Joshua Terrell

Metrology Jigs

I recently completed the third term of my co-op internship at an aerospace parts company located in Peachtree City, Ga. My responsibilities mainly consisted of assisting my manager with reverse engineering, data collection, and CAD modelling of various small aerospace parts like bearings, joists, machine parts, tray tables, etc.

I had the opportunity to work with a 3D Systems inkjet 3D printer on some of my projects. For several projects (mostly roller and ball bearing reverse engineering) I needed to measure parts using gages that didn’t have the proper blocking and jigs to accommodate the parts for measurements. I designed custom tools in SolidWorks and printed them out on the 3D printer, and used these to measure my parts.

Below are some of the tools I designed and printed for use in reverse engineering measurements.

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Roller bearing with internal rollers, it doesn’t fit on the chuck!

Close up showing the chuck jaws holding the adapter.

Close up showing the chuck jaws holding the adapter.

Adapter allows roller bearing to be measured.

Adapter allows roller bearing to be measured.

Ball bearing and stepped weight used to measure play along the ball bearing axis.

Ball bearing and stepped weight used to measure play along the ball bearing axis.

 

Doesn't fit!

Doesn’t fit!

Now it does.

Now it does.

Linear height gage measurements. The top weight section is quite heavy, demonstrating the need for a good fit to the bearing.

Linear height gage measurements. The top weight section is quite heavy, hence the need for a good fit to the bearing.

 

This device is an end shake gage. We were using it to measure the play of a spherical bearing. The green thing is my first attempt at a tool to press down on the spherical while keeping the faces parallel.

This device is an end shake gage. We were using it to measure the play of a spherical bearings sphere and outer ring. The green thing is my first attempt at a tool to press down on the spherical while keeping the faces parallel.

 

Second attempt was a bit nicer. And actually worked.

Second attempt was a bit nicer. And actually worked.

The holder was designed to fit the hardware we already had on the end shake gage.

The holder was designed to fit the hardware we already had on the end shake gage.

Closeup of how the inner holder fit.

Closeup of how the inner holder fit.