1、I INCH-POUND MIL-HDBK-204A(AR) 30 November 1990 I I MILITARY HANDBOOK I DESIGN OF INSPECTION EQUIPMENT FOR DIMENSIONAL CHARACTERISTICS Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-I MIL-HDBK-204A(AR) FOREWORD 1. This military hand hook is appro
2、ved for use by all Activities and Agencies of the Department of the Army and is available for usc by all Departments ,afid Agencies of the Department O( Defense. 2. Beneficial comments (recommendations, additions, deletions) and any pertinent data that may be of use in imprnving this document should
3、 he addressed to: Commander, US Army Armament Research, Development, and Engineering Center, ATTN: SMCAR-BAC-S, Picatinny Arsenal, NJ 07806-5000, by using the self-addressed Standardization Document improvement ,Proposal (DD Form 1426) appearing at tbc end of this document or by letter. 3. This hand
4、book was developed under the auspices of the US Army. Materiel Commands Engineering Design Handbonk Program, which is under the direction of the US Army Management Engineering College. This handhook was written hy the Research Triangle Institute under Contract No. DAAA08-80-C-0247. 0 Provided by IHS
5、 Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-204A(AR) . . CONTENTS CHAPTER1 ItiTRODUCTION I 1.1 I 1.2 I 1.3 I 1.4 1.5 1.6 1.7 CHAPTER 2 ELEMENTS OF Inspection EQUIPMENT Selection AND DE.fXGN I 2.1 2.2 I 2.3 I I I .9 INTRODUCTION . .2.l ANALYSIS OF RE
6、QUIREMENTS .2.l 2.2.1 TYPEsoF Inspection Requirements .2.2 2.2.1.1 2.2.1.2 2.2.1.3 2.2,1.4 2.2.1.5 2.2.1.6 2,2.1.7 Runout 2.3 Projected Tolerance Zone 2.3 2.2.2 SOURCES OF PARAMETERS TO BE INSPECTED .2-3 SELECTION OF INSPECTION EQUIPMENT .2.5 2.3,1 PHYSICAL CONSIDERATIONS .2.8 111 Provided by IHS No
7、t for Resale No reproduction or networking permitted without license from IHS -,-,-Paragraph 2.3.2.1 2,3.2,2 2,3.2,3 2.3.2.4 2,3.2.5 2,3.2,6 MIL-HDBK-204A(AR) CONTENTS (centd) POze l 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 Quantity of Parts to Be Inspected 2.1 Time Required for. Inspection 2.Ig Useful Life of
8、 Inspection Equipment 2.l8 Percentage and Costs of Errors 2.l8 Effect of Engineering Changes .2.l8 Availability of Commercial Inspection Equipment .2.19 2.4 DESIGN PHILOSOPHY AND POLICY .2.I9 2.4.1 FUNDAMENTAL RULES OF DESIGN . .2-19 2.4.1.1 Principles of Product Design That AffectGag5.2 3.5.3 COORD
9、INATE MEASURING MACHINES WiTH OPTICAL COMPARATORS 3-35 COORDINATE MEASURING MACHINES EQUIPPED WITH ELECTRONIC MEASUREMENT AND DIGITAL READOUT 3.35 COORDINATE MEASURING MACHINES WITH AUTOMATIC PRINTOUT .3-35 COORDINATE MEASURING MACHINES WITH COMPUTERS 3.37 UNIVERSAL MEASURING MACHINES 3.37 3.6.5 LOC
10、ATION .3+ 3.6.6 USE OF WIRES IN MEASURING. PITCH DIAMETER OF SCREW THREADS .3-45 REFERENCES 347 BIBLIOGRAPHY .347 CHAPTER 4 OTHERMEASURING EQUIPMENT INTRODUCTION 4.l OPTICALEQUIPMENT 4.l v Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL:HDBK-2
11、04A(AR) CONTENTS (centd) CHAPTER4 ,. OTHER MEASURING EQUIPMENT Paragraph Page 4,2.1 OPTICAL INSPECTION Instruments .4. 4.2.3.1 4.2.3.2 4.2.3.3 4.2.3,4 4.2.3.5 4,2.3.6 4.2.3.7 Laser Alignment System .4.?O 4.2.4 INTERFEROMETRIC METROLOGY INSTRUMENTS .4.3O 4.3 4.4 5. I 5,2 l o vi Provided by IHS Not fo
12、r Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-204A(AR) CONTENTS (centd) l ParaKraph Pare 5.3 5.4 5.5 l REFERENCES 6.1 6,2 CHAPTER6 MEASUREMENTS FOR INTERRUPTED DIAMETERS .5-27 vii Provided by IHS Not for Resale No reproduction or networking permitted without
13、 license from IHS -,-,-MIL-HDBK-204A(AR) CONTENTS (centd) CHAPTER7 ., BASIC GAGES VIII Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-204A(AR) CONTENTS (centd) ix Provided by IHS Not for Resale No reproduction or networking permitted wit
14、hout license from IHS -,-,-MIL-HDBK-204A(AR) CONTENTS (centd) CHAPTER 8 0 GAGES FOR INTERRUPTEDDIAMETERS pararraDh P“.v . . .-. . 8.1 8.2 8.3 8,4 8.5 9.1 9.2 9,3 9.4 9,5 CHAPTER 9 SPECIAL GAGES INTRODUCTION . 9-1 GAGES FOR WEAPON CHAMBERS 9.l 9.2.1 CHAMBER FEATURES TO BE GAGED 9.l 9.2.2 DESIGN OF GA
15、GES FOR WEAPON CHAMBERS .9.2 ALIGNMENT GAGES 9.5 9.3,1 DESIGN OF A COMPLETE ROUND ALIGNMENT GAGE FOR SMALL ARMS AMMUNITION 9.6 9.3.2 DESIGN OF A COMPLETE ROUND ALIGNMENT GAGE FOR LARGE CALIBER AMMUNITION .9.8 9.3.3 CARTRIDGE CASE PROFILE GAGES .9.lO INTERCHANGEABILITY GAGES 9.lI MECHANICAL COMPARATO
16、RS (COMPARATOR GAGES) 9.l2 9.5.1 BENCH COMPARATORS 9.l2 CHAPTER 10 ; AUTOMATED INSPECTIONEQUIPMENT l x Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-204h(AR) CONTENTS (centd) Paragraph Page 10.1.1 AUTOMATED INSPECTION EQUIPMENT lO.l 10.
17、1.2 COMPUTER-AIDED INSPECTION SYSTEMS lO.2 10.3 10.4 10.5 10.8 10.8.1.1 10.8.1.2 10.8.1.3 10,8.1.4 10.8.1.5 Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-204A(AR) CONTENTS (centd) Paragraph 10.8.2 10.8.3 10.8.4 Page l PROGRAMMING CONSID
18、ERATIONS .l6.5 Single-Probe Check for Spur and Helical Gears 6.6 Single-Probe Check for Bevel and Hypoid Gears 6.6 Double-Probe Check for Spur and Helical Gears 6.7 Double-Probe Check for Bevel and Hypoid Gears 6.7 Rolling Check of a Small Gear 6.8 Schematic of Pitch Checking Instrument .6.lO Automa
19、tic Tooth-Spacing Checker or Comparator .6.ll Tooth-Spacing Tester 6.l2 Index-Measuring Machine 6.l3 Charts of Both Sides of Gear Teeth Placed Side by Side for Easy Comparison 6-14 Determination of Maximum Pkch Variation and Maximum Index Variation . . . . . . 6-15 Angular Measurements for Index Var
20、iation 6-16 Tooth Profile and Corresponding Plot 6-20 Tooth Tolerance and Corresponding Plot . 6-21 Uad-Checking Machine 6.23 Setting of Pointer for External Spur and Helical Gears for Lead Check . . . 6-23 Graph of Right-Hand External Hefical Gear Teeth Wth Short Lead . . 6-25 Graph of Right-Hand E
21、xternal Helical Gear Teeth Wth Long Lead . . . 6-25 Graph of Left-Hand External Helical Gear Teeth With Long Lead .6.26 Graph of Left-Hand External Helical Gear Teeth With Short Lead 6-26 Graph of External Spur Gear With Crowned Teeth 6.27 Graph of External Helical Gear With Crowned Teeth . 6-27 Gra
22、ph of External Spur Gear Wth Tapered Teeth 6.28 Graph of External Helical Gear With Tapered Teeth and Lead Variation . . . . 6-28 Gear-Rolling Fixture Wkh Suspended Weight 6.29 xv Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-204A(AR) L
23、IST OF ILLUSTRATIONS (centd) Figure No. 6-29 6-30 6-31 6-32 6-33 6-34 6-35 7-1 7-2 7-3 74 7-5 7-6 7-7 7-8 7-9 7-1o 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-2 I 7-22 7-23 7-24 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-35 7-36 .7-37 7-38 7-39 740 741 7-42 743 ., Title Page Graph o
24、f Gear Tooth Variations Obtained From a Rolling Test . 6-30 l Schematic of Single-Flank Testing 6.3l Single-Flank Testing Data .&32 Vernier Tooth Caliper .6.33 Few of Possible Arrangements Indicating Cnrrect Reading in Span Measurement 6-34 Addendum Comparator in Use 6-35 Indicator Method of Blackla
25、sh Measurement 6.37 Single-Ended, Double-Ended, and Progressive Plug Gages .7.3 Wire-Type Plug Gages .7.3 Taperlock Plug Gages . .7A Trilock Plug Gages 74 Annular Plug Gage 7.5 Taper Plug Gages 7.5 Flat Plug Gage fnr Internal Diameters 74 Flat Plug Gages for Slots and Noncircular Holes 7-6 Product a
26、nd Plug Gage Tolerance Relationship 7.l5 Plug Gage Design Example .7.l5 Ring Gages . . . . . 7-16 Taper Ring Gages 7-17 Stepped Ring Gage .7.l7 Product and Ring Gage Tolerance Relationship . 7-21 Ring Gage Design Example .7.2l Plain Adjustable Snap Gages .7.23 Built-Up Snap Gages .7.24 Special Snap
27、Gages for Features Inaccessible by Standard Snap Gage 7-25 Product and Adjustable Snap Gage Tolerance Relationship 7-28 l Principles of Flush Pin Gage Operation 7.29 Standard Flush Pin Gages .7.3 Flush Pin Gage for Drilled Holes 7.32 Multiple-Pin Flush Pin Gage .7.32 Internal Flush Pin Gage 7.33 Flu
28、sh Pin Gage Design ExampleInspection Requirement 7-36 Flush Pin Gage Design Example .7.38 Template Gages for Depth and Length 74O Alternate Designs for a Template Gage for Depth and Length . 7-41 Product and Template Gage Configuration .742 Progressive Plug Gage Design ExampleInspection Requirement
29、. . 745 Progressive Plug Gage Design Example 747 Receiver Gage Design ExampleInspection Requirement 7-49 Receiver Gage Design Example . . . . 7-51 Spanner Gage for Feature Relation Gaging Design ExampleInspection Requirement .7-54 Spanner Gage for Feature Relation Gaging Design Example . . 7-56 Span
30、ner Gage for Feature Relation and Lncation Gaging Design ExampleInspection Requirement 7.56 Spanner Gage for Feature Relation and Location Gaging Design Example 7-58 MMC SPecial True Position Gage Design ExampleInspection Requirement . 7-59 MMC,Special True Position Gage Design Example 74l LMC Speci
31、al True Position Gage Design ExampleInspection Requirement 7-62 LMC Special True Position Gage Design Example .743 Strap Clamps 745 Lever Classes of Strap Clamps . 7-65 l xvi Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-204A(AR) LIST O
32、F ILLUSTRATIONS (centd) Figure No. Title Page 7-44 7-45 7-46 7-47 7-48 7-49 7-50 7-51 8-1 8-2 8-3 84 8-5 8-6 8-7 8-8 8-9 8-10 8-11 8-12 8-13 8-14 8-15 8-16 9-1 9-2 9-3 9-4 9-5 9-6 9-7 9-8 9-9 9-10 Swing Clamp .76 Hook Clamp .7&6 Quick-Acting Knob .746 Cam Clamps . . . . . . . . . 7-67 Wedge Clamps 7
33、.68 Toggle-Action Clamps 748 Fixture Gage Design ExampleInspection Requirement 7-71 Fixture Gage Design Example .7.72 Spline Terms, Symbols, and Drawing Data .8.3 Sector Spline Plug Gage Whh Two Teeth per Sector (Paddle Gage) . . . 8-4 Sector Spline Ring Gage With Two Teeth per Sector (Snap Ring Gag
34、e) 84 Involute Spline Space Wdth and Tooth Thickness Inspection 8-I Composite Spline Plug Gages and Equations “Go” and “Not Go”, Side Fit and “Not Go” Major Diameter Fh 8.8 Composite Major Diameter Fh Spline Plug Gage and Equations “Go” . 8-8 Sector Spline Plug Gage and Equations “Not Go” . 8-9 Majo
35、r Diameter Spline Plug Gage and Equations: “Go” and “Not Go” . . . 8-IO Tapered Tooth Composite Spline Plug Gage and Equations: Side Fit . 8-10 Tapered Tooth Sector Spline Plug Gage and Equations . 8-11 Composite Spfine Ring Gages and Equations “Go” and “Not Go” Side Fit and “Not Go” Major Diameter
36、Fit 8-15 Composite Major Diameter Fit SPi”e, Ri”g Gage and Eq”ationx “Go” 8-16 Sector Spline Ring Gage and Equations: “Not Go” . 8-17 Tapered Tooth Master for Composite Ring Gage and Equations 8-17 Tapered Tooth Master for “Not Go” Sector Ring Gage and Equations . . . 8-18 Woodruff Keyslot Gages and
37、 Dimensions 8-23 Typical Weapon Chamber Features 9.2 Gages for Small Cahber Chamber .9.3 Inspection of Barrel Wth MMC Gaging Element and Gaging Ring . . 9-3 ., Ammumtlon Nomenclature . 9-6 A C-Frame Comparator 9.l3 Work-Holding Centers for C-Frame Comparator .9.l3 Various Shapes of Contact Points for Bench Comparators .9.l4 Plate Comparator 9.l5 Portable Comparator for External Dimensions .9.l6 Portable Comparator for Internal Dimensions 9.l6 l xvii Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-
