table of contents - electronics inc · mil-s-13165 shot peening of metals (canceled) a-2™, n-2™...
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TableofContents
Description...................................................................................................................................................................3GeneralInformation.....................................................................................................................................................3Environment.................................................................................................................................................................3ControlFeatures...........................................................................................................................................................4QuickSwitchFromMMtoInch....................................................................................................................................4FactoryDefaultSettings...............................................................................................................................................4MeasuringthePre-BowofaNew(Unpeened)AlmenStrip.........................................................................................5MeasuringtheArcHeightofaPeenedAlmenStrip.....................................................................................................6ChangingtheBatteries.................................................................................................................................................7Calibration....................................................................................................................................................................8InspectionoftheGageHead........................................................................................................................................8DigitalIndicatorInstructionManualInformation........................................................................................................9ComputerInterfaceDeviceAccessory..........................................................................................................................9TroubleShootingtheModelTSP-M...........................................................................................................................10CheckingorSettingtheSpindleStartingPosition......................................................................................................11ContactingElectronicsInc..........................................................................................................................................11LimitedWarranty........................................................................................................................................................12Appendix.....................................................................................................................................................................13
IntroductiontoCorrelation..................................................................................................................................13TheAlmenStripsandCorrelationHolder.............................................................................................................13ExamplesofCorrelation.......................................................................................................................................14
Graph1-3.26Ato1.15MiniA....................................................................................................................15Graph2-3.25Ato1.25MiniA....................................................................................................................16Graph3–3.5Ato1.25MiniA,3.26Ato1.15MiniA..................................................................................17Graph4-5.79Ato2.40MiniA,5.95Ato2.46MiniA................................................................................18Graph5-5.95Ato2.46MiniA....................................................................................................................19Graph6-6.09Ato2.40MiniA....................................................................................................................20Graph7-12.08Ato5.68MiniA,18.40MiniN...........................................................................................21Graph8-12.32Ato4.93MiniA..................................................................................................................22Graph9-12.08Ato5.68MiniA..................................................................................................................23
CompilationofCorrelationData..........................................................................................................................24
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DescriptionThemodelTSP-MAlmenGage ismanufacturedtothespecificationsofSAEJ442TestStrip,HolderandGageforShotPeening. It is aprecisiondeviceused formeasuring the curvatureof ametal test coupon called anAlmenmini-strip.Ithasacalibratedelectronicdigitalindicatorwithalow-forcespindlespringtoprovidehighlyaccurateandrepeatablemeasurements.Thisgagewillprovidemanyyearsof trouble-freeservice ifproperlymaintained.Thegageshouldbecalibrated,theindicatorperformanceshouldbetested,andthesupportplatformcheckedforwearannuallyormorefrequentlyifconditionswarrant.Thegagecomeswithtwo(2)batterieswithalifeexpectancyofat leastone(1)year.Thebatteriescanbeeasilyreplacedwithoutlossofcalibration.
GeneralInformationAspecialZeroBlock(included)willsetthedigitalzeroreference.
EnvironmentThe indicator is built towithstand severe use. It has a gasket-sealed case, a hard crystal displaywindow and adurable stemassembly to resistmost dust and fluids. The gage should never be immersed in liquid as thiswillcausedamagetotheunit.Thesealsandbootsshouldberegularlyinspectedtopreventcontamination.Thedustcapfortheelectronic4-pinconnectorshouldalwaysbe inplacewheneveranoutputcable isnotattached.Thiswillpreventdamagetotheconnector.Pleaserespecttherecommendedtemperaturerangesshownbelow.
TemperatureRangeStorage: 4°F-140°F -15.5°C–60°C
Operation: 60°F-90°F 15.5°C-32°C
ThemagneticbasesecurestheZeroBlockforeasyaccess
TheZeroBlockonthemagneticbase
TheZeroBlock
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ControlFeaturesThreeredcontrolbuttonsonthedisplayperformtheseuserfunctions:
• ZERO/ON: Turns the unit “ON”. It can also be used to set the SpindleStartingPosition.Seethe“TroubleShootingtheModelTSP-M”sectionformoreinformationonthisfeature.
• M/OFF:Thisbutton,whenpushedandheldforthree(3)seconds,turnstheunit“OFF”.
• inch/mm:Allowstheselectionofthedisplayininchesormillimeters.
QuickSwitchFromMMtoInchSAEJ442requiresAlmengage indicatorstohavearesolutionof0.001mm;therefore, theTSP-MAlmenGage isfactorysettodisplay0.000mm,witha0.001mmresolution.Pressing the inch/mmbutton, changingmeasurementunits frommillimeters to inches, results ina five (5)digitdisplay(0.00000inch)witharesolutionof0.00005inch.Ifadisplayofonlyfour(4)digits(0.0000)ininchesispreferred,usethefollowingstepstoreprogramtheindicator.
1. TurnontheTSP-MbypressingZERO/ON.2. Pressinch/mmtochangethescaletoinches3. PresstheM/OFFandinch/mmbuttonsatthesametime(M1willappearonthebottomleftofthedisplay)4. PressM/OFFfour(4)times5. Pressinch/mmsix(6)timesuntilthedisplayshows0.00016. PressM/OFFtoexittheprogrammingmode
FactoryDefaultSettingsIndicatorPolarityThe indicator should be in theReverseMeasurementDirectionmode as indicated by “R” at the bottomof thedisplay.ThisallowsforpositivenumberstobeshownonthedisplayastheindicatorextendsintotheconcavearcoftheAlmenstrip.Ifthe“R”isnotshown,seethe“TroubleShootingtheModelTSP-M”sectiontoreturntotheReverseMeasurementDirectionMode.ResolutionMetricmoderesolutionisfactorysettothree(3)decimalplaces(e.g.,0.600mm).Iftheinchmodeisrequired,theresolutionwillbe setat five (5)places (e.g.,0.00240 inch)bydefault. See the“QuickSwitch fromMMto Inch”sectionabovetochangetheresolutiontoonlyfour(4)places.
Redcontrolbuttons
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ThesmallsideoftheZeroBlockisplacedonthegage.Thereadingis0.000mm.
MeasuringthePre-BowofaNew(Unpeened)AlmenStripThefollowingstepsshouldbeperformedonthestandardAlmenstripsandthemini-strips.
1. PushtheZERO/ONbuttontoturnthegage“ON”.2. Place the Zero Block on the gage with the indicator tip touching the small side of the block. Push the
ZERO/ONbuttontoachieve0.000mminthedisplay.3. Placeanew (unpeened)Almen striponto themeasurementposition.Be sure the strip touches theback
postsandiscenteredbetweentheendposts.4. Readandrecordthepre-bow(alsocalledflatness).5. Turnthestripoverandmeasuretheoppositeside.Ifthereadingfromeithersideexceedsthespecification
value,discardthestrip.(SeeTable1forcommonexamplesofacceptablepre-bow).
Table1.ExamplesofcommonindustryAlmenstriprequirementsformaximumpre-bowofunpeenedstrip
Specification Grade mm InchAMS2432,ShotPeening,ComputerMonitored A1-S™,N1-S™ ±0.013 ±0.0005AMS2430,ShotPeening A-1™,N-1™ ±0.025 ±0.0010J442,TestStrip,HolderandGageforShotPeening A-1™,N-1™ ±0.025 ±0.0010MIL-S-13165ShotPeeningofMetals(Canceled) A-2™,N-2™ ±0.038 ±0.0015
Anunpeenedmini-stripplacedonthemini-stripgage.
AnunpeenedStandardAlmen
stripplacedonthe#2Almengage.
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MeasuringtheArcHeightofaPeenedAlmenStripThefollowingstepsshouldbeperformedonthestandardAlmenstripsandthemini-strips.StepOne–ZerotheAlmenGage
1. PushtheZERO/ONbuttontoturnthegage“ON”.2. Place the Zero Block on the gagewith the indicator tip touching
thesmallside.PushtheZERO/ONbuttontoachieve0.000mminthedisplay.
StepTwo–PerformPre-BowCompensationIfyourshotpeeningprocedure,suchasprocessdevelopmentorsystemcapability studies, requires higher intensity accuracy, pre-bowcompensation may be used. This technique can provide an additionalreduction inprocessuncertainty.Apre-bowcompensationensures thatonlythenetdifferenceinarcheightofapeenedAlmenstripisplottedonasaturationcurve.Toperformpre-bowcompensation:
1. ZerotheAlmengageandthenplacetheunpeenedAlmenstriponthegageandrecorditsvalue.
2. Besuretonoteifvalueispositiveornegativeandwritethevalueontheoppositesideofthestrip.
3. Do not peen the side of the Almen stripwith your handwrittennote.
4. Apositivenumberissubtractedfromthearcheightreadingafterthestriphasbeenpeened.Anegativenumberisaddedto the arc height reading after the strip has been peened.Forexample:a) If thepre-bow is+2and thearcheight reading is10,
theadjustedarcheightreadingis8b) If the pre-bow is -2 and the arc height reading is 10,
theadjustedarcheightreadingis12In summary,most peening applications can tolerate the SAE J442pre-bowbiasof±0.001”forNandAstrips.Ifthistolerancelevelistoo high, you can apply the pre-bow compensation discussedabove.StepThree–MeasuretheArcHeight
1. Place thepeenedAlmenstriponto themeasurementpositionwiththeindicatortiptouchingthenon-peenedside(concaveside)ofthestrip.Record thevalueof thearcheight shown in thedisplayor, ifusingpre-bowcompensation, thearcheightshowninthedisplaywiththepre-bowcompensationapplied.
2. Removethestripandplaceitonceagainonthegage.Dothisthree(3)timestoassureanaccuratereading.3. Whenfinished,pushandholdtheM/OFFbuttonforthree(3)secondstoturnthegage“OFF”. (Thegage
automaticallyturns“OFF”ifitisnotactivefor15minutes.)
Peenedmini-stripplacedonthemini-stripgage.Thereadingis0.199mm.
PeenedstandardAlmenstripplacedonthe#2Almengage.
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BatteryLowmessage
ChangingtheBatteriesThe Almen gage has a battery tray that holds two (2) CR2450 lithium batteries. Awarningmessageappearsinthegage’sdisplaywhenthebatteriesneedtobereplaced.
Tochangethebatteries:
Thebatteriesareontheundersideofthetray.Step3.Removetheexpiredbatteriesandplacethenewbatteriespositivesideupinthetray.(ThecurrentAlmengageset-upandcalibrationinformationareretainedwhenthebatteriesarereplaced.)Placethebatteryholderinthebatterycompartmentandpushitinuntilitlocksintoposition.
Step1.Usingasmallflat-bladescrewdriver,carefullyslidethebladeintotheopeningandreleasethebatteryholder.DoNOTremovedigitalindicatorfromthegage.
Step2.Oncethebatteryholderisunlocked,graspitwithyourfingersandpullthebatteryholderout.
DoNOTremovethedigitalindicatorfromthegage
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CalibrationPeriodic calibration of the Almen gage is important to assureprocessrepeatabilityandaccuracy.Thegage’sdigitalindicatorshould be removed and calibrated annually or sooner if itappears to be damaged or inaccurate. Use of a standardcalibrationstandasshownisrecommendedoryoumayreturnthegagetoElectronicsIncorporatedforservice.Thedigital indicatorshouldbere-installedwiththeZeroBlockinplaceandthephysicalpositionofthe indicatoradjustedontheframesothatitisnearTrueSpindleZero±0.025mm.Thisassures that the indicator is in the preferred accuracy range.Seethesectiontitled“CheckingorSettingtheSpindleStartingPosition”formoreinformation.
InspectionoftheGageHeadExaminetheconditionofthebackpostforwear,whichmayinterferewithproperseatingofthestripontotheplatform.
FederalCalibrationStand
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DigitalIndicatorInstructionManualInformationForadditionalinformationonthedigitalindicator,pleaserefertotheMahrFederalIncorporatedDigitalIndicatorManualincludedwiththegage.Ifmissing,themanualisavailablefromElectronicsInc.
ComputerInterfaceDeviceAccessoryEntering multiple measurements is quick and easy with theComputer InterfaceDevice.Thedeviceplugs intoa computer’sUSB port and pulls the value displayed on the ElectronicsIncorporated Almen Gagedirectly into a computer program(Excel, Word, or similar software). The Computer InterfaceDevice eliminates data entry errors and accelerates themeasurementprocess.Apush-buttonorfootswitchcontrolsthedevice. There are no power requirements as the device ispoweredfromtheUSBportandtherearenodriverstoload.
CoverpageoftheinstructionmanualfortheDigitalIndicator
TheComputerInterfaceDevice(partnumber999144)
(DoesnotincludeanAlmengage)
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TroubleShootingtheModelTSP-MIf theTSP-MAlmenGage indicatordisplay is flashing,or if thegagewillnot zero,or the resolutionneeds tobechanged, the following instructions will return the gage back to its factory default settings and remedy theseconditions.Performeverystep—onethroughsix—insequenceuntiltheproblemisresolved.Ifmoreassistanceisneeded,pleasecallElectronics IncorporatedCustomerServiceDepartmentat1-800-832-5653(USAandCanada)or(574)256-5001.StepOne
• PressM/OFFandtheinch/mmbuttonatthesametime."M1"willappearonthescreen.• Ifthe"R"isnotonthebottomleftsideofthescreen,pressZERO/ONbuttonuntilthe“R”isonthescreen.• Ifthe"X1"isnotonthebottomcenterofthescreen,presstheinch/mmbuttonuntil“X1”isselected.
StepTwoPressM/OFFbutton."M2"willappearonthescreenanditshouldread000.0000.
• If“-“precedesthedigits,presstheZERO/ONbuttontoremoveit.• Presstheinch/mmbuttontomovethecursorovertothefirstnon-zerodigittobechanged.• PresstheZERO/ONbuttonrepeatedlytotogglethroughnumbersuntil“0”isdisplayed.Repeatforother
digitsnotat“0.”StepThreePressM/OFFbutton."M12"willappearonthescreenanditshouldread000.0000.
• If“-“precedesthedigits,presstheZERO/ONbuttontoremoveit.• Presstheinch/mmbuttontomoveacursorovertothefirstnon-zerodigittobechanged.• PresstheZERO/ONbuttonrepeatedlytotogglethroughnumbersuntil“0”isdisplayed.Repeatforother
digitsnotat“0.”StepFourPressM/OFFbutton."M23"willappearonthescreenanditshouldread000.0000.
• If“-“precedesthedigits,presstheZERO/ONtoremoveit.• Presstheinch/mmbuttontomoveacursorovertothefirstnon-zerodigittobechanged.• PresstheZERO/ONbuttonrepeatedlytotogglethroughnumbersuntil“0”isdisplayed.Repeatforother
digitsnotat“0.”StepFive
• PressM/OFFbutton."M13"willappearonthescreen.ThisistheDigitalResolutionModescreen.• Whenusingthemmmode–presstheinch/mmbuttonrepeatedlytoselect0.001.• Whenusingtheinchmode–presstheinch/mmbuttonrepeatedlytoselect0.0001.
StepSix
• PressM/OFFbutton-thegagewillbeinrunmode.• PlacetheflatsideofthecurvedZeroblockontopofgageandpresstheZERO/ONbutton.• Theindicatorwillread0.000mmifinmetricmodeor0.0000ifinEnglishmode.• Thebottomofthescreenwillread"RX1mm"or"RX1in".
StepSevenCheck theSpindleStartingPosition toensure it is in thepreferred range.See thenext section fordirectionsoncheckingorsettingtheSpindleStartingPosition.
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CheckingorSettingtheSpindleStartingPositionToevaluatetheSpindleStartingPosition,placetheZeroBlockonthegageandenterthegage intoTrueSpindleModebypressingandholding theZERO/ONbutton for three (3) seconds (the“X1”willdisappearwhen inTrueSpindleMode).ThevalueoftheSpindleStartingPositionshouldbesetto0.000mm+0.025mm(0.0000inch+0.0010 inch). If theSpindleStartingPosition isoutof tolerance, reposition the indicatoron the frameusing theinstructionsbeloworcallElectronicsIncorporatedoranAuthorizedDistributorforassistance.Instructions:Besurethezeroindicatorblockisinplaceandthenloosenthe8mmglandnutholdingtheindicator.AdjusttheindicatorplacementontheframeuntiltheSpindleStartingPositioniswithintolerance.Carefullytightentheglandnutandbesuretheindicatorissecure.Itshouldnotmoveorrotate,andtheSpindleStartingPositionshouldnotchangeas theglandnut is tightened.Placeadabofproof lacquerat theglandnutandstemasa tamper-proofseal.
ContactingElectronicsInc.MailingandShippingAddress:
ElectronicsInc.56790MagneticDrive
Mishawaka,IN46545USA
Telephone:1-800-832-5653(Toll-freeinUSAandCanada)or(574)256-5001Fax:(574)256-5222
Email:[email protected]:www.electronics-inc.com
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LimitedWarrantyThewarrantyobligationsofElectronicsInc.fortheTSP-Marelimitedtothetermssetforthbelow.LengthofWarrantyPeriodThis limited warranty lasts one (1) year from the shipping date of this product from Electronics Inc. or itsauthorizeddistributor.WhatisCoveredThislimitedwarrantycoversdefectsinmaterialsandworkmanshipinthisproduct.WhatisNotCoveredThislimitedwarrantydoesnotcoveranydamageordeteriorationofthisproductresultingfromanyalterationormodification,improperorunreasonableuseormaintenance,orimproperhandlingorstorage.HowtoObtainaRemedyUnderThisLimitedWarrantyToobtainaremedyunderthislimitedwarranty,contactElectronicsInc.ordistributorfromwhomthisproductwaspurchased. If it isdeterminedthatthisproductmustbereturnedunderthis limitedwarranty,aReturnedGoodsnumber(RG),obtainedfromElectronicsInc.,willberequired.Thisproductshouldbeproperlypacked,preferablyin the original carton, for shipping. Cartons not bearing a RG number will require additional processing time.Shippingandinsurancechargesmustbeprepaid;ElectronicsInc.isnotresponsiblefortheseexpenses.WhatElectronicsInc.WillDoUnderThisLimitedWarrantyElectronics Inc.will,at its solediscretion,provideoneof the following tworemedies towhateverextent it shalldeemnecessarytosatisfyaproperclaimunderthislimitedwarranty:1)Repairtheproduct.ElectronicsInc.willpaytheshippingcostsnecessarytoreturnthisproducttothecustomeroncetherepairiscomplete.2)Replacethisproductwithacomparablecurrentmodel.ElectronicsInc.willpaytheshippingcostsnecessarytoreplacethisproduct.LimitationonLiabilityThemaximum liabilityof Electronics Inc. under this limitedwarranty shall notexceed theactualpurchasepricepaid for the product. Electronics Inc. is not responsible for direct, special, incidental or consequential damagesresulting from any breach of warranty or condition, or under any other legal theory to the maximum extentpermittedbylaw.ExclusiveRemedyTo themaximumextentpermittedby law, this limitedwarrantyand the remediesset forthaboveareexclusiveand in lieuofallotherwarranties, remediesandconditions,whetheroralorwritten,expressor implied.To themaximumextentpermittedbylaw,ElectronicsInc.specificallydisclaimsanyandallimpliedwarranties,including,without limitation, warranties ofmerchantability and fitness for a particular purpose. If Electronics Inc. cannotlawfully disclaim or exclude implied warranties under applicable law, then all implied warranties covering thisproduct,includingwarrantiesofmerchantabilityandfitnessforaparticularpurpose,shallapplytothisproductasprovidedunderapplicablelaw.RightsunderStateLawThiswarrantydefinesspecific legalrightsrelativetotheseproductsprovidedbyElectronics Inc.Legalrightsmayalsovaryfromstatetostate.
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Appendix
IntroductiontoCorrelation
Almen mini-strips must be compared to standard-size Almen strips to assure compliance with intensitymeasurementpractices.ThecomparisonsaredescribedincorrelationtrialswherethestandardAlmenstripisusedtosettherequestedintensityandthemini-stripispresentedtothesameblaststream.Itisimportanttodocumentthe test results, especially the parameters and all test conditions. Testingmultiple strips and the creation of ahistogramcanhelpvalidatetheprocess.
TheAlmenStripsandCorrelationHolder
It is convenient to peen the standard-size Almen strip and themini-strip at the same time using a correlationholder.Therearetwomethodsofaffixingthemini-striptothecorrelationholder.Inthefirstmethod,twoscrewssecure the ends of the mini-strip. For the second method, double-sided adhesive tape or a temporary glueadhesive,suchasrubbercement,securesthemini-striptotheholder.Thesecondmethodisusedonlywhenitisnotpossibletoattachthemini-striptotheholderwithtwoscrews.Forbothmethods,thestandardAlmenstripmustbeaffixedtotheholderwithfourscrews.Thefirstimagebelowshowsthemethodusingtwohold-downscrewstosecurethemini-striptotheEICorrelationHolderformini-strips(ElectronicsInc.partnumber970070).Thestripispositionednexttotwoprotrudingback-stopstohelpkeepitaligned.Inthesecondimage,themini-stripisattachedtotheholderwithdouble-sidedtape.
It isveryimportanttouseonlyonemethod.Thetwohold-downscrewswillkeepthestripfirmlysecuredtotheholder during the blast cycle while the tape or glue may allow some lift-off or curvature. This curvature mayinfluence the mini strip response. As long as the technique is consistent, the results should be consistent. Asufficientnumberoftrialsshouldberuntovalidatetheprocedure.Theexamplesshowninthenextsectiontitled“ExamplesofCorrelation”usemultipletrialsandthedataisshowninastatisticalcapabilitychart(histogram).Whenindoubt,runmoretestsandanalyzethedatacarefully.Note:Whenusingtapeorgluetoaffixthemini-striptotheholder,makesurethetapeandgluearecompletelyremovedfromtheholderandstripbeforemeasuringthestriporreusingtheholder.
Twoscrewsholdingamini-stripinplace Amini-stripheldinplacewithdouble-sidedtape.Thismethod should be used only when the mini-stripcannotbeattachedtotheholderwithscrews.
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ExamplesofCorrelation
Thefollowingexamplesofcorrelationbetweenstandard-sizeAlmenstripsandmini-stripsareforillustrationonly.Actualcorrelationmustalwaysbedoneonajob-specificbasis.ThespecialAlmenholderforcorrelationusestwoscrews tocapture themini-strip.Othermethodsmaybeusedsuchasdouble-sidedtapeor temporaryadhesive(e.g.,rubbercement).Forbestresults,allproceduresmustbeconsistent.Whenindoubt,repeatatest.
Test StandardStripx.001inch
MiniStripx.001inch
Graph1 3AtoAmini(36)samplestest2 3.26A 1.15MiniAGraph2 3AtoAmini(36)samples 3.25A 1.25MiniAGraph3 3AtoAMini2tests 3.5A
3.26A1.25MiniA1.15MiniA
Graph4 6AtoAMini2tests 5.79A5.95A
2.40MiniA2.46MiniA
Graph5 6AtoAMiniTest2 5.95A 2.46MiniAGraph6 6AtoAMini 6.09 2.40MiniAGraph7 12AtoAMiniandNMini 12.08A 5.68MiniA
18.40MiniNGraph8 12AtoAMini 12.32A 4.93MiniAGraph9 12AtoAMini 12.08A 5.68MiniA
Note:Theseexamplesareforillustrationonly.Differencesinmachinedesign,nozzletypeandplacement,typeandsizeofmedia,andmediaconditioncanaffectresults.Documentwhatyoudoanddowhatyoudocument.Whenindoubt,repeatatest.Keepaccuraterecordsofeverytest.UseacurvesolvercertifiedtoSAEJ2597.Placethemini-striponthegagemultipletimestoassurethereadingisconsistent.Do not rely upon these examples. We do not warrant that these examples will be appropriate for yourapplications.Createyourowncorrelationstudies.
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Graph1-3.26Ato1.15MiniA
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Graph2-3.25Ato1.25MiniA
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Graph3–3.5Ato1.25MiniA,3.26Ato1.15MiniA
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Graph4-5.79Ato2.40MiniA,5.95Ato2.46MiniA
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Graph5-5.95Ato2.46MiniA
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Graph6-6.09Ato2.40MiniA
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Graph7-12.08Ato5.68MiniA,18.40MiniN
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Graph8-12.32Ato4.93MiniA
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Graph9-12.08Ato5.68MiniA
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CompilationofCorrelationData
The following graph compares the performance of the standard “A” strip to the “A” mini-strip based on thepreviousgraphs.Theexamples shown in thisdocumentare included foreducationalpurposesonly.Donot relyuponthisdata.Wedonotwarrantthattheseexampleswillbeappropriateforyourapplications.Createyourowncorrelationstudies.
0.00
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0.00 5.00 10.00 15.00 20.00 25.00
Mini-AStrip
StandardAStrip
CorrelationAtoMini-AArcHeightx.001inch