Calibrating a Template Gage

L

Lab Geezer

#1
This is just my second post after lurking for quite some time but my question is this. We are a precision forging and machining operation of drivetrain components for the heavy truck industries and in our forging operation we use a considerable number of templete gages to "hot" check the form on drivr pinion and spindle forgings and I am concerned about our method of calibrating these template gages. We make them from the print on a wire EDM and at this time we verify them to the print on a optical comparator. This has past muster in the past but we are working on TS 16949 certification and I am not sure if this will satisfy the auditor.
Any comments and suggestions would be greatly appericated. The basic use of the gage is to insure enough stock for machining and the forged blank has a tolerance of +.060 / -.030 in most cases. I have about 200 of these in my gage system so it can be time consuming to calibrate them. I also have them on a 2 year cycle as wear has never been a problem.

Thanks in advance for your help:confused:
 
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Stijloor

Staff member
Super Moderator
#2
This is just my second post after lurking for quite some time but my question is this. We are a precision forging and machining operation of drive train components for the heavy truck industries and in our forging operation we use a considerable number of template gages to "hot" check the form on driver pinion and spindle forgings and I am concerned about our method of calibrating these template gages. We make them from the print on a wire EDM and at this time we verify them to the print on a optical comparator. This has past muster in the past but we are working on TS 16949 certification and I am not sure if this will satisfy the auditor.
Any comments and suggestions would be greatly appreciated. The basic use of the gage is to insure enough stock for machining and the forged blank has a tolerance of +.060 / -.030 in most cases. I have about 200 of these in my gage system so it can be time consuming to calibrate them. I also have them on a 2 year cycle as wear has never been a problem.

Thanks in advance for your help:confused:
Here is a post from our Friend Jim Wynne that may help you.

Stijloor.
 
E

erbearica

#3
This is just my second post after lurking for quite some time but my question is this. We are a precision forging and machining operation of drivetrain components for the heavy truck industries and in our forging operation we use a considerable number of templete gages to "hot" check the form on drivr pinion and spindle forgings and I am concerned about our method of calibrating these template gages. We make them from the print on a wire EDM and at this time we verify them to the print on a optical comparator. This has past muster in the past but we are working on TS 16949 certification and I am not sure if this will satisfy the auditor.
Any comments and suggestions would be greatly appericated. The basic use of the gage is to insure enough stock for machining and the forged blank has a tolerance of +.060 / -.030 in most cases. I have about 200 of these in my gage system so it can be time consuming to calibrate them. I also have them on a 2 year cycle as wear has never been a problem.

Thanks in advance for your help:confused:
I verify all templates/mylars but do not enter them in our calibration system. We replace as needed.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#4
I verify all templates/mylars but do not enter them in our calibration system. We replace as needed.
Verification is good, but they should be in the gage system to track when they were verified, how, when is next due date, and link to a print if they need to be remade.

I place a 1" X 1" box on the template to very the polyester is still stable using a gage block, check a couple lines on the comparator, check readability and cleanliness and let them go.
 

Jim Wynne

Staff member
Admin
#5
Here is a post from our Friend Jim Wynne that may help you.

Stijloor.
As bobdoering has pointed out, while actual calibration might not be required, the things still need to be included in the gage control system, and requirements for use/replacement/refurbishment should be documented.

Before anyone decides that calibration for a given item isn't necessary, you must be prepared to justify the decision on the basis that calibration isn't required to ensure valid results, which is the criterion given in the standard(s).
 
J

JaxQC

#6
Just for an example, overlays used to pass / reject product, are calibrated. This is done by having (3) targets (crosshatch) on the master Cam template. Picture “L” shaped made up of the three targets. To calibrate we measure both the “X” & “Y” directions or distance between the hatches. Quick and easy for what we do and hold max +/- .020”.
 
P

Patzer

#7
Hi Guys,

I'm just looking at this issue from the outside and as far as I can see the following line in the original post is very important:

The basic use of the gage is to insure enough stock for machining

Basically the gauges you use are for an in process check and do not have an impact on the final quality of the parts. While there is a business risk i.e. parts are too big, therefore longer machining times etc., too, small, not possible to machine them, I presume that the finished parts will undergo further inspection, therefore reducing/removing the potential impact of errors in the gauges (and therefore the need to calibrate). The suggestion to verify is a very good one though..

My expertise is in pharma/med devices but I hope that this adds something to the topic.

Thanks,

Pat.
 
E

erbearica

#8
As a company with 3700 active gages in our calibration system we consider templates/mylars visual aids. We have a procedure in place we follow for this. We have never had a problem during an audit.
 
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