
- Move the bushing to get the value.
- The difference between the largest measured value ∆𝑚𝑎𝑥 and the smallest
measured value ∆𝑚𝑖𝑛 is the parallelism value. Take 5 different values at 5
measuring times.
 Concentricity: By dial indicator
- Put the datumn A of the workspiece on the V-Block.
- Draw 3 sections parallel with the datumn B on the datumn A, each section is 3mm
away to each other.
- Use both internal and external dial indicator to indicate the datumn A and the face 4
at those sections in the same time then record the data.
 Position:
- Cannot measure due to the lack of support equipment.
c. Data processing and comments
 Dimension
 Table 3.2 The dimensional data (mm)

Mearsure time
Dimension
1st 2nd 3rd Average
8.075
8.090 8.070 8.080 8.068
7.925
+0.075
∅ 8−0.075

18.027
17.980 17.970 17.980 17.976
+0.027

18.000
∅ 18 0

28.000
28.010 28.010 28.010 28.010
27.979
0
∅ 28−0.021

18
17.890 17.670 17.620 17.702
17.982
0
∅ 18−0.018

20.105
19.800 19.810 19.820 19.816
+0.105

19.895
20−0.105

5&8 23.950 24.080 24.000 24.000

24.042
6&9 24.130 24.180 24.090 24.130
+0.042
24−0.042

23.958
7&10 24.120 24.100 24.130 24.118
35.050
35.090 35.030 34.990 35.052
34.950
+0.050
35−0.050

 Evaluating:
- The measurement data that satisfy the requirement in drawing: ∅8, 24 (5&8).
- The measurement data that are not satisfy the requirement in drawing: ∅18, ∅28,
∅18, 20, 24 (6&9, 7&10), 35.
 Conclusion:

From the table, we can get that only two dimensions requirement satisfy the
requirement. This is because of the machining process, preservation process and measuring
process.

 GD&T:
 Table 3.3. The geometric dimension and tolerance data (mm)

Measurement time
GD&T
1st 2nd 3rd 4th 5th Average
Straightness 0 0 0 0 0 0
Flatness (B)
0

Perpendicularity (B)
0 0 0 0 0 0

Parallelism (1)
0.060 0.100 0.100 0.080 0.070 0.082

Position
Unable to measure due to the lack of equipment

Concentricity (11)
Unable to measure due to the lack of equipment

 Evaluating:
- The GD&T that meet the requirement of drawing: flatness, perpendicularity.
- The GD&T that do not meet the requirement of drawing: parallelism.
 Conclusion:
- Although the flatness and perpendicularity satisfy the requirement, the result is not
reliable. The minimum value of the steel leaf gauge is 0.03 so any value that
smaller than that value is not recorded. For more reliable, they need to determine by
the modern machine ( if necessary).
- The parallelism does not meet the requirement due to the error in machining
process (cutting tool, chip, cooling liquid,…), measuring process (temperature,
cleaning condition,…) and preservation process.

- The position tolerance can not measure by the traditional tool, it needs something
more modern like CMM. Moreover, the concentricity can not measure because
there is a lack of internal indicator, we change the way to measure the
 concentricity by the CMM.

2.1.1. Use CMM coordinate measuring machine (optional)

a. Students are instructed on how to perform measurements with a CMM
coordinate measuring machine: Appendix 1

Figure 3.7. The CMM at measurement room

b. Based on the coordinate data of the measuring points on the CMM,

students perform data analysis to determine dimensional tolerance
requirements, shape, position and relative position.
 Concentricity

Procedure to analyze the data:

- Determine the extracted center of measured profile.

- Compare the distance of that point to the nominal center point of drawing profile.
 Figure 3.8. Understand the concentricity and measured profile

Data:

Table 3.4. Concentricity measured data

Position
No. Surface Mearuring diameter Tolerance
x y z
3 419.809 229.760 -4.166 27.979
1 0.020
11 419.809 229.762 -4.164 18.101
3 419.809 229.760 -9.166 27.971
2 0.020
11 419.809 229.761 -9.157 18.097
Average value of concentricity tolerance 0.020
  Position
 First way

Procedure to analyze the data:

- Using AutoCAD, we plot the measure profiles

- Matching each peak of the hexagon to the circle, the tolerance is the maximum
distance between the two profiles.

Figure 3.9. Way to indicate the position tolerance

Table 3.6. Position measured data

Tolerance
No.
5&8 6&9 7&10
1 0.2456 0.1757 0.2635
2 0.1516 0.3018 0.1209
Maximum 0.2456 0.3018 0.2635

From the table, we got these results. The position tolerance is 0.05 and those for
5&8, 6&9, 7&10 do not satisfy the condition.
 Figure 3.10. The hexagonal surface of sample 2 measured by CMM

Sample 2:
Using the CMM method, we determined a diameter of ϕ=27.971 from the surface
being measured to surface A at approximately 5 mm distance, differing from the
specified diameter in the drawing which is ϕ=28 mm, with an error of 0.029 (mm).
Diameter ϕ=27.973 from the surface being measured to surface A at approximately 10
mm distance, differing from the specified diameter in the drawing which is ϕ=28 mm,
with an error of 0.027 (mm).
Diameter ϕ=17.933 from the surface being measured to surface A at approximately 30
mm distance, differing from the specified diameter in the drawing which is ϕ=18 mm,
with an error of 0.067 (mm).
Diameter ϕ=17.934 from the surface being measured to surface A at approximately 33
mm distance, differing from the specified diameter in the drawing which is ϕ=18 mm,
with an error of 0.066 (mm).
The concentricity between the first and third circles, or relative to the standard surface
A is 0.145 mm.
The measured distance from the standard surface to the hexagonal surface obtained by
the machine is 28.017 (mm), with an error compared to the drawing of 0.017 (mm).
Sample 2 Second Round:
Diameter ϕ=27.979 from the surface being measured to standard surface B at
approximately 4 mm distance, differing from the specified diameter in the drawing
which is ϕ=28 mm, with an error of 0.021 (mm).
Diameter ϕ=27.971 from the surface being measured to standard surface B at
approximately 9 mm distance, differing from the specified diameter in the drawing
which is ϕ=28 mm, with an error of 0.029 (mm).
 Diameter ϕ=18.101 from the surface being measured to standard surface B at
approximately 4 mm distance, differing from the specified diameter in the drawing
which is ϕ=18 mm, with an error of 0.101 (mm).
Diameter ϕ=18.097 from the surface being measured to standard surface B at
approximately 4 mm distance, differing from the specified diameter in the drawing
which is ϕ=18 mm, with an error of 0.097 (mm).
c. Comment on the obtained values compared to the requirements from the drawings
 Concentricity
From the result above, we conclude:
- The machining process and preservation process are excellent. The temperature at
the measuring room is suitable.
- The preservation process including lubrication and covering makes the surface
roughness suitable for measuring.
 Position
From the result above, we conclude the reason for the failure:
- Due to poor cleaning of the cutter, uneven oiling leads to chips remaining on the
cutter, affecting the milling process.
- Due to the old measuring tool is not suitable for measuring the exact size.
- Effect of cutting speed.
- Effect of Knife Running Amount.
- Effect of Cutting Depth.
- The machining process and preservation process are excellent. The temperature at
the measuring room is suitable.
- The preservation process including lubrication and covering makes the surface
roughness suitable for measuring.
3.3. Analyze and evaluate the results of measurement and inspection operations

- 3.3.1. Use traditional measuring tools (required)

3.3.1.1. Evaluate reference surfaces

 Table 3.7. Measurement results of standard surfaces

Num The reference Required Measured Required Measured Result

surface is geometric geometric roughness (Ra) roughness (Satisfied/
numbered tolerances tolerances Unsatisfied)
(mm) (mm)
1 1 Flatness 0.01 0.07 1.6 1.658 Satisfied
2 1 Rectangular < 0.03 1.6 1.129 Unsatisfied
level
0.02

3 2 20 18.5 0.8 0.766 Unsatisfied

3.3.1.2. Evaluate other surfaces

Table 3.8. Measurement results of other surfaces

Num The reference Required Measured Required Measured Result

surface is geometric geometric roughness roughness (Satisfied/
numbered tolerances tolerances (Ra) Unsatisfied)
(mm) (mm)
1 3 X X 1.6 0.961 Unsatisfied
2 4 X X 12.5 X Satisfied
3 6 Concentricity 0.02 0.8 0.734 Unsatisfied
0.01

3.3.1.3. Evaluate tolerances of machining dimensions

Table 3.8. Measurement results of checking machined dimensions

Num Dimensions and Standard Measured surface Measured Results

technical requirements surface dimension (Satisfied/Unsatisfied)
+18
1 ϕ 180 (mm) 2 6 18 Satisfied
0
2 ϕ 28−21 (mm) 2 2 27.9 Unsatisfied
+50
3 35−50 (mm) 1 5 35.5 Unsatisfied
+42
4 24−42 (mm) 2 3 23.9 Unsatisfied

3.3.1.4. Evaluate tolerances of relative positions

Table 3.9. Measurement results check the relative position tolerances

Nu Name of Standard Measured Required Measured Result

m relative surface surface value value (Satisfied/Unsatisfied)
position
1 Position 2 3 0.05 X Undefined
deviation
2 Parallel 1 5 0.04 0.1 Unsatisfied
level
 - 3.3.2. Use CMM coordinate measuring machine

3.3.2.1. Evaluate standard surfaces

Table 3.10. Measurement results of standard surfaces

Num The Required Measured Required Measured Results

reference geometric geometric roughness roughness (Satisfied/Unsatisfied)
surface is tolerances tolerances (Ra)
numbered (mm) (mm)
1 2 ϕ 28 ϕ 27.98 1.6 X Satisfied
3.3.2.2. Evaluate other surfaces
Table 3.11. Measurement results of other surfaces

Num The Required Measured Required Measured Results

reference geometric geometric roughness roughness (Satisfied/Unsatisfied)
surface is tolerances tolerances (Ra)
numbered (mm) (mm)
1 6 ϕ 18 ϕ 18.007 1.6 X Satisfied
2 4 ϕ8 ϕ 8.278 1.6 X Unsatisfied
3 3 ϕ 24 ϕ 24.35 0.8 X Unsatisfied

3.3.2.3. Evaluate Tolerances of machining dimensions

Table3.12. Measurement results of checking machined dimensions

Num Dimensions and Standard surface Measured surface Measured Results

technical requirements dimensions (Satisfied/
Satisfied)
+18
1 ϕ 180 (mm) 2 6 17.933 Unsatisfied
0
2 ϕ 28−21 (mm) 2 2 27.971 Unsatisfied
+50
3 35−50 (mm) 1 5 35.9 Unsatisfied
+42
4 24−42 (mm) 2 3 23.96 Satisfied

3.3.2.4. Evaluate Tolerances of relative positions

Table 3.13. Measurement results check the relative position tolerances

Nu Name of Standard Measured Required Measured Results

m relative surface surface Value value (Satisfied/Unsatisfied)
position
1 Position 2 3 0.05 0.119 Unsatisfied
deviation
2 Concentricity 2 6 0.01 0.005 Satisfied

- 4. Conclusion
 There is a difference between the dimensions measured at the factory and the
dimensions measured at the laboratory. The cause of the above difference may come
from:

+ Errors of measuring instruments in factories and laboratories are different: different

measuring instruments have different errors, leading to readings from those instruments
being affected by those errors. together. To overcome this situation, it is necessary to use
only one measuring instrument at a certain temperature condition.

+ Effect of temperature on the size of the workpiece: aluminum is a material with high
thermal expansion. After the turning operation, the workpiece receives heat generated by
the machining process, so it expands, causing the measured size to be larger than the
size measured in the laboratory.

% N136 T3// Drill big hole N176 G00 Z150. N216 G00 X26.
O01111 N138 G59 N178 T4// Exterior N218 G01 X20.
N100 G99 G97 G90 G21 N140 S700 M03 surface finishing N220 G00 X31.
N102 T1// Rough N142 G00 X0 N180 G58 N222 G00 X21.
machining of the outer N144 G00 Z5. N182 S1100 M03 N224 G01 X15.
surface N146 G83 Z-18. R5. Q5. N184 G00 X31. N226 G00 X35.
N104 G55 F0.1 N186 G00 Z0. N228 G00 X16.
N106 S1100 M03 N148 G00 Z50. N188 G01 X17. Z0. F0.1 N230 G01 X10.
N108 G00 X31. Z2. N150 T3// Fine N190 G01 X28. Z0. N232 G00 X31.
N110 G71 U0.2 R1. machining of holes N192 G01 X28. Z-40. N234 G00 X11.
N112 G71 P114 Q118 N152 G57 N194 G1 X27. Z0. N236 G01 X6.
U0.1 W0.1 F0.2 N154 G97 S1500 M03 N196 G1 X28. Z-0.5 N238 G00 X31.
N114 G01 X17. Z0. N156 G00 X17.3 N198 G00 X31. N240 G00 Z50.
N116 G01 X28. Z0. N158 Z2. N200 G00 Z200. N242 T2
N118 G01 X28. Z-40. N160 Z1. N202 T2 // Cut off work N244 G54
N120 G00 Z150. N162 G71 U0.1 R0.1 piece N246 G00 X0.
N122 T3 // Drilling N164 G71 P166 Q168 U0 N204 G54 N248 G00 Z2.
N124 G56 W0. F0.1 N206 S850 M03 N250 M05
N126 S1400 M03 N166 G01 X18. N208 G00 X31. N252 M30
N128 G00 X0. Z5. N168 G01 Z-18. N210 G00 Z-39. %
N130 G83 Z-40. R5. Q5. N170 G1 X19. Z0 N212 G01 X25. F0.01
F0.2 N172 G1 X18. Z-0.5 N214 G00 X31.
N132 G00 Z5. N174 G1 Z1.
N134 G00 Z50.