web: www.qsyst.com email: [email protected] Threads, Tools, Gauges and Calibration Management Software for Calculation of Screw Threads, Cutting Tools, Thread Gauges, Tolerances and Fits for Linear Sizes, Plain Gauges and Calibration Management Table of contents 1. Introduction ............................................................................................................................... 2 1.1. Types of threads, cutting tools, thread and plain gauges ................................................................... 4 1.2. Software description ...................................................................................................................... 8 1.3. Software application for calculating threads and thread gauges ......................................................... 9 1.4. Software application for calculating plain gauges for linear sizes ....................................................... 10 1.5. Printout of the calculated thread workpiece, threading tools and gauges ........................................... 10 2. Full gauge specification for incoming and subsequent inspections purposes ......................... 11 3. Calibration management of thread and plain gauges .............................................................. 14 3.1. Calibration procedures, catalogues and additional settings................................................................ 14 3.2 Calibration of thread and plain gauges ............................................................................................. 20 3.3 Examples for Calibration Certificates ................................................................................................ 30 1 web: www.qsyst.com email: [email protected] Threads, Tools, Gauges and Calibration Management 1. Introduction The QMSys Threads software is a powerful thread engineering program, especially useful in the manufacture and quality control of threaded products, tools and gauges by saving time and costs for supplying standards and computations. The results are based on international and national standards, and comprise information about nominal and limit sizes of thread parameters of threaded products, cutting tools, working, setting as well as checking gauges. QMSys Threads software assists users in the following activities: • Thread measurement and control – determining the nominal and limit sizes of the parameters of external and internal threads • Design and inspection of thread cutting tools – determining the limit sizes of the threaded portion • Inspection of working and check gauges – determining the nominal and limit sizes of parameters of thread check gauges • Product design – selection of threaded joints. • Calibration management - calibration of all types of thread and plain gauges in accordance with national and international standards and guides. Editions of the QMSys Threads software Threads, Threads Threads, Edition Gauges and Threads and Tools and Functionality Calibration Gauges Gauges Management External and internal threads Yes Yes Yes Yes Gauges for internal and external threads No Yes Yes Yes Cutting and forming taps No No Yes Yes Tolerances and fits for linear sizes Yes Yes Yes Yes Plain gauges for linear sizes No Yes Yes Yes Calibration management No No No Yes Software versions The software is offered in following versions which include the same functions: • Single-User version - this version is computer based and can be installed on one single computer. • Portable version – the single-user version can be installed on any current USB memory sticks. In this case, the software is licensed for a specific USB flash drive. The client can install the software on his/her own USB memory stick or order a USB memory stick from us with installed software. The user can then work with the QMSys software on any computer the flash drive is plugged into. • Server version - this version allows the simultaneous use of the software in the amount of the acquired number of licenses (concurrent users). The software is installed only on the server and every user who wishes to use the software creates only a shortcut on their working computer to the server software. • Library versions - for integration in client software products. These versions are also available as single-user, portable or server version. Software trial versions The QMSys Threads software can be downloaded at http://www.qsyst.com/html/software_en.htm. Request an evaluation unlock key by sending an email to [email protected] and you will have the full version of all software editions for a 30-day evaluation period. You may also share the trial unlock key we will send to you and the downloaded software with anyone in your organization. 2 web: www.qsyst.com email: [email protected] Threads, Tools, Gauges and Calibration Management Calculating thread, tolerances, fits, thread and plain and gauges The most important features offer: • Compliance with the latest revisions of ISO, EN, DIN, ANSI, ASME, BS, JIS, IS, SAE, API and other corresponding national standards. • Calculation of threads with nominal sizes from 0.25 mm up to 1250 mm (0.1 - 50 in.) • Calculation of tolerances and fits for linear sizes up to 10000 mm (ISO) or up to 200 in. (ANSI) • Plain gauges according to ISO standards up to 500 mm, according to ASME standards up to 19.69 in. and according to BS standards for workpiece tolerances 0.005 - 3.2 mm (0.0002 - 0.125 in.) • The thread parameters can be chosen from the respective list or can be inserted directly; this facilitates and smoothens the work process, since it is not necessary to remember the designation of each thread type • Recommended in the respective standards nominal sizes, pitches and tolerance classes • After entering the thread parameters, all types of working, setting and checking gauges are being calculated; the user does not have to bother with repeated entry of the same data for different gauges. • Nominal and limit sizes on all thread and gauge characteristics - diameters, pitch, lead, flank angles, length of gauge and tolerance steps, crest and root flats, etc. • Figures from the corresponding standard for thread profile, tolerance zone, gauge profile. • Calculation of diameter corrections for all types of finishing: removing (reshaping) or adding (altering). • Computation of limits for measuring of the pitch diameter with wires or balls, with consideration of the influence of a measuring force, material of the threaded workpiece and the resulting deformations. • Printing out in standard or custom adjustable templates in RTF, XLS or TXT format • Coping of the results in the clipboard • User-friendly interface, evidently easier design for usage and result interpretation. • Possibility for development of customer thread types (after providing the respective standards). Calibration management for thread and plain gauges Calibration process of the thread and plain gauges is developed in accordance with international and national standards and guidelines: • ISO, ANSI/ASME, DIN and BS standards for the respective thread types • DAkkS-DKD-R 4-3 Testing instructions, Parts 4.1, 4.2, 4.3, 4.6, 4.7, 4.8, 4.9 • VDI/VDE/DGQ 2618 Testing instructions, Parts 4.1, 4.2, 4.3, 4.6, 4.7, 4.8, 4.9 • MIL-STD-I20 Gauge Inspection • IFI 301 Gage Calibration Requirements and Procedures for Thread Gages • EURAMET cg-6 - Extent of calibration for cylindrical diameter standards • EURAMET cg-10 - Determination of pitch diameter of parallel thread gauges by mechanical probing • ILAC-G8:03 - Guidelines on the reporting of compliance with specification • ISO 14253-1 - Decision rules for proving conformance or non-conformance with specifications • ASME B89.7.3.1 - Guidelines for decision rules: Considering measurement uncertainty determining conformance to specifications. Before calibrating the gauges, the user should create calibration procedures for the respective types of gauges and fill in the catalogues for measuring instruments, wire and ball probe sets. The calibration procedures include all relevant metrological characteristics - gauge length, lengths of tolerance steps, thread and flank angles, pitch and lead, major diameter, pitch diameter, minor diameter, taper, form deviations. The software also offers several methods for measurement of the pitch diameter over wires and balls - three or two wires, ball probes, perpendicular or inclined. During the measurement, the software calculates the limits of indicated values for the selected method, diameter of the wires or balls and measuring force. Measurements can be entered manually by the keyboard or transferred automatically from any measuring instrument or machine, equipped with serial RS 232 or USB interface. Inspection and adjustment of working gauges with the respective checking, setting or master gauges is also implemented in the design of calibration procedures and the calibration process. 3 web: www.qsyst.com email: [email protected] Threads, Tools, Gauges and Calibration Management 1.1. Types of threads, cutting tools, thread and plain gauges The following table represents an overview of the available types of threads and the standards for the calculation of the thread cutting tools and thread gauges: Thread type Thread Nominal size (d), Gauges acc. to Threading tools (Designation Symbols) standards pitch (P), TPI standards acc. to standards General purpose screw threads Metric screw thread (M, MF) ISO 965-1 d: 0.25 - 1000 mm ISO 1502 ISO 2857, EN 22857 DIN 13-1 to 52 P: 0.075 - 100 mm JIS B 0251 DIN 802-1,