BMD PLUG GAUGES Technical Guide Version 4 Content Page Page 3 DIATEST - Expertise for precision and safety 27 Indicator holders with adjustable spring pressure 4 Technical description 29 Electrical probe holders 9 Basic plug gauge types 30 Special gauge holders 10 Basic type - Standard 33 Holders for Analodig indicators 11 Basic type for through bores 34 Adapters 12 Basic type for blind bores 36 Right-angle attachments 13 Basic types with compressed air supply 37 Depth extensions 14 Plug gauges for automatic gauging 40 Depth stops 15 Special-purpose plug gauges 42 Small measurement fixtures 21 PA for measuring parallel wall gaps 46 Floating holders 22 Multiplane plug gauges 50 Spare parts 24 Indicator holders 51 General and technical abbreviations 2 Competence for precision and safety Safety through quality High-volume engineering does not work without precision. no matter whether it is a question of standard products To achieve highest possible safety in production, preci- or special solutions made to customer’s specifications. sion is necessary starting from design to final product. This is the company’s philosophy, carried out by an expe- Here the trademark DIATEST stands for quality. rienced staff: Highest quality at a fair cost effectiveness, Gauges with repeatabilities to 0.001 mm/0.00005“ combined with expert advice and absolute faithfulness and even better guarantee exact results. to deadlines in dealing with all DIATEST customers. For us this is a service taken for granted which our DIATEST bore gauges are manufactured according to DIATEST partners worldwide appreciate. DIN EN ISO 9001. Using state-of-the-art manufacturing engineering the highest quality standards are achieved. This is what partnership means to us. Our products withstand technological demands, 3 Technical description Plug gauges (BMD) are self-in- Design and material Technical data The most suitable setting rings dicating, self-centering, high characteristics: are those which comply with the precision measurement All dimensions are quoted in mm specifications of DIN 2250-C. instruments. These easy-to-use Probe: spring steel, approx. 61 unless otherwise specified. Setting rings with larger dimen- gauges are suitable for both static HRC We reserve the right to make sions or for minimum, medium and dynamic measurements. Needles: carbide, approx. technical modifications in order and maximum dimensions are They can be used for manual 1650 HV to improve performance. Minor generally not required. detection of dimensional Guide cylinder: gauge steel, deviations which do not impact deviations and shape defects approx. 60 HRC significantly on measurement Function in bores in serial measurement Hard chrome coating on guide equipment performance may at the machine but may also cylinders, approx. 1000 HV occur. The guide cylinder (4) centers the be installed in measuring equip- (standard design) Information regarding technologi- probe gauging contacts (6) fixed ment and automated systems. Special cylinder designs: cal advances and the most to the split ball probe (5) axially OCR = steel cylinders, hardened recent version of our documenta- and radially in the bore. A broad range of applications, and black finished tion is also available on the The lapped cone of the needle ease of handling, superior preci- Please note: OCR plug gauges Internet at www.diatest.com (3) translates the distance travelled sion and rugged construction are not suitable for rough by the gauge contacts 1:1 to are combined in a highly cost- measurement conditions. Zero setting the indicator (1) clamped in the effective system. ZHML = cylinder with carbide holder (2). A wide selection of basic types bars, page 14 Zero setting should be performed in the standard programme, ZKUL = cylinder with plastic bars, with the aid of a setting ring that supplemented by useful accesso- page 17 corresponds precisely to the ries, ensures that nearly all bores minimum bore size. This ensures encountered in actual practice that the risk of radial and axial can be measured precisely. errors is largely eliminated during the calibration process. The range of display instruments includes mechanical indicators, digital displays and sensors connected to analytical equip- ment. Peripheral equipment provides for static data analysis, dimension-based tool control and many other useful options. Special models The BMD Technical Guide is intended to assist you in selecting the most suitable measurement equipment. For special measure- ment problems we need a detailed description of the measurement task as well as a drawing or sample in order to prepare an offer. An optimum offer depends on precise, complete TA-KW information. Please note: Deviations regarding technical aspects of specially designed BMD gauges as opposed to standard gauges are possible! Special markings (SO-B) Special markings data matrix code (SO-B-DMC) (extra charge) We can provide special markings, such as customer-specific ID numbers, tolerances, etc. Please keep in mind that the possibilities for adding special markings to SO-ZL small plug gauges are limited. The surcharge for SO-B is calcu- lated for each commenced 10 characters (see price list). 4 Technical description Safety through quality Production times Please note: The needle taper Gauging accuracy ability due to tipping and lateral should be greased prior to shifting. Production times are quoted ex installation (e.g. Vaseline). Maximum allowed deviations factory, as shown in the table below. When installing needles for Series with new plug gauges: Nominal dimensions and 6 and 10, please ensure that standard measurement Service life springs are remounted (no springs Repeatability ranges in Series 4). 2-point design Service life depends upon such fw ≤ 0.001 mm Plug gauge order dimension conditions as work piece surface 3-point design (nominal dimension) = minimum quality (roughness, coating), fw ≤ 0.002 mm bore dimension material, length of measured Example: bore, dirt accumulation, gauging Measuring range transmission Ø 35 D7 = Ø 35 +0.08/+0.105 pressure etc. Up to a few million error (Linearity) BMD nom. dimension = 35.08 measurements are possible under 2-point models Ø 35 H7 = Ø 35 +0/+0.025 optimum conditions. fe = 1% of gauging distance BMD nom. dimension = 35.0 min. 0.001 Repair Service 3-point models Measuring range fe = 3% of gauging distance extension (MB-SO) DIATEST offers a fast and cost- min. 0.002 (extra charge) effective repair service for stand- ard BMD. FB design The standard measuring range Service 1: Exchange of gauging fe = 2% of gauging distance can be extended for applications unit and functional testing. min. 0.001 requiring measurement of larger Approx. 10 days, ex works. bore tolerances. Please note: Service 2: Exchange of gauging Measurement range extension Some plug gauges with MB-SO unit, fully re-chromed cylinder and (MB-SO) and special designs may have smaller contact point radii. functional testing. Approx. 15 lead to a reduced measuring This poses the danger of axial days, ex works. accuracy. and radial errors. Please enquire A cost estimate for special BMD before using diamond measure- plugs will be provided (on request). Axial and radial centering ment contacts. errors A measuring range extension Maintenance of e.g. MB-SO+0.4 indicates that The plug gauge guide cylinder the entire measurement range of No special maintenance is positions the gauging contacts in the plug gauge is 0.4 mm, based required. If cleaning is needed, the bore and ensures high on the nominal plug gauge remove the needle and clean the repetition accuracy. Short guide dimension. plug gauge and the needle care- paths and/or excessive clearance Measurements taken in horizon- fully with compressed air and a between the bore and the guide tal direction may lead to smaller cleaning solution. cylinder result in lower repeat- measuring ranges. Standard production times Measuring range, based on nominal BMD dimension Plug gauge type working days BMD series Application range Measuring range S, D, PK, OR, 2R, S-FB up to nom. dim. 100 mm 10 4 Ø 2.98 - 9.0 + 0.1 mm S, D, PK, OR, 2R, S-FB above nom. dim. 100 mm 15 6 Ø 7.0 - 20.0 + 0.15 mm FB, 3P, L, PK-2Z, MZ, AT0 15 10 Ø 15.0 - 270.0 + 0.2 mm SO-TA, UM, PA, SO-GL, SO-W10, T-BMD 25 FB6 Ø 7.0 - 16.0 + 0.15 mm SO-KO, SO-ZL, SO-2Z, ZHML, SO-PA etc. 30 FB10 Ø 15.0 - 150.0 + 0.15 mm Saturdays, Sundays, public holidays and company holidays are not 3P (Series 6) Ø 8.0 - 20.0 + 0.15 mm counted as production days and will extend delivery times accordingly. 3P (Series 10) Ø 15.0 – 100.0 + 0.2 mm T-BMD Ø 2.25 (PA 1.0) - 2.98 + 0.15 mm Express production times (extra charge) Measuring range extension (MB-SO) Plug gauge type working days BMD series max. meas. range (order suffix) S, D, PK, OR, 2R, S-FB up to nom. dim. 100 mm 5-8 Series 4 Ø 2.98 - 4.0 max. MB-SO + 0.15 S, D, PK, OR, 2R, S-FB above nom. dim. 100 mm 8-10 Series 4 Ø > 4.0 max. MB-SO + 0.2 FB, 3P, L, PK-2Z, MZ, AT0 8-10 Series 6 max. MB-SO + 0.4 SO-TA, UM, PA, SO-GL, SO-W10, T-BMD 15 Series 10 to Ø 120 mm max. MB-SO + 0.8 SO-KO, SO-ZL, SO-2Z, ZHML, SO-PA etc. 15 Series 10 Ø > 120 to 180 mm max. MB-SO + 0.6 Delivery times for all other plug gauges, including multiplane gauges, Series 10 Ø > 180 to 220 mm max. MB-SO + 0.4 etc, will be quoted on request. Series 10 Ø > 220 to 270 mm max. MB-SO + 0.3 Series FB10 + FB6 max.