Tool And Gage House

Reference Guide

In the medical device manufacturing industry, accurate measuring of products is critical. That is especially true in the development of orthopedic implant devices, which not only have to meet exacting specifications for a successful surgery, but also must satisfy internal design standards before they ever reach the end customer. A coordinate measuring machine (CMM) is an essential tool that quality inspection at Ortho Development Corporation relies on every day to satisfy their key internal customer first – the product development department. Ortho Development Corporation, located in Draper, UT, has been focusing on the design, manufacture, and sales of orthopedic implant devices and related surgical instrumentation since 1994. They specialize in products for total hip and total knee joint replacement, and spinal fusion. Their 40,000ft2 facility includes its corporate offices, research and development, manufacturing, inspection, and warehouse space. In 2004, Ortho launched the first of several new products, all with critical dimensions and performance features. Looking to the future, company management knew they needed more dynamic and efficient inspection measurement equipment to ensure the highest precision while reducing inspection lead times. The quality inspection group needed to start their CMM research quickly. Tasked with the job of collecting information on different CMM systems, including a Carl Zeiss CMM, was Joe Lucero, QA manager at Ortho. After preparing all of the data reports for management’s review on three comparable machines, from three different manufacturers, it was concluded that a Zeiss Contura CMM was the best system for their needs. Its accuracy and repeatability capabilities were exactly what they needed for their demanding measurement applications. They also liked the technical support options available from Carl Zeiss and the user-friendly Calypso metrology software. Ortho purchased the Contura 1000 in 2005 along with the Vast XT active scanning sensor. They value the durability of the machine, including the granite table providing a secure surface for their parts, and the ceramic guideway technology that offers stability against temperature changes and moisture. In addition, the complex probe configurations easily changes out for different measurement programs with the MSR probe rack. Ortho was surprised with how accurately the Vast XT sensor continually monitored probe deflection. Prior to the purchase of the Zeiss CMM, Ortho was using handheld and other manual gauges. Depending on the part, their target tolerances range from 0.005" to 0.0002". Previous inspection methods could get close to these targets but they took significantly longer. Efficient measurement on the previous machine was not possible for some of the parts with critical intricate features – such as acetabular shells and liners used in hip replacements, and tibial base trays and inserts used in knee surgeries. Inspection of incoming parts from vendors accounts for about 90% of Ortho Development’s CMM inspection work. The other 10% of inspection is on parts they manufacture in-house. Depending on the part type, they measure anywhere from 10 to 100 parts a day on the Contura. This CMM is also used in the design stages of product development and to provide routine gage R&R reports for product management. Since purchasing the Zeiss CMM, Ortho has experienced a significant reduction in inspection time and had excellent operational success. They are now saving approximately 15 to 30 minutes per lot on inspection time. Ortho also relies on Zeiss Care, which includes an annual software maintenance agreement plus an A2LA accredited calibration service for annual calibrations and maintenance. This package allows them to verify the status of the CMM prior to service and makes sure that it is always running in peak condition. With the excellent care from Ortho and annual calibrations, the Contura has been problem free since 2005. One Calypso metrology software feature that Ortho particularly likes is Parameter-Coded Measurement (PCM). PCM offers menu-guided control of parameter-supported measuring runs. Programming of measurement plans is in such a way that various workpiece variants can be measured, and parameters can be set to influence the automatic run of a measurement plan. PCM is a powerful tool for using variables in a program. Some variable examples include using feature attributes (size and location), controlling scanning speed, making one program work for an entire part family, and creating user inputs or prompts before or during a program. Due to continual growth and confidence in Zeiss systems, Ortho is planning to purchase a Contura G2 in the near future for their inspection needs. They also plan to add Vast XXT sensor technology with the RDS articulating probe holder for measuring new parts with complex angles. This sensor accepts extensions up to 100mm in length and is well suited for measurements of parts requiring many angular probe positions. One thing Ortho has learned from the quality inspection process is that the Contura is a critical component in both ensuring their high standards for accuracy and in giving them confidence that they are delivering premium orthopedic implants to their customers. Two principal benefits of owning a Carl Zeiss system are decreased inspection time and user-friendly software.

Discovering the Usage of Gage Blocks | Home Improvement Tips & ideas

The gage block is known as as the accurate ground and also the lapped length measuring standard. This tool can be used as the reference for the setting of measuring devices that utilized in machine retailers like sine bars, micrometers, dial indicators and calipers. Also, it is created as a accurately formed instrument to evaluate the distances between opposing faces.

Moreover, this tool is used for transferring the dimensional values from the state length standard the manufactured article. The utilization of gage block can ensure the standardization of measuring equipment that used in the machine building. It is also utilized for examining the tooling in checking and measurement devices, for setting up the techniques of measuring nominal dimensions, and in modifying tool machines and fixtures and performing layout work.

There are certain kinds of gage blocks which currently available. The types contain square, angle, rectangular, and wear. The square does not contain a central hole which is held together with external holder. The angular is made to the precise angle to gage the angles or to examine the angle gages and protractors. The rectangular comes with one or more centrally located to mount on holding bars. The wear is required on the ends of the stack of gage block that contacts the various components or variable gages being evaluated.  

This device comes in a set of some gages and accessories that packaged into a kit generally in a situation with the adjusting tools. Occasionally the tool kits offer the alternate extension and contact tips, bases, holders, and standards. The measurement device for this tool can be either metric or English. Some are set up for measuring both.

Moreover, this device is produced to accurate gage-maker tolerance grades to calibrate, check, and set the fixed and comparative gages. The square, rectangular, scribing, wear and angle forms can be found in the carbide, hardness steel, and ceramic materials. The other proprietary blocks may be available for the particular purposes with higher or lower tolerances and configurations.

One of the most common gage blocks that you can obtain on the market today is provided by MItutoyo. All of the tools from Mitutoyo can meet or exceed all recognized requirements. The flatness and parallelism surface finish is needed for achieving the required accuracies that are the same as or better than government needs.

A certificate of inspection is furnished with all Mitutoyo products with a serial number on the case and an identification number on each block. The change of every block is registered. For this inspection, each instrument is measured in accordance with the upper level master utilizing a comparator. The Grade K gauge blocks are produced by the absolute measurement using an interferometer. The gauge block set and discrete gauge block are offered with a certificate of calibration. The certificate of calibration can designate the deviation from the nominal length.

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