Training for measurement hand skills tools methods caliber screw bolt nut ruler thread head flatness

1. Confidential ©2015
MEASURING SKILLS
CD2100005EN
Name Surname

2. – Itinerary
– Knowledge Quiz
– Measuring Units
– Measurement Types
– Equipment Care
MEASUREMENT TYPES
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– Equipment Selection
– Measuring Equipment
– Fasteners, threads and HeliCoil™ Thread Repair
– Practical Measuring Activities.

3. – System International (SI) Measuring Units
System International (SI) units (Metric)
– When measuring any component, exact data is
available in the Specifications section of the
Workshop Manual on TOPIx
– However, it is important to have a thorough
understanding of the numbers and values in use.
MEASURING SKILLS
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4. – Linear Measurements
Linear Measurements
Most measurements carried out in the workshop are
linear
The ‘line’ measured between two points
For Example:
– The length of a bolt
– The track or wheelbase of a vehicle.
MEASUREMENT TYPES
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5. – Non-Linear Measurements
Non-linear Measurement
Essential to assess service components for the
following conditions:
– Flatness
– Roundness and Ovality
– Taper
– Run-out.
MEASUREMENT TYPES
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6. – Non-Linear Measurements
Flatness
The deviation of a flat surface from its perfect flat form
Checked by running a straight edge over the surface
and using feeler gauges to measure the distortion
Essential in certain components for the correct mating
of surfaces
For Example:
– Cylinder Head Straightness.
MEASUREMENT TYPES
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7. – Non-Linear Measurements
Roundness
Whether or not an object is truly circular
Can be checked by:
– Multiple readings using an External Micrometer
– Using Dial Test Indicator (DTI) to check for
deflection
For example:
– Main Bearing Journal Wear.
MEASUREMENT TYPES
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8. – Non-Linear Measurements
Ovality
Term used to measure how ovular an oval is
For Example:
– Cylinder Bore Wear
– Brake Drum Roundness
Calculated by measuring the diameter of the oval
through its longest axis and shortest axis
X - Y = Ovality.
MEASUREMENT TYPES
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9. – Non-Linear Measurements
Taper
The gradual thinning or narrowing towards one end of
a shape
Sometimes referred to as conicity
Calculated by measuring the width of an object at the
beginning of the taper (X) and the end of the taper (Y)
X - Y = Taper.
MEASUREMENT TYPES
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10. – Non-Linear Measurements
Run-Out
The measurement taken to ensure a rotating item
runs true and free from distortion
Measured using a Dial Test Indicator (DTI) to measure
the amount of lateral difference in surface
measurements
For Example:
– Brake Disc Run-Out measurement.
MEASUREMENT TYPES
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11. – Non-Linear Measurements
Angular Measurement
There are only a small number of opportunities for
angular measurement in automotive applications
For Example:
– Suspension and steering angles
– Using the torque angle gauge when tightening down
a cylinder head.
MEASUREMENT TYPES
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12. – Measurement Types
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Question 1
What type of measurement is being carried out in Figure E188508?
Linear

13. – Measurement Types
MEASURING SKILLS
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Question 2
In Figure E157197, what are the cylinder head and engine block being checked for?
Flatness or Distortion

14. – Measurement Types
MEASURING SKILLS
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Question 3
What tools can be used to check for roundness?
Dial Test Indicator (DTI) or External Micrometer

15. – Equipment Care
Measuring instruments are easily damaged, which
can make them inaccurate
Inaccurate readings can cause more damage than no
reading at all
This could be caused by:
– Drops
– Water/Corrosion
– Dirt and dust
– Extreme temperature changes.
MEASURING EQUIPMENT
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16. – Vernier Caliper
Can be used to take a variety of measurements:
– Internal Measurements
– External Measurements
– Depth Measurements
Error factor of ±0.02 mm
Checked for accuracy by using calibration blocks
Not to be used if measurements are critical to the
component being measured
E.g. where tolerance is < ±0.02 mm,
a Micrometer should be used.
MEASURING EQUIPMENT
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17. VERNIER CALIPER
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– Construction
1 2 3 4 5 6 7 8 9
External
jaws
Internal
jaws
Depth
probe
Main
scale
(mm)
Main
Scale
(inch)
Vernier
Scale
(mm)
Vernier
Scale
(inch)
Retainer Lock

18. – How to Measure
Ensure the area to be measured and the tool is clean
and dry
Ensure the Vernier Scale slides freely
'0' marks on both scales line up accurately when fully
closed.
VERNIER CALIPER
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19. Internal Measurements
– How to Measure
External Measurements
VERNIER CALIPER
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Depth Measurements

20. – How to Read
Two measuring scales and therefore should be
read in two stages
A – Main Scale
B – Vernier Scale.
VERNIER CALIPER
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21. – How to Read
Stage One – Main Scale
Taken from the marking on the Main Scale that aligns
with the '0' on the Vernier Scale
NOT the edge of the Vernier Scale
If a marking does not align, then the Main Scale
marking to the left of the '0' on the Vernier Scale
should be used
Whole millimetres - written as two digits before a
decimal point
Example = 10.__ mm.
VERNIER CALIPER
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22. – How to Read
Stage Two – Vernier Scale
Taken from the marking on the Vernier Scale that
closest aligns with a marking on the Main Scale
More than one of the markings may appear to align
Pay close attention as one marking
will align closer than others.
VERNIER CALIPER
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23. – How to Read
Stage Two – Vernier Scale
Numbered markings indicate Tenths of a millimetre -
written as two digits after the decimal point
Example : __.40 mm.
VERNIER CALIPER
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24. – How to Read
Stage Two – Vernier Scale
Shorter markings between the numbered markings
indicate Two hundredths of a millimetre
- written as two digits after the decimal point
Example : __.86 mm.
VERNIER CALIPER
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25. – How to Read
Total Reading
To record the total reading, simply add the Main Scale
and Vernier Scale measurements together
Main Scale = 10.__mm
Vernier Scale = __.86 mm
Total Reading = 10.86 mm.
VERNIER CALIPER
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26. – ACTIVITY 3
VERNIER CALIPER – MEASUREMENT EXAMPLES
MEASURING EQUIPMENT
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27. VERNIER CALIPER
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– Measurement Examples – Question 1
10.00 + 00.16 = 10.16 mm.
10.00 mm 00.16 mm

28. VERNIER CALIPER
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– Measurement Examples – Question 2
20.00 + 00.68 = 20.68 mm.
20.00 mm 00.68 mm

29. VERNIER CALIPER
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– Measurement Examples – Question 3
25.00 + 00.78 = 25.78 mm.
25.00 mm 00.78 mm

30. VERNIER CALIPER
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– Measurement Examples – Question 4
30.00 + 00.02 = 30.02 mm.
00.02 mm
30.00 mm

31. – External Micrometer
As the name suggests, used to take external
measurements
Error factor of ±0.01 mm
Calibrated using special blocks and test rods
Available in a variety of sizes, for example:
– 0-25 mm
– 25-50 mm
– 50-75 mm
50-75 mm variant common for automotive use
Adapter rods supplied to measure 0-25 mm / 25-50
mm.
MEASURING EQUIPMENT
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32. EXTERNAL MICROMETER
32
– Construction
1 2 3 4 5 6 7 8
Anvil Sample Spindle Lock Vernier Thimble Ratchet Frame

33. – Zero Check
Prior to carrying out any measurements, it is
essential to carry out a Zero Check
EXTERNAL MICROMETER
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How?

34. – Zero Check
Prior to carrying out any measurements, it is
essential to carry out a Zero Check
Ensure measuring surfaces are clean and dry
Ensure thimble rotates freely
Rotate thimble clockwise until spindle almost touches
the anvil.
EXTERNAL MICROMETER
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35. – Zero Check
Prior to carrying out any measurements, it is
essential to carry out a Zero Check
Continue to close the gap slowly using the ratchet
until the spindle touches the anvil and the ratchet
starts to click
Ensure the '0' line on the Thimble accurately aligns
with the datum line
If the '0' line does not align, the Micrometer must be
aligned.
EXTERNAL MICROMETER
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36. – How to Measure
Ensure area to be measured and tool are clean and
dry
Ensure thimble rotates freely and the tool is calibrated
Support the instrument using the frame
EXTERNAL MICROMETER
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37. – How to Measure
Place item to be measured between spindle and anvil
Turn thimble slowly until spindle is close to the item
Close the gap slowly using the ratchet until spindle
touches item and ratchet starts to click
Apply lock if necessary and take your reading.
EXTERNAL MICROMETER
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38. – How to Read
Three measuring scales and therefore should be
read in three stages
A - Upper Scale
B - Lower Scale
C – Thimble Scale
The Upper and Lower scales are separated by the
datum line - D.
EXTERNAL MICROMETER
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39. – How to Read
Upper Scale markings indicate whole millimetres
Lower Scale markings indicate half millimetres
Therefore, the distance between a mark on the upper
scale and lower scale is 0.50 mm.
EXTERNAL MICROMETER
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= 0.50
mm

40. – How to Read
Thimble Scale is divided into one hundredths of a
millimetre
Each 360° turn of the thimble = 0.50 mm - Therefore
each one of the 50 increments is 0.01 mm
Readings are taken against the datum line and will
always be less than 0.50 mm.
EXTERNAL MICROMETER
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41. – How to Read
Stage One – Upper Scale
Marking on the Upper Scale that aligns with the edge
of the thimble
Markings indicate whole millimetres - written as two
digits before a decimal point
If a marking does not align, the Upper Scale marking
to the left of the edge of the thimble should be used
Example = 03.__ mm.
EXTERNAL MICROMETER
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42. – How to Read
Stage Two – Lower Scale
Marking on the Lower Scale that aligns with the edge
of the thimble
Markings indicate half millimetres - written as two
digits before a decimal point
As one complete turn of the thimble is 0.5 mm,
this reading will always be either:
__.00 mm OR __.50 mm.
EXTERNAL MICROMETER
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43. – How to Read
Stage Two – Lower Scale
If the half millimetre mark can be seen after the whole
millimetre reading on the Upper Scale, the reading is
__.50 mm.
EXTERNAL MICROMETER
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44. – How to Read
Stage Two – Lower Scale
If the half millimetre mark cannot be seen after the
whole millimetre reading on the Upper Scale, the
reading is __.00 mm.
EXTERNAL MICROMETER
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45. – How to Read
Stage Three – Thimble Scale
Divided into hundredths of a millimetre - written as
two digits after the decimal point
Each 360° turn of the thimble = 0.50 mm - Therefore
each one of the 50 increments is 0.01 mm
Thimble Scale readings are taken against the number
that lines up with the datum line
Example = __.37 mm.
EXTERNAL MICROMETER
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46. – How to Read
Total Reading
To record the total reading, simply add the Upper,
Lower and Thimble Scale measurements together
Upper Scale = 03.__ mm
Lower Scale = __.50 mm
Thimble Scale = __.37 mm
Total Reading = 03.87 mm.
EXTERNAL MICROMETER
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47. – ACTIVITY 4
EXTERNAL MICROMETER – MEASUREMENT EXAMPLES
MEASURING EQUIPMENT
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48. EXTERNAL MICROMETER
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– Measurement Examples – Question 1
8.00 + 00.00 + 00.20 = 8.20 mm.
8.00 mm 00.00 mm 00.20 mm

49. EXTERNAL MICROMETER
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– Measurement Examples – Question 2
10.00 + 00.50 + 00.00 = 10.50 mm.
10.00 mm 00.50 mm 00.00 mm

50. EXTERNAL MICROMETER
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– Measurement Examples – Question 3
13.00 + 00.50 + 00.15 = 13.65 mm.
13.00 mm 00.50 mm 00.15 mm

51. EXTERNAL MICROMETER
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– Measurement Examples – Question 4
17.00 + 00.00 + 00.37 = 17.37 mm.
17.00 mm 00.00 mm 00.37 mm

52. – Dial Test Indicator (DTI)
Used to take dynamic measurements
Dynamic means measuring something whilst it is
moving
For example:
– Brake Disc/Hub Run-Out
– Crankshaft/Camshaft End Play
Error factor ±0.01 mm
Scale may be unidirectional, typically measures up to
20 mm of movement.
MEASURING EQUIPMENT
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53. DIAL TEST INDICATOR (DTI)
53
– Construction
1. Setting Ring
2. Stem
3. Spindle
4. Outer Scale
5. Inner Counter
6. Dial.

54. – How to Use
A DTI cannot be used independently
Must be used in conjunction with a support tool
Most common is the magnetic stand
Some tasks require the use of special tools to support
the DTI, such as a measuring bridge when measuring
piston protrusion.
DIAL TEST INDICATOR (DTI)
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55. – How to Measure
Ensure the area to be measured and the tool is clean
and dry
Ensure the DTI is secured correctly to the supporting
tool by the stem
Ensure the supporting tool is sufficiently secured
Position the DTI so the spindle is at a right-angle to
the item to be measured
Carefully set the DTI against the component so that
spindle is touching the surface
Move the DTI closer to the component until the Outer
Scale Needle moves approximately one full turn, to
apply some pre-load to the spindle.
DIAL TEST INDICATOR (DTI)
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56. – How to Measure
Secure the DTI in position
Turn or move the component very slowly to find the
smallest reading
Turn the setting ring until the '0' on the Outer Scale
aligns with the Large Needle
Take note of the reading on the Inner Counter
Turn or move the component very slowly to find the
largest reading
Always pre-load the DTI before any measurements
are carried out to allow measurements in both
directions.
DIAL TEST INDICATOR (DTI)
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57. – How to Read
Two measuring scales and therefore should be
read in two stages
A – Inner Counter
B - Outer Scale.
DIAL TEST INDICATOR (DTI)
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58. – How to Read
Stage One – Inner Counter
Markings indicate whole millimetres - written as two
digits before a decimal point.
Example = 09.__ mm
Remember, DTIs can measure uni-directionally, so
pay close attention to the readings you take.
DIAL TEST INDICATOR (DTI)
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59. – How to Read
Stage Two – Outer Scale
Markings indicate hundredths of a millimetre - written
as two digits after the decimal point.
Example = __.89 mm
Remember, DTIs can measure uni-directionally, so
pay close attention to the readings you take.
DIAL TEST INDICATOR (DTI)
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60. – How to Read
Total Reading
To record the total reading, simply add the Inner
Counter and Outer Scale measurements together
Inner Counter = 09.__ mm
Outer Scale = __.89 mm
Total Reading = 09.89 mm
It is essential you consider the amount of pre-load
applied to the DTI when calculating your
measurement.
DTI measurements very rarely start from absolute
zero.
DIAL TEST INDICATOR (DTI)
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61. – ACTIVITY 5
DIAL TEST INDICATOR (DTI) – MEASUREMENT EXAMPLES
MEASURING EQUIPMENT
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62. DIAL TEST INDICATOR (DTI)
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– Measurement Examples – Question 1
3.00 + 00.40 = 3.40 mm.
3.00 mm 00.40 mm

63. DIAL TEST INDICATOR (DTI)
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– Measurement Examples – Question 2
6.00 + 00.07 = 6.07 mm.
6.00 mm 00.07 mm

64. DIAL TEST INDICATOR (DTI)
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– Measurement Examples – Question 3
6.00 + 00.70 = 6.70 mm.
6.00 mm 00.70 mm

65. DIAL TEST INDICATOR (DTI)
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– Measurement Examples – Question 4
4.00 + 00.56 = 4.56 mm.
4.00 mm 00.56 mm

66. – FEELER GAUGES
MEASURING EQUIPMENT
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67. – Feeler Gauges
MEASURING EQUIPMENT
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Very simple, versatile measuring instrument with
many applications
Thin steel blades machined to a specific thickness
with an accuracy of up to 0.01 mm
Range of blade thickness varies depending on the set
in use, however a typical set ranges from around 0.03
mm - 1.00 mm
Blade thickness is indicated on the blade itself.

68. – Feeler Gauges
MEASURING EQUIPMENT
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Very simple, versatile measuring instrument with
many applications
Used to measure tolerances between two
components such as:
– Valve Tappet clearances
– Spark plug gaps
– End float clearances
– Flatness.

69. – Feeler Gauges
MEASURING EQUIPMENT
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Ensure the area you are measuring and the tool itself
are clean and dry
Select an appropriate thickness blade and insert it
between the components to be measured
Slowly remove the gauge from between the
components
If the correct thickness gauge is being used, slight
resistance will be felt whilst pulling it out
If no resistance is felt, select a thicker blade, or
combination of blades until the correct thickness is
achieved
The number of blades used as a combination must
be kept to a minimum.

70. – Feeler Gauges
Never force the blades in between the
components as damage can be caused to both the
component and the blade itself
Any damaged, bent, kinked or corroded blades
must not be used.
MEASURING EQUIPMENT
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71. – SPRING GAUGE
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72. – Spring Gauges
The Spring Gauge is generally used to check the
turning load on a component
For Example:
– Swivel hub pre-load
Adjustment is made by removing or adding shims to
the top swivel pin.
MEASURING EQUIPMENT
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73. – Equipment Selection
There are various measuring instruments used
within the workshop, each with different
applications
It is essential to be able to confidently and accurately
interpret readings when taking measurements
When carrying out any measuring, it is important that
the most appropriate tool is selected.
MEASURING EQUIPMENT
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74. – Equipment Selection
For Example:
Brake Disc Assessment
– Dial Test Indicator (DTI) and Micrometer
Brake Pad Thickness
– Vernier Caliper
Cylinder Head Straightness
– Feeler Gauges and Straight Edge
Valve Tappet Clearances
– Micrometer and Feeler Gauges.
MEASURING EQUIPMENT
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75. – Equipment Selection
Incorrect use of the
appropriate measuring
equipment may lead to
inaccurate readings and
potential component failure.
MEASURING EQUIPMENT
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76. – Fasteners
A technicians understanding of fasteners is
essential for safety and longevity of the vehicle
Numerous types in are use in the automotive industry:
– Screws
– Bolts
– Studs
– Nuts
– Washers
– Stretch Bolts
– Encapsulated Fasteners
– Triolubular Bolts
Many look similar but are NOT interchangeable.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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77. – Fasteners
Screws:
– Less than 6 mm
– Threaded all the way up the shank
– Fits into a threaded hole
Bolts:
– Over 6 mm
– Un-threaded portion of shank below the head
– Secured with a nut.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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78. – Fasteners
Studs:
– Threaded both ends
– No ‘head’
– One end in a threaded hole, secured with a nut
Nuts:
– Used to secure bolts and studs
– Internally threaded
– Hexagonal head
Washers
– Spread load evenly from nut to component
– Prevent a nut working loose.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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79. – Stretch Bolts
All metals have an elastic limit
(Limit of the ability to stretch and return to its original
shape)
Once a bolt has been stretched beyond its elastic limit
it will not return to its original shape
Stretch bolts are designed so that they can be
elongated beyond their elastic limit into the plastic
region
Ensures a high and uniform bolt clamping force and
no re-torque is necessary.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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80. – Stretch Bolts
Reuse of stretch bolts will cause distortion to
components and consequent damage
In many cases the bolts may not be reused or have a
limited, specified number of reuse applications
Always follow the recommendations in TOPIx
regarding stretch bolt replacement.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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81. – Encapsulated fasteners
Thread locking agent applied to the threads during
manufacture
Nylon patched bolts and screws have a locking agent
either applied to, or inserted in the threaded portion
Caution: Do not reuse self-locking fasteners.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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82. – Trilobular Bolts
A unique fastening system utilizing TAPTITE™
fastener technology
– Various parts including replacement engines and
cylinder heads now supplied with un-threaded bolt
holes by design
– Bolt creates its own thread when inserted into a
machined hole on first application
– No preparation required, no tapping
– Simply insert bolt in to machined hole and torque to
specification.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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83. – Trilobular Bolts
A unique fastening system utilizing TAPTITE™
fastener technology
– Comprises a triangular shaft circumference with a
unique Radius Profile™ thread (Rolled)
– Triangular shape creates a locking effect
– Bolts can be re-used, make note of bolt locations
– Metric thread bolt can be used in its place if
replacement is required.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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84. – Bolt Nut and Identification
Markings indicating the strength grade
For Example: 8.8, 10.9, 12.9, 14.9
Fasteners may also have the ‘M’ symbol marked to
indicate a Metric thread.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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85. – Thread Identification
Many different types of screw threads in use
Some threads look similar but are not
interchangeable
Use a thread gauge to identify an unknown thread
CAUTION: A thread file may be used to determine
thread type and size and to repair minor thread
damage – not to recondition a bolt
Always replace bolts with excess damage to head
and/or thread.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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86. – ACTIVITY 6
THREAD IDENTIFICATION
MEASURING EQUIPMENT
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87. – HeliCoil™ Thread Repair
HeliCoil™ Inserts are a method used to repair a
damaged thread in a component
This process saves money on replacement
components
The repair involves using specific drill and tap to cut a
new thread in the damaged component
A size specific helical coil is then inserted in to the
freshly drilled and tapped hole
Thread inserts are available in many sizes.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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88. – HeliCoil™ Thread Repair
1. Measure depth to drill
2. Drill out the hole with a special drill
3. Tap a new thread with a special tap, to match
the outside of the HeliCoil™
4. Insert the HeliCoil™
5. Snap off the insertion tang
6. New thread is now ready to use
CAUTION:
When drilling out the damaged thread ensure that it is
of the correct depth.
FASTENERS, THREADS AND HELICOIL™ INSERTS
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